Onan CCK Series Instruction Manual Download Page 5

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Summary of Contents for CCK Series

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Page 3: ...er s obligation under this warranty is limited to oor reeting without charge at its factory any part or parts thereof wllich shan be returned to its factory or one of its Authorized Service Stations transportation charges prepaid within ninety 90 days after being put into service by theoriglnal user and which upon examlnlltioll shall disclose to the ManUfacturer s sat isfaction to have been origin...

Page 4: ...ollow in Starting the Plant 34 27 Air Cleaner Service 38 28 servicing the Breaker Points 40 29 Servicing the Crankcase Breather Valve 42 30 Governor Adjustments 45 31 speed Booster Adjustments 45 32 Throttle stop Lever Position 48 33 Oil Pressure Relief Valv e Adjustment 49 34 Carburetor Adjustments 50 3 5 Electric Choke Adjustment 51 36 Magneto StatorInstallation 55 37 Coil and Circuit for Magnet...

Page 5: ...on Lubrication Air Cleaner Fuel Before Initial start Operation starting the pIant Applying the Load Charge Rate Stopping the Plant Changing Fuel Function of the Controls Abnormal Operating Conditions Low Temperatures High Temperatures i Dust and Dirt Periodic Service Daily Service Weekly Service Monthly Service Adjustments General Governor and Booster Voltage Chart Speed Chart Oil Pressure Relief ...

Page 6: ...s ______ Replace piston rings __ Check the air cleaner often Thoroughly clean and put in fresh oil at least every 100 hours If it is necessary to remove parts for inspection and gaslmts are dis turbed they should be replaced with new ones Periodic Inspection For loose or poor connections fittings etc t Recommended fuel Use regular gradegasoline of at least 68 octane Do not usepremjurn type If a hi...

Page 7: ...ions specified bythe purchaser Due to the wide variety f uses for which these plants are suitable these instructions must be of a general nature I M use ofauxiliary or specialequipment spectal installation requirements or unusual operating conditions may require the operator of this generating plantto modify these instructions How ever by using the instructions and recommendations given in this ma...

Page 8: ...ting it with no load connected or with the starting battery on remote plants disconnected The direct curI Einf dc plant is made in twobasic types 1 for direct service application asa power source for lights power tools etc and 2 a specially designed generator for lifting magnet service The dualpurpose plant produces alternating current plus 32 volt de for battery charging When the maximum battery ...

Page 9: ...R 1A 5CCK 1RV 1A Magneto Battery 4 Quart 4 Quart Mounted 4 CHART OF ACPLANT TYPES PLANT FEATURE Typical example Ignition Oil Capacity U S Quart FuelTank U S Gallon Cranking and Choking Gasoline Carburetor Gas GasQJJI1e Carburetor Engine RPM 60 cycle EngineRl M 50 cycle Housing NOTEt MANUA 5CCK 1M 1A Magneto 4 Q rt Separate 5 Mtd Optional Manual Standard Optional 1800 nominal 1500 nominal 4 Outlet ...

Page 10: ...er walls and head Plants which are pressure cooled have blower fins on the flywheel which draw air in throughthe opening at the front of the blower housing Special modelsof the remote control type plants may be Vacu FloCooled and have blower fins which expel heated air out through the duct at the front of the blower housing as desirable for small enclosure installa tions The letier V appears in th...

Page 11: ...ratedoutput is 3500 watts for either 60 cycle or 50 cycle andvoltage regulation is within plus or mlnus3 of narneplate r atllig The larger generator us s a 7 1 2 inch staci o laminations rated Qutput is50pOwatts for60cy cle 01 42 50 wattsfor 50 cycleandvoltageregulaHoniswithinpluSor minus 5 of nameplate rating The directservice direct CI l rrent generator isa 4 pole compOuI1dw und commlltatingpole...

Page 12: ...es over the load Theplant stops automatically when regular service is restored UNDERGROUND FUEL TANKS AND LINES 55 gallon and 110 gallon fuel tanks and 5 16 inch and 3 8 inch copper fueLlinesin either 25 or 50 foot length are avail able for installing the fuel tank underground REMOTESTART STOPSWlTCHES Additiollairemote start stop switches are available from your dealer a CONDUCTOR CABLE This 18 wi...

Page 13: ...be more or less centrally located in relati on tothe elec rical load Plan toaYoici runningwiringwhich carries a heavy e lectljical load foralongdisb U ce The greater Ule distance lhe largert ewirell1 ust be The selected site should be in a clean dry wellyelltJlated location preferably heated in extremely cold weather A dustyor dan ip locationwilln G ilsitate more frequent ser vicing MOBILE INSTALL...

Page 14: ... z IG 1 7 TYPICAL INSTALLATioN ...

Page 15: ... leasta largeas that of the air inlet FIG 2 VENTl1 A ION PRESSURE COOLED PLANT The installation of additional openings maybe necessary under some conditions to prevent recirculatioriof heated air If this becomes nec essary airoutJets in the roof orin the wall near the ceiling win help The size of the air inlet canbe nc re sed or an additional air inlet in stalled nearby If the unit is tobeoperated...

Page 16: ...he mounting cushions asillustrated The metal spacer and the fIat w asher at each end p r vents excessive compl ssion of the rubber cushions EXHAUST Pipe the exhaust gases outside the enclosure using 1 inch pipe or larger Increase the pipe size used one siz e for each additional 10 feet in distance Avoid sharp bends if possible by uSingbentpipe or sweeping elbow where necessary Connect ihefIex ible...

