Onan 5GO-F Instruction Manual Download

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Summary of Contents for 5GO-F

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Page 3: ...ame plates on the plant Give all other available details r w i 1 The manufacturer warran ts each new engine or electric plant to be 1 free from defects in material and workmanship Under normal use and...

Page 4: ...ating Conditions Low Temperatures High Temperatures Dust and Dirt Periodic Service Daily Service Weekly Service Monthly Service Six Monthly Service _ Adjustments Carburetor Gasoline Carburetor Gas or...

Page 5: ...lock and Head Group 40 2 Crankshaft and Camshaft Group 41 3 Gear Cover and Oil Pan lroup 41 4 Oil Pump and Pil Fil ter Group 42 piston and Connect g Rod Group 43 6 Valve Group 43 7 Water Pump and Fan...

Page 6: ...rating hours 2000 to 4000 miles depending on operating conditions About every 5 000 to 10 000 miles 120 to 250 hours services have to be performed on an auto such as checking ignition points replacing...

Page 7: ...oper ation of this plant GENERAL DATA OUTPUT WATTS OUTPUT VOLTS CYCLES PHASE WIRES U S MJi ASURE CAPAC IN UARl S t PARTS REF SYMBOL SYSTEM EL TANK CRANK CASE 5000 115 60 1 2 11 24 3 3 A B 5000 115 2...

Page 8: ...plants are equipped to burn gaseous fuel GENERATOR The generator is air cooled has four stationary poles and a revolving armature The generator is directly coupled to the engine Vith the armature turn...

Page 9: ...allow condensation to drain out Extend the muffler outlet at least 24 above ground and fit it with a pipe gooseneck The site should be dry clean and well ventilated Either a damp or a dusty condition...

Page 10: ...tion the distance between the plant and the load and the type of load Consult a competent electrician and observe applicable electrical codes in making the installation See that the main line is prote...

Page 11: ...e phase circuit 2o8 V I I I 208V lcI 208V I I t 120V I4 120V 14 l 120V lcjI 208V 3cj1 230 VOLT THREE PHASE 2 WIRE PLANT No terminal is grounded Reversing the connections between any two of terminals...

Page 12: ...L HERE ARMATURE BEARING ENGINE STARTER D C Plants FUl KEEP OIL AT THIS LEVEL EMPTY 01 L LEVEL GAUGE MARKS AIR CLEANER BATTERY CHARGE GENERATOR D C Plants GOVERNOR CONTROL LINKAGE BALL JOINT ICATION I...

Page 13: ...ly 1 quart used in the operation of the oil filter Vhenanew oil filter element is installed it will be found that the element will absorb approximately 1 quart of o i l The use of a heavy duty deterge...

Page 14: ...only when the plant is running If it is desired to check the fuel when the plant is stopped throw the ignition switch to the HAND START position while making the observation Be sure to return the swit...

Page 15: ...e If the plant is equipped for natural or Liquid Petroleum Gas operation see that the arm of the choke control mounted upon the exhaust manifold is locked do WIl so as to make the choke inoperative No...

Page 16: ...een 2 and 7 amperes depending upon the charge condition of the batteries When the plant is not in operation the water temperature gauge will register 2120 F The fuel gauge oil pressure gauge and charg...

Page 17: ...e generator On the 115 230 volt plant divide the load asclosaly as possible between the two circuits when using 115 volt current Confine the load on each 115 volt circuit to not more than 2500 watts S...

Page 18: ...engine is warm Drain the oil filter when changing to a lighter oil Add sufficient oil to compensate for that used to fill the oil filter AIR CLEANER If congealed oil or frost formation within the air...

Page 19: ...e provide sUfficient air circulation for proper cooling Keep the cooling system clean and free of rust and scale See that the high water temperature cut off switch is correctly set and that the ignit...

Page 20: ...SE OIL LEVEL Check the oil level as indicated on the bayonet type oil level gauge Do not allow the engine to operate with the oil level close to the low level mark on the gauge Add sufficient oil of t...

Page 21: ...lty condenser wh i ch shoul d be replaced with a new one MONTHLY SERVICE If the plant is operated more than 200 hours a month perform the MONTHLY SERVICE operations every 200 hours FUEL SYSTmL Remove...

Page 22: ...machined finish If the commutator or collector rings become heavily coated clean with a lint free cloth Sllght roughness may be remedied by llghtly sanding with 00 sandpaper Clean out all carbon and s...

