Onan 3.0 AJ User manual

Table of contents

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SAFETY

PRECAUTIONS

The

following

symbols

in

this

manual

signal

poten¬

tially

dangerous

conditions

to

the

operator

or

equip¬

ment.

Read

this

manual

carefully.

Know

when

these

conditions

can

exist.

Then,

take

necessary

steps

to

protect

personnel

as

well

as

equipment.

WARNING

I

Onan

uses

this

symbol

throughout

this

manual

to

warn

of

possible

serious

personal

injury.

This

symbol

refers

to

possible

equipment

damage.

Fuels,

electrical

equipment,

batteries,

exhaust

gases

and

moving

parts

present

potential

hazards

that

could

result

in

serious,

personal

injury

Take

care

in

follow¬

ing

these

recommended

procedures.

•

Use

Extreme

Caution

Near

Gasoline.

A

constant

potential

explosive

or

fire

hazard

exists.

Do

not

fill

fuel

tank

near

unit

with

engine

running.

Do

not

smoke

or

use

open

flame

near

the

unit

or

the

fuel

tank.

Be

sure

all

fuel

supplies

have

a

positive

shutoff

valve.

Fuel

lines

must

be

of

steel

piping,

adequately

secured

and

free

of

leaks.

Use

a

flexible

section

of

fuel

line

between

generator

set

and

stationary

fuel

line

in

the

vehicle.

This

flexible

section

must

be

100%

NON-METALLIC

to

prevent

electrical

currents

from

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

appropriate

for

all

applications.

Consult

the

local

fire

department

for

the

correct

type

of

extinguisher

for

various

applications.

•

Guard

Against

Electric

Shock

Remove

electric

power

before

removing

protec¬

tive

shields

or

touching

electrical

equipment.

Use

rubber

insulative

mats

placed

on

dry

wood

plat¬

forms

over

floors

that

are

metal

or

concrete

when

around

electrical

equipment.

Do

not

wear

damp

clothing

(particularly

wet

shoes)

or

allow

skin

surfaces

to

be

damp

when

handling

electrical

equipment.

Jewelry

is

a

good

conductor

of

electricity

and

should

be

removed

when

working

on

electrical

equipment.

Always

use

an

appropriately

sized,

approved

double-throw

transfer

switch

with

any

standby

generator

set.

DO

NOT

PLUG

PORTABLE

OR

STANDBY

SETS

DIRECTLY

INTO

A

HOUSE

RECEPTACLE

TO

PROVIDE

EMERGENCY

POWER.

It

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

or

death.

Follow

all

state

and

local

electrical

codes.

Have

all

electrical

installations

performed

by

a

qualified

licensed

electrician.

•

Do

Not

Smoke

While

Servicing

Batteries

Lead

acid

batteries

emit

a

highly

explosive

hydrogen

gas

that

can

be

ignited

by

electrical

arcing

or

by

smoking.

•

Exhaust

Gases

Are

Toxic

Provide

an

adequate

exhaust

system

to

properly

expel

discharged

gases.

Check

exhaust

system

regularly

for

leaks.

Ensure

that

exhaust

manifolds

are

secure

and

not

warped.

Be

sure

the

unit

is

well

ventilated.

•

Keep

The

Unit

And

Surrounding

Area

Clean

Remove

all

oil

deposits.

Remove

all

unnecessary

grease

and

oil

from

the

unit.

Accumulated

grease

and

oil

can

cause

overheating

and

subsequent

engine

damage

and

may

present

a

potential

fire

hazard.

Do

NOT

store

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

generator

set

operation

(cooling,

noise

and

vibration)

may

be

adversely

affected.

Keep

the

compartment

floor

clean

and

dry.

•

Protect

Against

Moving

Parts

Avoid

moving

parts

of

the

unit.

Loose

jackets,

shirts

or

sleeves

should

not

be

permitted

because

of

the

danger

of

becoming

caught

in

moving

parts.

Make

sure

all

nuts

and

bolts

are

secure.

Keep

power

shields

and

guards

in

position.

If

adjustments

must

be

made

while

the

unit

is

running,

use

extreme

caution

around

hot

manifolds,

moving

parts,

etc.

Do

not

work

on

this

equipment

when

mentally

or

physically

fatigued.

TO

THE

OWNER

Welcome

to

the

growing

family

of

Onan

Power

users

.

.

.

We

are

proud

to

have

you

as

a

customer.