Page 17: ...ater a t any time Usea heavy metal drum or pail and weld s itable fittings for inlet and outlet pipes Do not use a container which contained any flammable liquid with o ltfirst making sure that all explosive vapors havebeen driven out Re move the bottom of the drum or drill holes in the bottom to allow con deU 3ation from the exhaust gases to drain away The muffler exhaust pipe Sho lj ld extend a ...

Page 18: ...rFF rfl 1 TI I I OIL PRESSURE GA 4MTG HOLES FOR mDIA BOLTS ON 4QT BASE DRA lN IS ON OIL DRAIN i PIPE PLUGS OIL FILL MODEL DIM A GEN CONN OF IUNAL IL BASE l 30 5 CCK 264 8 1 p 2WIRE BASE CAP IDIM B IDIM CIDIM U 305CCK 28 1 J t3 1 3WIRE 3QUART 19 iz I B 1 6 IS7 161 D W ONAN t SONS INC 5 CCK 29 VB 1 J 2 WIRE 4 QUART 120 1 9 14 116 5 I MINNEAPOLIS MINN SCCK 31 Y2 1 J13 l 3WIRE SCCK 4 V2 3 4 WIRE DWG N...

Page 19: ...I I I I I 1 1 L r k PIPE THf FAR SlPE 1 11 Il A J t r r Z t Il t lv to 3 o N t I t i 0 I fLf4 I o z It 6 I 12 1 PRESSURE GA MTGHOLES 5 DRAIN i PIPE PLUG FOR 16 DIA BOLTS OIL FILL NOTE URNISHE D WITH SEPAR TE M lOF 305 CCK 305CCK seCK seCK DIM A GEN CONN 26 y8 1 2WIRE 28 l t3d 3W 297 p 1 2 WIRE 31 Y2 1 3 1 3WIRE S GAL I UEL TANK HOSE 3 FT F LEX EXHAUST TU61l G D W ONAN t SONS INC Y ITH TAN K TyP E ...

Page 20: ...LRECEPTACLE EOX yflR SlOE V ODEL DIM GEN CONN 305 CCK 26 s 1 j 2WIRE 305 CCK 28 IQfr3 D 3WIRE SCCK 29 V8 11j 2WIRE seCK 31 1 2 1 3 3IWIRE seCK 34V2 3dl 4 WIRE REFERENCE NOTE SE E DR WING 2 410C2 35 x OPTIONAL O L DI 2 C I PORTABLE C C K H Z 00 1 3 t t 1 3 H o Z FOR DOLLY D W ONAN t SON5 INC MINNEAPOLIS MINN OWG N 50oA473 ...

Page 21: ...ect the other battery cable between the negative battery post and the ground terminal screw stud or solderless type onthe generator Connect the 32 volt battery for the dual purpose plant in the same manner1 using a fused double pole switch between the plant and the battery Refer tothe wiring diagram Be sure all electrical connections are tighL Coat batteryclampsand posts with a light coating of gr...

Page 22: ...bt consulia licensed electrician Use sufficientlyla rge insulated wire between the plant and the load Install a circuit breaker or a fused main switch in the load line near to the plant REFER TO THE APPLICABLE PLANT WIRINGDIA GRAM Where connections are made by joining two wires always be sure to tape the connections thoroughly Apply two layers of half Iappedelec trician s tape and two layers of ha...

Page 23: ...d Wire into the pnne ltQ r AAd tightening the s lrew Thoroughly strip 1 26f aninchQf ins J ation from the end of each wire before msert ing lfintbate minal Hoa4w tii s ent r the lontrolbox throl lgh a gram meted hole aa su re c9PMetioIis ar clean and tight Leave tbelo q lines wttFhj p inllntil the plant Ms been started j l nd cheCked Nodamag tR nerat r or Controls wm resJ 1ltfrpm run ning the plan...

Page 24: ...SIDE OF LOAD CIRCUIT HERE M2 ECTUNGROUNDED BLACK SIDE OF LOAD CIRCUIT HERE Mil CONNECT GROUNDED WHITEl 5 1DEOF LOAD CIRCUIT TO LEAD MARKED M MANUAL PLANTS 240V REMOTE PLANTS MANUAL 120 V PLANTS 240V 120 1 240 V I PH REMOTE PLANTS 240 V lPH ifiZl r _ 240V 240 v 3PH I PH FIG 14 AC LOAD WIRE CONNECTIONS ...

Page 25: ... only 1000 watts of 240 volt current can be used at the s metime To de termine the current available on each 120 volt circuitwhenthe 240 volt load is known subtract the 246 volt load from the plant rated capacity and divide the remainder by two 3 Phase 3 Wire AC Remote For three phase current connect onEiloadwire to each of the three generator terminals M1 j M2 and M3 If a testrtin indicates wrong...

Page 26: ...d switch in the main load line to provide for automatic disconnecting of the load If the application is essentially stationary the tiser may desire to con nect the load leads within the outlet box on the plant using bolts or con nectors and taping each lead If the main load lines are to be run in ri gid condUit install a short length of flexible conduit between the outlet box and the rigid conduit...

Page 27: ... to the plant as possible Make certain that the groWld rod will always pen etrate moist earth Fasten an approved groUild clamp to the rod Run a wire number 8 or larger never smaller than 2 sizes smaller than the largest wire used in the system from the clamp to the pla J t ground terminal If no separate groWlding term inal is provided on the plant connect to the BATTERYNEGATIVE or to the grounded ...