Page 23: ...ecessary Check the operationa various loads There is no idle adju stment necessary for gas or Butane Propane vapor operation except to see that the throttle lever stop screw is adjusted to 1 32 clear...

Page 24: ...owN WHEN pLANT IS TO BE OPERATEO ON GAS UTOMATIC CHOKE UTOMATIC CHOKE CONTROL ROD ENTIRE CHOKE ASSEMBLY PARTS MARKEt ARE USED ONLY ON COMBINATION GAS GASOLINE PLANTS ELECTRIC CHOKE USED ON GASOLINE OP...

Page 25: ...pread between no load and full load of not more than 100 r p m 4 If th plant tends to hunt alternately increase and decrease speed under load conditions increase very slightly the distance between the...

Page 26: ...emperat re The switch will not operate if the ign i tion switch is at the HAND STAAT POSITION FAN BELT TENSION The fan belt tension is regulated by the width of the fan pulley groove The front half of...

Page 27: ...the exhaust valve tappet clearance to 0 010 Make sure the lock nut on each adjusting aerew is secure tightened after the adjustment is made Tappets set too close may cause burned or warped valves seat...

Page 28: ...MAINTENANCE AND REPAIRS FIG E TIMING GEARS FIG F TAPPET ADJUSTMENT 22...

Page 29: ...as far as possible without causing a ping or detonation under normal running conditions PISTON RING REPLACEMENT The piston and connecting rod assemblies are removed from the tops of the cylinders Chec...

Page 30: ...IGNITION MARKS ON FLYWHEEL I RADIATOR END OF ENGINE_____ FIG G IGNITION TIMING FIG H PISTON RING GAP o FIG I PISTON FITTING 24...

Page 31: ...are made in pairs for each individual bearing but front eenter and rear bearings are not interchangeable as pairs The same general directions given for fitting the connecting rod bearings should be o...

Page 32: ...bling the pump make sure that the set screw projects far enough to line up the impeller on the shaft Press the impeller on flush with the end of the shaft Pack the space between bearings with a good...

Page 33: ...Conventional 012 Valve Seat Width Intake and Exhaust 1 1611 Crankshaft Main Bearings 0015 Crankshaf t End Pla 00411 Connecting Rod Bearing 0015 Connecting Rod End P1a 00611 Piston in Cylinder 0015 Ca...

Page 34: ...F l YWHErl HOUMNv F VWHttL 0 A W A V U I U8 ARMAi TUFlC G J FIG L CARE OF COMMUTATOR AND BRUSHES 28 L FIG K ALTERNATING CURRENT GENERATOR ASSEMBLY BRUSH RIG ALIGNMENT...

Page 35: ...ial getting into it After the commutator is turned down the mica between bars must be undercut as described above when the anmature is reinstalled align it as carefully as possible before installing t...

Page 36: ...cated in one of the relays the high water temperature switch or a loose connection An open circuit be tween the generator and the stop relay will also prevent the plant from running with the ignition...

Page 37: ...ry Refer to MAINTEtIJANCE AND REPAIR Check the fuel system Clean ad just or replace parts necessary Clean and refill See that choke opens properly Remove carbon Clean or increase the size ENGINE MISFI...

Page 38: ...es Defective or improperly adjusted points Clean and adjust Replace Clean stems and guides Replace Replace Adjust or replace breaker points See Periodic Service Weekly LOW OIL PRESSURE Too long screw...

Page 39: ...sed Intake valves leaking EXCESSIVE OIL CONSUMPTION Worn piston rings Oil leaks from engine or connec tions This does not cause smoky exhaust OU too light or diluted Too large bearing clearance Oil pr...

Page 40: ...tall needed car buretor parts adjust float level Choke not open See that choke opens properly Se e ADJUS l MENTS Dirty air cleaner Clean refill to proper level LIGHT POUNDING KNOCK Loose connecting ro...

Page 41: ...T ADJUS l MENT Use good fresh fuel Clean carburetor ENGD1E CFUU KS TOO STI FLY Too heavy oil in crankcase Drain refill with lighter il Engine stuck Disassemble and repair ENGINE WILL NOT b TART WHEN C...

Page 42: ...nnections Tighten connections Fluctuating load Correct any abnormal load condition causing trouble TAPPING SOUND Tappet clearance too great Adjust or replace tappets Broken valve spring Install new sp...