Page 28: ... styles of momentary contact toggle switches for use as Remote Start Stop Stations are illustrated Connect aU number 2 or OFF switch terminals to the number 2 terminal on the planttet minal block Likewise connect together all number 3 or tON ter minalsand also aU number I or SINGLE not marked terminals If the switch is to be mounted vertically start position should be upward to conform with at the...

Page 29: ...ine into the carburetor for the engine to start On installations where automatic unattended starting after extended shut down is necessary an auxiliary gravity feed fuel tank should be installed FueI irom this tank flows by gravity to the carburetor thus replacing any fuel lost through evapora Uon andpromotes quick starting after an idle period Note Return line to underground Jl Nr C 4P h iol F I ...

Page 30: ...s are all electrically cranked RUNNING TIME METER Don t Guess Know how many hour s your plant runs so that you can change oil and service the plant at proper intervals This meter will be an investment rather than an expense Simple to connect This meter runs only when the plant is operating PART NO USED WITH PLANT 302 212 60 Cycle 120 V A C c 302 102 50 Cycie 120 V A C 304 99 Resistor adding to eit...

Page 31: ... turn the adjusting screw G out until the fuel seeps through slowly making the soap bubble grow If fuel pressure is quite low it may be necessary to remove the adjusting screw before fuel will flow 6 Turn the adjusting screw in just to the point where the soap bubble holds If the screw projects above the casting surface turn it just flush No further operating adjustment will be necessary Install t...

Page 32: ...s type of cooling is de sirable where the plant must be installed in a small enclosure Provide AT LEAS 140 square inches of free net air inlet area Install duct work to exhaust heated air outside of the enClosure using flexible ma terial next to the engine airducting scroll Vacu Flo type cooling is available only for remote type plants all Qfwhich have battery ignition Conversion in the field toVa...

Page 33: ... _ 0 _ 27 PREPARA rI QN BESrJRE TO SCREW ort FILLER CAP DO l lif TIGHT LY I I i I I I t I i I FIG 24 FUEL SHUT OFF VALVE I ...

Page 34: ...nsumption is not a factor the use of multi viscosity oil may be justified oonot use anon detergent oil unlessun avoidable TEMPERATURE SAENUMBER Above 900 F 320 C 300F t0900 F loC to 320 C OOF to 300F lSOC to loC Below OOF lSoC 50 30 lOW SW or lOW plus 10 kerosene NOTE For temperatures below O F lSOC U SAEnnmber 5W oil is not available use SAE number lOW ail diluted with 10 kerosene Use40unces of k...

Page 35: ...bserve the usual precautions when handling gasoline NEVER FILL THE TANK WHEN THE PLANT IS RUNNING BECAUSE OF FIRE HAZARD Open all ofthefuel shut off valves all the way to backseat and inspect the fuel system for leaks If the preceding instructions have been followed the plant should be ready for operation Before starting the plant however carefully study the sections OPERATION and ABNORMAL OPERATI...

Page 36: ... switch to crank the engine As soon as the engine starts release the start switch As with any automotive starter damage may occur if the starter is engaged while the engine is running STARTIN GTHEREMOTE CONTROLPLANT MANUALLY If the bat ery charge condition is 100 low to crank the engine but is sufficient to supply igni tion current the plant maybe started manually Snap the control box switch to it...

Page 37: ...LL THE WAY IN AIBe II FIG 25 PRIMING THE FUEL PUMP APPLYING THE LOAD Best results are obtained if the plant is al lowed to thoroughly warm up before apply ing a heavy load Load wires shouldbe connected before operatirlg according to the model in question as instructed under INSTALLATION Apply the load to the remote control type plant by throwing the main line switch to the ON position If no mainli...

Page 38: ...plete stop The high tenSion mag neto provides a firing spark even when the engine is runningat very few rpm Release of the STOP switch too soon will allow the plant to again pick up speed and continue to run To stop the a c remote control plant push the START STOP switch to the STOP postion To stop the magnet service plant snap the ignition switch to its OFF position In an emergency if the STOP bu...

Page 39: ...ne starts I Operate startswitch until generator speed builds up I Generator DC current AC outputcnrr ent pro produced duced and fed to load Helease start I sWitch I I Startsolenoidi Takesoverenergiz Recharges Takes over opera de energized ing of stop relay ting of choke Battery The charge rate is high when the When the battery becomes fully balteryls notft illy charged DC charged the voltage regul...

Page 40: ...tion When the charge switch is at the LOW position the fullaccapacity of 3 000 watts can be used The plant produces alternating current ac as well as direct current de and must operate at about 1800 rpm for 60 cycle plants in order to produce the correct current frequency NEVER INCREASE ENGINE SPEED TO INCREASE THE CHARGING RATE Engine speed should be adjusted only as necessary to obtain the corre...

Page 41: ...m highly leaded gasoline should not be used Keep gasoline supplies free of moisture condensatiQr I Leave room in the fuel tank to compensate forexpanslon AIR CLEANER The oil in the air cleaner should be the same U l that used in the crankcase If frost forms in cleaner and reStricts theHow of air empty the air cleaner oil rurlthe plantwlth the air cleaner dry Refill the cup when temper conditions a...

Page 42: ...onditions To lengthen battery life reducethe electrolyte from a normal 1 275 specific gravity reading at full charge to a 1 225 reading Attach a tag to the battery noting that the specific gravity has been reduced the cranking power of the battery is somewhat reduced when its electro lYte is diluted for longer life but if the temperature is consistently high the reduced power will not be noticed 1...