Page 43: ...rush rig out of position Turn down Clean See GENERATOR Undercut mica Line up marks on brush rig and support ENGINE OVERHEATING Low water iri radiator Overloaded lmproper lubrication Radiator obstructe...

Page 44: ...NOTICE Refer to page 67 for detai Is on servici ng or orderi ng parts for 6000 watt direct current gener ating plants 1...

Page 45: ...nce Sym bols are given in the Data TC ble on page I g 00 not order by reference number or group number use part number and description Give the part number description and quantity needed of each item...

Page 46: ...3 4 2 5 f II 8 9 10 12 9 13 14 15 31 30 J 2224 J 23 l 29 CYLINDER BLOCK AND HEAD GROUP 19 Il 1 f f 25 26 27 Flg 1...

Page 47: ...IOII B 15 16 17 14 Fig 2 CRANKSHAFT AND CAMSHAFT GROUP 6 1 i V 1M o Fig 3 GEAR COVER AND OIL PAN GROUP 12...

Page 48: ...j 10 1 0 i 1 5 to J 0 g I O IO 0 0 I s 0 11 f5t N co 0 t i 4 1...

Page 49: ...2 3 2 3 t 4 f 5 6 7 5 4 6 1P 8 1 9 1 10 12 t1 11 mr 7 17 La 16 9 4 tJr 9t 15 10 II t Fig 5 PISTON AND CONNECTING ROD GROUP Fig 6 VALVE GROUP...

Page 50: ...Q _ 9 m 01 I...

Page 51: ...4 ____ 2 3 1 0 gJiJ 6 0 o t J1 Fig 8 FLYWHEEL GROUP Fig 9 MUFFLER GROUP 7...

Page 52: ...1 2 3 4 6 e_ Q 8 Fig 10 RADIATOR GROUP 5 4 3 8 2 14 27 28 26_ 7 33 Fig 11 FUEL SYSTEM GROUP 241 T 221...

Page 53: ...II 13 16 12 17 18 141 2 113 9 J 1 I 0 I Fig 13 CARBURETOR GROUP 15 Fig 12 GAS GASOLINE FUEL SYSTEM GROUP 6...

Page 54: ...14 if21 1 9 t J 19 3 I 7 J 0 8 4 3 1 5 t 7 8 4b Fig 14 IGNITION GROUP Fig 15 GOVERNOR GROUP 13 2 5 Ii I 2...

Page 55: ...t 0 E z t Oil 49...

Page 56: ...p 0 0 I I 0 z 0 rtl 0 50...

Page 57: ...Il I 0 0 0 z J oil...

Page 58: ...217 Seal Crankshaft Rear Bearing Filler Block 18 D600B 406 Block Crankshaft Rear Bearing Filler 19 Y400G 2061 Bearing SheIl Crankshaft Rear Upper and Lower Pair 20 Y400G 3061 Bearing Shell Crankshaft...

Page 59: ...IB x 3 4 Front End Plate Screw Spacing Cylinder Head Stud stud Cylinder Head 3 B x 4 stud Cylinder Head 3 B x 3 1 2 11 Stud Water Outlet Elbow 5 16 x 1 5 S CRANKSHAFT AND CAMSHAFT GROUP Fig 2 Cr8llksh...

Page 60: ...Gears Strainer Frame Screen Cover Shaft Idler Stud SUction Tube Screws and Nuts 2 15SL 2ll Plunger Oil Pressure Relief Valve 3 W5L 2l3 Washer Oil Pressure Relief Valve Spring 4 10EL 230 Spring Oil Pr...

Page 61: ...mpression Ring piston BottOm Groove Oil Control Ring Set For 1 Piston Rod Connecting Cylinders 1 and 3 Includes Rod Cap Bearings Pin Bushing Bolts and Nuts Rod Connecting Cylinders 2 and 4 Includes Ro...

Page 62: ...le Lbo Valve Cover Ventilat1 ng Tube Stud Valve Gover 114ft 20 X 2 1 4 Gasket Washer Valve Cover Nut WATER PUMP AND FAN GROUP Fig 7 PUl lP Assembly water Includes Body Bearings Support Shaft Bushing I...

Page 63: ...I Nut Fall Hub or _ II 11 II stud Prive Shaft Support 3 8 ft 16 x In Screw Set 1 4n 20 Water Pump Impeller FLYWHEEL GROUP Fig 8 Fl neel Assembly Includes Blower and Ring Gear Gear lling Flywh eel _ Ho...