Page 43: ...w cooling fins of cylinders or cylinder heads to become dirty or obstructed Keep the generator commutator brushes and brush guides clean LUBRICATION Change the crankcase oil every 50 operating hours instead of every 100 operating hours during sever ely dusty operating conditions Important 4 GIVETHESE NUMBERS WHEN ORDERING REPAIR PARTS OR REQUESTING SERVICE INFORMATION fOR YOUR UNIT WRITE IN NUMBER...

Page 44: ... gasoline is not recommended CRANKCASE OIL LEVEL R emove the oil fill cap and check the crank case oil level Add oil as necessary to keep the oil level at the full mark on the gauge Recommended grades ofoil ar given underPREPAR TION Avoid overfilliilg whIch will allow the connecting rod to strike the oil and cause oil foamlngwhich interferes with efficient lubrication The oil fill cap gasket must ...

Page 45: ...o of lubricating oil at the point where the link engages the carburetor throttle arm Lubricate the governor arm ball joint with a dry type lubricant such as powdered graphite to assure best performance and longest life of the ball joint If graphite is not available use a light non gummy oil SPARK PLUGS Clean the sparkplugs and reset the gap as given in the Table of Clearances Test the plug under c...

Page 46: ...r point gap tb O 020 inch at lull separation after dres sing the points or changingthem Place a drop of light lubriCating oil on the breaker arm pivot after installing new points The ignition condenser is faulty and should be replaced if thefollow1rlg conditions persist 1 ExceSsive arcing at the breaker points 2 Breaker points continually burn over 3 Yellow colored spark at the points PLACE A DROP...

Page 47: ...a heavy carbon for mation within the cylinders If readings indicate a compression loss remove the spark plugs and squirt only enough SAE number 50 au into each cylinder to seal the rings Take the compression readings again If the readings remain about the same the valves probably need servicing However if the readings have increased quite a bit the valves are probably in good condition Loss of com...

Page 48: ...on dust from the gener ator NEUTRAL BRUSHPOSITION Brushes will arc excessively and brush wear will be rapid if the btushrig is moved from its original neutral position as marked at the factory CAUTION If a new armature or brush rig is installed the neutral brush position mu st be re Iocated and re marked Neutral brush pOSition is that point at which the least arCing of the brushes occurs Ifa voltm...

Page 49: ...efetably both should be connected to the generator output in order to correctly adjust the governor of the a c plant A small speed drop not noticable without instruments will result in an objectionablevoltagedrop The engine speed can be checked with a tachometer The governor arm is fastened to a snaft which extends from the gear cover and is connected by a ball joint and link to the carburetor thr...

Page 50: ... the carburetor idle needle with no load connected c Adjust the length of the governor linkage d Check the governor linkage and throttle shaft for binding or exces sive looseness e Adjust the governor spring tension for rated speed at no load opera tion with booster disconnected or held inoperative f Adjust the governorsensitivity g Recheck the speed adjustment h Set the carburetor thr6ttle stop s...

Page 51: ... M EN tS CARBURETOR THROTTLE PLATE rn THROTTLE STOP SCREW L J s C1 GOVERNOR CUP GOVERNOR SHAFrYOl E FIG 80 GOVERNOR ADJUSTMENTS A 6 ACKEl S LJNK C SPRING PRING E SRACKET F pIN C DIAP HRAGM ClNCL Ut tS H H l EVER ...

Page 52: ... no 265 245 Preferred Voltage Spread 20 SPEED CHART FOR CHECKING GOVERNOR REGULATION Note For models Prior to Spec D speed is 2400 2700 rpm NQte t For modelspriortd S pec D speed is 2500 2750 rpm DIRECT CURRENT TYPES OF PLANTS Mjlximum No Load Speed RPM Revolutions Per Minute Minimurn FullLoad speed Without Booster RPM Revolutions per Minute Maximum speed Drop From No Load Operation to Full Load O...

Page 53: ...rred Voltage Spread ALTERNATIN CURRENT TYPES OF PLANTS Maximum No LoadSpeed RPM Revolutions Per Minute Cycles Curren Frequency Minimum Full Load SpeedWithQut Booster RPM Revolutions Per Minute CyCles Current Frequency Maximum Speed Drop From No Load Operation to Full Load Operation RPM Revolutions Per Minute CyCles Current Frequency I Preferred Speed Regulation No Load to Full Load Operation 1lPM ...

Page 54: ...ually requires a compensat ingspeed spring tension adjustment 6 THROTTLE STOP SCREW The throttle Jeyerstop Screw should b e set at 1 32 inch distance from the manifold w1j entheengine is operating with no load connected Refer to theillust ratian Throttle Stop Leyer Position IOLING POSITION FIG 32 THROTTLE STOP LEVER POSITION 7 SPEED BOOSTER ADJUSTMENT After satisfactory perf rmance unde r variou l...

Page 55: ...p of the engine intake manifold Do not enlarge this hole If there is tensicm on the external spring when the plant is operating at no load or light load it maybe due to improper adjustment restrictedho ein the small vacuum tube or a leak in the booster diaphragm or gasket _ OILPRESSURERELIEF VALVE ADJUSTMENT Th r UPtessur e of the plalltcallbe easily adjusted by means of the slotted stud and lockn...

Page 56: ...rom its seat NEVERfOI ce the needle against its seat more than fffinger tightl1 be too t1o t I tl u If the carburetor IS entirely out of adjustment open the main needle about 2turns and the idle needle about 1 turn to permit starting Make final adjustments afte t theplant reaches normal operating temperature To make the final adjusbnei tt slowly turn the main needle inward clock Wise for leanetmix...

Page 57: ... in thecboke cover This heating element causes the thermal coil to wind tighter and turn the choke shaft gradually opening the chokeas the plant warms up Wheu the plant is stopped the thermal coil cools off causing the choke shaft to returnto the correct position for the next start The thermal coil bi metal is installed in the choke tlodyin acounter clockwise direction as viewed starting from the ...

Page 58: ...t may beus ed to manually operate the choke in the event the electric element burns out or the choke does not operate for any reason Turn the knoblIi the direction shown on the knob If electric choke failure occurs the choke will remain at closed pOSition By removing thethermostaticcoil to permit an emer gency run the airstream will hold the choke at open position If the engine starts between 6 an...

Page 59: ...e SEAT Angle Valve InterferenceAngle Crankshaft Main Bearing Clearance 0 015 0 017 0 015 0 017 0 001 0 0025 0 0025 0 004 1 32 440 3 64 450 10 Aluminum Alloy Flanged Prior Spec F 0 002 0 003 Bronze Faced Begin model Spec F Crankshaft End Play Camshaft Bearing Clearance Camshaft End Play Connecting Rod Bearing Clearance Alum Rod Connecting Rod End Play Timing Gear Backlash Oil Pump Gear Backlash Pis...

Page 60: ...e wire may be used to clean jets the float is not damaged If necessary to reset the f1oan vel a small screw drlv er to bend the lip of the float With the carbure toi casting inverted and the float resting llghtly against the needle in its seat clearance between the bowl cover gasket and the free end of the float should be 5 16 7 32 ifa DAY reservoir tank is used Carburetor adjustments appear inthe...

Page 61: ...N Coil connections differ between mag neto ignition plants and battery igni tionplants Refer to the illustration which applies The ignition coil is grounded on magneto ignition plants but not grounded with battery ignition The spark occurs aUhe build up of magneto current and at the collapse of battery current HIGH TENSION LEAD MAGNETO STATOR BREAKER ASSEMBLY MECHANISM SPARK PLUG HIGH TENSION LEAD...

Page 62: ...f 2500 rpm and up use the 250 spark advance The correct timing is stamped on the cylinder block near the breaker box Timing procedure follows 1 Remove the cover from the breaker box If the timing is very far off attain an approximate setting by loosening the mounting screws and shifting the breaker box and spacer if used to align the witness marks on the cylinder block and breaker box or spacer 2 ...

Page 63: ...ate when the mark ontheflywheel aligns with the correct degree mark 190 or 250 on the gear cover If the marks align as the points break timing is correct If they do not loosen the breaker box mounting screws and shift the whole breaker box assembly slightly toward the air cleaner to retard the timing points breairing too soon or shift it slightly away from the air cleaner to advaricethe timing poi...

Page 64: ...is removable for valve servicing Do not use a pry to loosen the cy linder head rap sharply on the edge with a soft faced hammer taking care not to break any cooling fins A conventional type valve spring lifter may be used when removing the valve spring locks which are of the sp ttt type Clean all carbon deposits from the cylinder head piston top valves guides etc If a valve face is burned or warpe...

Page 65: ...ing an air pressure type testing tool If such a tool is not available make pen cil marks at intervals across the valve face and observe if the marks rub off uniformly when the valve is rotated part of a turn against the seat Lightly oil the valve stems and reassemble aU parts removed Adjust the valve clearance The positive type exhaust valve rotocaps serve to prolong valve life and need for valve ...

Page 66: ...tration Valve Service To correct the valve clearance simply turn the adjusting screw as needed to obtain the right clearance The screw is self locking and will stay where set If valve clearance can no longer be held within given limits replace the valve To adjust the valves on the right hand cylinder crank the engine over one complete revolution and again line up the mark on the flywheel and the T...

Page 67: ... if the race surface is grooved or rough The governor must be a free spinning fit on the camshaft center pin but without any looseness or wobble When installing the governor cup tilt the engine so the gear tsup put the flyballs in place equally spaced and install the cup and snap ring on the camshaft center pin This distance provides an in and out travel distance of7 32 for the governor cup as ill...

Page 68: ... straight and thaUhe key is properly in place Install the gov ernor cup assembly before installing the camshaft and gear in the en gine Note that each timing gear is stamped with 0 mark near the edge The gear teeth must mesh so that these marks exactly coincide when the gears are installed in the engirie Be sure when installing the camshaft gear and shaft assembly that the thrust washer is properl...

Page 69: ...n cylinder walls Install new rings where there is any doubt about the condition of the old rings I I Before installing new ringsonthepistcin check the ring gap by placing eachring squarely lnits cylinder at a position correspondlng to the bot tom of its travel The gap betweeJ l the ends of therlng should beas given intl1e Table ofClearances Rings which are slightly oversize may be HIed as necessar...

Page 70: ...n standard or 0 020 inch undersize The connecting rod bearing surface is aluminum aUoy andpr operclear ance between the rod bearing surface and the crankshaft bearing surface is obtamedbprdressingtheconnectingrod cap 1 hecorrect clearance is shown in the Table of Clearances Use a s heet of 320 grit or finer abra sive onasmooth fiatsllrface Place the ends ofthe connecting rod caR on the abraaive ma...

Page 71: ...n bearing to shrink it Align the oil hole s in bearing with the oil hole s in bearing bore The oil passage must be at least 1 2 open The cold oiled preCision bearing should require only light taps to position it Install the flanged type bearing used prior to Spec F with its notch engaged with the stop pin Install the bronze faced bearing used beginning with Spec F flush with the inside end of bore...