Page 64: ...or Nipple Pipe 1 4 x 3 ft Radiator Drain Coupling Pipe 1 4 x I Radiator Drain FUEL SYSTEM GROUP Fig 11 Bolt Wing Air Cleaner Cover Clea ner Ai r to Cap Fuel Tank For Mtd Tank Tank Fuel Optional Mtd In...

Page 65: ...ank Braoket Fuel Filter Mtg Used W Mtd Tank Elbow Inverted Yele l S ft x 5 6n Carburetor Inlet Elbow Inverted Male 1 8 x 1 4 Shut Off Valve Connector Inverted Yale 1 8 x 5 16 Fuel Pump Outlet Stud Fue...

Page 66: ...Bociy to Bowl Ot l7 l4 76 Wa er Lock Body to Bowl 0 to l8 l4l 70 Plug Fuel Passage 1 Bowl Drain 1 i 19 14 195 J at Idle 20 141 197 Valve Assembly Fuel Inlet Needle Valve Seat and Gasket 21 141 205 Flo...

Page 67: ...0 Ill Clamp t CQi l Insert Coil Clamp Switch starl Solmoid Cable Battery 15 Cable Batter r Jllm per n CraIlk l a n ual Btartmg Spark Plug Champion J 8 14 mm Condenser Distributor ilL IGB l025 Condens...

Page 68: ...nerator Without Windings or Pole Shoes 62 00 1 1 1 1 Coil Assembly Field Set of 4 Coils 8 222Ali71 1 97 50 9 2OlA2 32 Armature Assembly Includes Drive Disc and Bal 1 Bearing New Rebuilt 1 87 50 Trade...

Page 69: ...a Breaker Circuit 2 Pole 25 Amps Breaker Circuit 3 Pole 15 Ampa Switch Toggle Ignition Switch Toggle Panel Light Resistor Fixed Charge Circuit 6 O 75 Watt Switch Voltmeter Selector Regulator Assembly...

Page 70: ...nd Includes Door 5 6 405C192 Plate Side Right H d PaIlel Left Hmd Door 7 lMD l96 B 406A30 Handle Door 9 405A35 Cover Bearing Inspection Plate 10 159A64 Band Fuel Tank Mounting Optional I I 416B61 Fram...

Page 71: ...ter y SERVICE KITS Val ve Grlnd Parts tit Gasket Kit Complete Plant Overhaul Kit AC Plants Overhaul Kit DC Plants Fuel P1 lIIlp Repair Kit Carburetor Repair Kit Gas Conversion Kit AC Plants Gas Conver...

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Page 73: ...for or added to the information on the corresponding pages 1n the instruction manual to make the manual applicable to the 6000 watt direct current plant READ THIS SUPPLEMENT CAREFULLY Note that some p...

Page 74: ...ed to the start solenoid switch to the remaining positive post of the two batteries Connect the cable which is grounded on the cylinder head to the remaining nega tive post If the plant was boxed for...

Page 75: ...king is pro vided on the magneto ignition plant Page 2l Add the following information to MAINTENANCE A JD REPAIRS STARTER iU lD BATTERY CHARGING GENERATOR When servicing the starting motor and small b...

Page 76: ...nd sub stitute the illustration Fig 17A Add an illustration starter and Battery Charging generator Group Fig 19 Page 62 Delete the Generator Group and substitute the DC Generator Group page 74 Pa ge 6...

Page 77: ...2 C t I Of 00 71 I...

Page 78: ...o 0 o o 9 o O Jl 0 4 o 20 Fig 17A CONTROL PANEL GROUP...

Page 79: ...2 3 1 t i t 9 10 Fi 19STARTER AND BATTERY CHARGING GENERATOR GROUP...

Page 80: ...es Drive Dille and Ba ll Bearing New Rebuilt Trad in AliomlIlee 10 510A 32 B earizlg B Am ature 11 2 32A 3 3 3 Clip Bear ig Retai ning 12 221Bl Shoe Pole Main 13 22lA10 Shoe Pole CQl DInutating 14 212...

Page 81: ...C 0 150 Volts VoltJneter DC 0 300 Volts Resistor Adjustable 50 Ohm 50 Watt Resistor Adjustable 100 Ohm 50 Watt Sll UXlt Ammeter Block Fuse Ill to Block Fuse oil II Fuse Cartridge tIJ Amp liS Volt III...

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