Page 72: ...e bore After the sealis in place it is advisable to apply a thin coating of shellac or Permatex around the outer surface of the seal at the point where it comes in contact with the bearing plate hoss Use a seal expander or place a piece of shim stock around the end of the crankshaft when replacing the bearing plate tb avoid damaging the seal Remove the shim Stock as soon as the plate is in place L...

Page 73: ... of the crankshaft If necessary clean them to assure proper lubrication of the connecting rods When installing the crankshaft use gaskets as needed behind the bear ingplate to assure end playas given in the Table of Clearances herein OIL PUMP To remove the oilpump it is necessary to detach the intake cup assembly as illustrated Check the oil pump thoroughly for worn parts Oil the pump to prime e i...

Page 74: ...epair the pump rather than install a new one the use of a complete repair kit is recommended ALWAYS RETURN THE HAND PRIMING LEVERALL THE WAY IN WARD so that the priming lever does not prevent the normal operation of the pump If the fuel pump rocker arm is being lifted by the cam shaft the engine must be cranked 1 revolution before the priming lever will be effective Rotating the diaphragm 1 4 turn...

Page 75: ...reful not to iet the frame assembly restor dragon the armature Turn thearmaturenutoutto the end of the armature through stud While pulling outwardwith one hand underthe armature strike a sharp end wise blow on the nuttoloosenthe ar mature Remove the armature and blower as an assembly The blower is a keyed and pressed fit on the armature shaft and isa keyed and tapered fit to the engine crankshaft ...

Page 76: ... matk falls This is coml ll oillyknowll as the neutral brush positibn l i i COLLECTOR RINGS AC Units If the collector rings become groov e d o r out of round or the brush Sur face becomes pitteqor rough so that goodbtush seating cannot be main tained ur em ove thearmattireamd refiniSh the collectorrihgsin a lathe If the commutator appearst6 bce rough or scored lJefinishit at th same time Remove or...

Page 77: ...w If the test lamp does glow the dc winding or thecomrtlutator is grounded To testthe a c winding place one test prod on One of the collector rings and the other test prod on the armature shaft li the test lamp glows the a c windingor a collector ring is grounded Ite ar TEST LAMP FOR JESTING FOR OPEN CIRCUITS AND GROUNDS I f 1 3 OJ CANDL POW II BULB FIG 52 CONTINUITY FIG 53 ARMATURE TEST LAMP GROW...

Page 78: ...n for cranking and battery charging pur poses When testing a field coil assembly disconnect all of its exter nal leads from their terminals Tag and mark each lead te assure pro per cennectionswhen reassembling TESTING FIELD WINDINGS FOR GROUNDS To test a coil assembly fer a ground disconnect its exte t nal leads and teuch one test pred te the terminal of one of its leads and the ether test prod te...

Page 79: ...he generator see that there are no nicks or dirt on the arm ature blower tapered surface These conditions may cause an excessive run out wobble at the bearing end Run outshould be within 0 002 Ti hten the armat re through stud nut securely FIG 54 GENERATORABSEMBLY I ...

Page 80: ...e to repair such parts as meters fuses switches relays or receptacles Check all electrical connec tions and contacts whenever servicing control equipment Always disconnect the battery whenever servicirig controls to avoid accidentally starting the plant When disassembling controls tag each lead that has to be removed and mark the connection point ofthe lead on the tag to assure correct connections...

Page 81: ...be inserted in the recess of the starter cover It may be necessary to Uethespringwithapiece of wire to prevent its unwinding during in stallat io unless other help is available Place the spring in the cover recesS in crankshaft rotation direction Remove the tying wire if used While holdlngthespringto prevent its unwindinginst8 11 the inside end of thespririgontheroll pin 7 in the cover With the pu...

Page 82: ... MTCHET WHEEL 5 START R COVER II PAWL 17 SCREW 23 Sl ECIAL CAl SCHEW 5 COGWHEEL 12 PAWL SPRING IS FLEXl OCK NUT 6A SPruNG WASHER 12A SPlROL PIN FlG 55 SERVICINGTHE READI PULL STARTER i I I I I i il SPECIAL NUT BLOWER HOUSING fL T WASHERS POSI1 ION Cr STAR 1 ER ASSEM6L f MAY BE CHANGEC BY LOOSENING CLAMP SCREWS LOCK WASHER I ORILLEO r4l 0 HEAD SCREWS RATCHET WHE EL I I ALIGNING STARTER ON ENGINE Fl...

Page 83: ...rrQllpins in the starter rope sheave wiUalign with th se two holes Wl ljle llOlding inthealigned position insert a ten pennYCOmlllon naUthrough eacho the holes Push the nails in up to their heads 5 Install thesta rt a ssembly 3 to the blower housing making sure that the nail ends etltel lllepilot holes in the ratchet wheel mounting sCJ ews It will probably be necessary to turn the flywheel a parti...

Page 84: ...ng pin 12 instal ter center screw 14 allowing 3 8 to pl otrude For reinstallations readjust pin depth 4 Center the starter assemblyover the ratchet wheel with thecen tering pin engaging the center hole of the flywheel mounting screw While holding in position mount the starter usingahex head screw lock washer and two flat washers at each mounting arm as shown in detail A Tighten the mounting screws...

Page 85: ...ch NGINEWI LNOT Faulty ignition Lack of fuel orfaultYcarbure Replac 3 brushes or cleancommut itor Repair or replace parts necessary Disconnectload Replace switch START WHEN CRANKED Clean adjust qr replace breaker points spar k plugs condenser etc orretime ignition Refill the tank Checkthe fuel Sy Cylinders flooded tion stem Clean adjust or replace parts necessary Clogged fuel filter Clean Ground s...

Page 86: ... or brush Rl3finish commutator or undercut contact mica if necessary See that brushes seat well on commutator and collector rings are free in holders are not worn too short and have good spring tension Loose connections Tighten connections Fluctuating load Correct any abnormal load con dition causing trouble GENERATOR OVERHEATING Short in load circuit Correct short circuit Generator overloaded Red...

Page 87: ...d exhau t line Carburetor idle jet clogged or improperly adjusted Sparkplug gaps too na rrow Intake air leak Faulty ignition Clean Adjust to correct gap Tighten Replace gaskets if nec essary Clean adjust or replace breaker pOints spark plugs condenser etc jor retime ignition See r emedi l mder Engme Mis it E s tEeavYLoadl I igbten cyHnder heads and spark plugsi If stillJ10t corrected grind the val...

Page 88: ...r replace breaker points LOW OIL PRESSURE Oil too light or diluted from Drain refill with proper oil Re leaking fuel pump diaph ragm pair or r eplace fuel pump Oil too low Add oil Oil relief valve not seating Remove and clean or replace Badly worn bearings Replace Sludge on oil screen Remove and clean Badly worn oil pump Replace Defective oil pressure gauge Replace HIGH OIL PRESSURE Oil too heavy ...

Page 89: ...s from oil base or con nections This doesnotc ause smoky exhaust on too Ughtor diluted Too large bearingclear ance Engine misfires Faulty ignition Too much oil Refinish cylinders Install oversize pistons and rings Replace ga skets Tighten screws and conne ctions Check breather valve Drain Refll with proper oil Replace bearingsilecessary Refer to Engine Misfires at AU Speeds Clean adjust or replace...

Page 90: ... Low oil supply Add oil Change if necessary Oil badly diluted Drain Refill with proper oil Low oil pressure See Low Oil Pressure for re medies ENGINE STOPS UNEXPECTEDLY Empty fuel tank Refill Defective ignition system Check the ignition system Repair or replace as needed See that the STOP button lead is not grounded DULL METALLIC THUD IF NOT BAD MAY DISAPPEAR AFTER FEW MINUTES OPERATION IF BAD INC...

Page 91: ...AUSE Carbon incylinders Spark advancedtoofar Spark plug burn ElI 19rCllf boned REMEDY Ren ioY Mcarbon Resetbr e r points or retime ignitiorl In allcOfrect sparkplugs Clean Install newplugifneces sary Adjust tappet clearance Fuel staleQ r lOW octane Lea nfuel mixture Engine hot Use good fresh fuel iCIeanfuel ystem Adjust car buretor jef i l properly Check air rculation AdjusttoProper clearance Inst...

Page 92: ... Brqsh rig out of position Line up properly SPARK PLUG FOULED IN SHORT PERIODS OF TIME ON GASOLWE OPERATION Wrong spark plug gap Spark Clean spark plugs and set at 0 025 plug may be set at 0 018 for gaseous operation but not changed to O 025 when switching over to gasoline operation HARD STARTING MISSING POPPING ERRATIC OPERATION ON GASEOUS FUEL OPERATION Spark plug gap too wide Spark Set sparl pl...

Page 93: ...LE TYPEPLANTWITaCARRYIl TG FRAME ARMAtURE iALTERNATING CURRENT 120VOLT 1 PHASE 2 WIRE BOX N2a01C Z79 PANEL N 30IB 52 5 MrG BJ WT N Z OICi t76 CONNCcrO R iii 33 o Z7 NS DE VI 7 _ ____ ___ ______ ___ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ c __ _______ _ _ _ ____ _ __ _______ _ _ _ _ _ _______ _ __ ...

Page 94: ...AN I GNITII N 30S CCk ZPl oo SPE C fA 100 iCCK ZP PFCIA TO SPANk P UIIS COlt I I EI INS DE VIEW a AJF C J I AI7 r IV l COND S lMI N 3 J ZASa c i Lei J _ I I A C t rrl SI IPRINGS PORTABLE TYPE PLANT WITH CARRYING FRAME L RIvM TV i ALTERNATING CURRENT 240 VOLT 1 PHASE 2 WillE h ...

Page 95: ...U l I ZNL PJ OTI Al P o I N 3zz IL 1 TO _ _ _ _ _ _ I I I I I I SPAR PLUGS D l TllUARl 1 c s 0 l N 3Z2AZ2 V I I I J BOXN 3o rC Z79 PANEL N L301 8 S2 MTGo BRI T Nt 301C 216 eF0HN C70R N 3 3I 7 BLOWER HOU51NG OrE NG1NE WIRiNG DIAGRAM 602B146 PORTABLE TYPE PLANT WITH CARRYING FRAME ALTERNATING CURRENT 120 240 VOLT 1 PHASE 3 WmE _1 _ sen ...

Page 96: ...MECHANISM_ RCCEPT IIt E ZZ 21 PILOTUMP TO N i 3zz S9 I UGI IT6 JARD N 3ZZAza I I I BOX N Q C 1 2 79 PANEL N 301E 2 6S MTG E RKT N 30JCIZ76 CONNECTOR NP 3 JJ Z7 lHSlDE BL WER HOUSING OI ENGINE WIRING DIAGRAM If 602B147 PORT ABLE TYPE J LANT WITH CARRYING FRAME ALTERNATING CURRE NT 240 VOLT 3 PHASE 3 WIRE 3 1 Mro COND S 11 13312 58 LC J __ l iJ o ...

Page 97: ... I I COVE If 3 30 6 I SOX J O i 8 I IISlf D O yAu MODel S I I SHOWN ON D Jt JGRA W t M tM2 _ N 7t S ISCC IM SPEC IA JU IMit 30 1 S CtA Z M liS IMF l _ 5 70 7 1 E Jrro V i L 1 t I i I I 51 I I Givm 1 l I Call J __ _ _ WIRINGDIAGRi M if 602B143 I MANUAL TYPE PLANT NOT IN CARRYING FRAME ALTERNATINQCURRENT t lor PHAI3E 2or 3 WIRE Ie _ _ _ _ _____ c _ _ _ _ _ c _ _ ___ ...

Page 98: ... 1 J U Z s 1 ____ _ 1 j DNA 1GNrTIOhl COIL r _____ _ to I I 2 1 co I l I I WIRING DIAGRAM if 611C178 p Q 0 5 NG5 REMOTE TYPE PLANT ALTERNATING CURRENT 240 VOLT 3 WIRE 3 PHASE j ...

Page 99: ...V J I 12 va 7Z k M lMrTFP ZSWArr Ai Q4 4i N S STbR t t Faa s L ENlJILJ j 07 P3JZ W WNv5 r rrE Fok VACUUM CO J ED PLANTS v 5E COYEP NI 30ICI1 4 f eND PI ATE N OI ElIZ 71 WIRING DIAGRAM i611C176 REMOTE TYPE PLANT ALTERNATING CURRENT 120 VOLT 2 WIRE and 240 VOLT 2 WIRE 1 PHASE co w ...

Page 100: ...A OIl b i Cn KC P z IA l sOLEt CJtl 1 t 3Q JB 4Q1 f T HA Z WAT T RES1STOR I V RELAY S 030 1S Z I __ _ II I N 304 bcr R L_ A 1 E T v fC h t s i J V WIRING DIAGRAM 611C 164 REMOTE TYPE PLANT ALTERNATING CURRENT 120 240 VOLT 3 WIRE 1 PHASE f ...

Page 101: ...1 l8RE A ER POINTS _CONDE Nse R _1_ rt NIT ION rl 1 1 I I MAGNETO I J I COr or 1 L_L _J STOP SUTTON MOUNTEOON BLoweR HSG7 I q RESISTOR eox N 30Je4l Z PANE l N 30185 5 _MTG I3RK T N 30 I B 5 7 BOX N 130ICSbb HEAV WIIU WmING DIAGRAM 602B165 PORTABLE TYPE PLANT 115 VOLT DmECT CURRENT U1 SMrD COtW_ I co ...

Page 102: ... 1 I I L j i__ 1 I I fa VOLT STARTER L ___ I I IGNITION I I I SWITCH I I I N 2 3 O 8 69 I I JUMF ER N l 33ZA s7 a 1 I I I I I d J __ J START SUTTON N 306AZ9 i ENR y kPOINTS I I I r I I I I I 1 L _ _ _ ONAN IGI lITION COIL OPTIONAL CHARGE GENERATOR r _ ______ _ __ _ _ NOTE RHE OSTAT FURNISHED BY C JsTOr iE R GENE AT PR I I I I _I IFF I 1 I t _ _ _ _ _ _ _ a RKT CONTROL N 301 C 1494 611B244 611B276 ...

Page 103: ...7 __ TO sPARK PLO S Bli J CON Tl tUIYE 30 l c I l 4e I I I 117 I ER___ Y n 2LJ V I I J I J AJUlr2IIlll E sHVH r7 7EtD 300 0HM _ oe WATT I HEO IIE 3IY3 Sr NtlT FURNISHED WITH PtANr 7CLOAD INSIDE VIEw IJLO I I IJ INr O t h N WIRING DIAGRAM H602B164 250 VOLT DIRECT CURRENT 6 VOLT STARTER VACU FLO MAGNET SERVICE 1_ S 3 _ ...

Page 104: ...Az I ifY f MAGNETO I _ I COl t I I I __ J 1 I stop B UTTON tD D 1 I I J 9lIJ I 2 l C l on J i MQUNTeD ON _ ONAN lGWIT ON __ CO l__ __ BLOWER II 40U NG 7 I d I TO SPA RI ___ I S r N O TE __ _ RHE OSTAT FUFUJISHED SY CUSTt MeR 602A166 602A174 wmING DIAGRAM 250 volt DC MAGNET SERVICE MANUAL START ...

Page 105: ...N i 1 C GE rs i I 3 8 o SW J r H N J E J L _n I I I I I I gJlJc Kj i 4 Ie MODEL USE COVER NS 20Jl 1244 I NPI ArE N 1 oIBI27 J eC T RJC CN l r f 1 I WillING DIAGRAM No 611C234 DUAL PURPOSE TYPE PLANT 120 VOLT AC 32VOL t DC ...

Page 106: ...Oj PA NELA J S l NJ 3C C IGO COin He L 4 X MIG 1f iT i0t7 Alf30J B 8 C J E HR 30 C 2 EN pJ l l7 V i i tt7 J7 llT S7oE w MrC Sh Ar Z 501 97 0 N Cnx V VRfW r Dl JU r NF S I i i E 4 1 D lIn otJu B I l __ _ u I I I 1 I r I I J wUH4 s uP RJNlJ VUI ut 1 E WIlUNG DlAGRAM 6ilc206 o REMOTE TYPE PLANT ALTERNATlNG CURRENT 120 208 VOLT 4 WIRE 3 PHAsE _____ IF fJ ...

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