Read

this

manual

carefully

and

observe

all

safety

rules

within.

Operating

instructions,

adjustments

and

periodic

maintenance

procedures

are

given

so

that

you

.

.

,

the

owner,

can

keep

your

unit

running

like

new

and

expect

many

years

of

dependable

service

from

it.

Remember

.

.

.

any

machine,

regardless

of

design

or

type,

will

perform

only

in

relation

to

the

services

it

receives.

If

your

generator

set

needs

special

attention,

ask

your

Onan

dealer

for

assistance;

the

Onan

Parts

and

Service

Organization

has

been

factory-trained

to

provide

up-to-date

know-how

for

keeping

your

RV

electric

generating

set

“on

the

road”,

A

complete

Parts

Catalog

is

available

at

nominal

cost

and

may

be

ordered

under

924-0222.

TABLE

OF

CONTENTS

General

Information.

2

Specifications.

3

Installation

Checks.

4

Operation.

6

Adjustments.

9

Engine

Troubleshooting

Guide.

12

Maintenance.

13

Control

Troubleshooting.

17

Remote

Accessories.

19

Parts

Information.

21

EARNING

TO

PREVENT

FIRE

OR

ACCIDENT

HAZARD.

.

.

THIS

UNIT

MUST

BE

INSTALLED

ACCORDING

TO

THE

MANUFACTURER’S

DETAILED

IN¬

STALLATION

PROCEDURES

OBSERVING

ALL

MINIMUM

CLEARANCES.

TO

AVOID

POSSIBLE

PERSONAL

INJURY

OR

EQUIPMENT

DAMAGE,

ANY

INSTALLATION

AND

ALL

SERVICE

MUST

BE

PERFORMED

BY

QUALIFIED

PERSONNEL.

1

GENERAL

INFORMATION

YOUR

MANUAL

This

manual

contains

operation

and

other

informa¬

tion

to

properly

maintain,

service,

and

make

ad¬

justments

on

your

AJ

generator

set.

Study

and

follow

the

instructions

carefully.

A

well-planned

service

and

maintenance

program

will

result

in

longer

unit

life

and

better

performance.

Because

the

most

important

part

of

repair

is

diagnosis,

a

troubleshooting

chart

is

included.

Throughout

the

manual,

engine

end

of

the

generator

set

is

the

front.

Left

and

right

sides

are

determined

when

facing

the

engine

(front)

end.

When

contacting

your

Onan

dealer,

distributor,

orthe

factory

about

the

generator

set,

always

supply

the

complete

model

number

and

serial

number

as

shown

on

the

nameplate

(see

Model

Designation

following).

This

information

is

necessary

to

identify

your

generator

set

among

the

many

types

manufactured

by

Onan.

MODEL

DESIGNATION

The

following

typical

model

number

is

broken

down

into

code

segments

used

by

Onan.

3.0

AJ

-

1

R

16017

S

—I

-

r-

-r

-

\

-

T~

1

2

3

4

5

6

1.

Indicates

kilowatt

rating.

2.

Series

identification.

3.

Voltage

code

of

the

generator,

1

=

120

volts.

4.

Method

of

starting:

R—Remote

electric

starting.

5.

Factory

code

for

designating

optional

equipment,

if

any.

6.

Specification

letter

which

advances

when

the

factory

makes

production

modifications.

FUEL

REMOTE

CONTROL

PUMP

PLUG

GOVERNOR

ADJUSTMENT

VIBRATION

ISOLATOR

FUEL

SOLENOID

SHUTOFF

VALVE

FUEL

INLET

GENERATOR

OIL

DRAIN

OIL

FILL

VACU'FLO

SCROLL

START-STOP

SWITCH

CARBURETOR-

AIR

CLEANER

EXHAUST

OUTLET

CIRCUIT

BREAKER

GENERATOR

COOLING

AIR

IN

BREAKER

BOX

ENGINE

/

DRIP

PAN

TYPICAL

AJ

RECREATIONAL

VEHICLE

GENERATOR

SET

2

SPECIFICATIONS

This

manual

contains

SI

metric

equivalents

that

follow

immediately

in

parentheses

after

the

U.S.

customary

units

of

measure.

GENERAL

Nominal

Dimensions

of

Set

Height.

1

5

.

5

0

in.

(394

mm)

Width.12

in.

(305

mm)

Length.

23.19

in.

(589

mm)

Weight.160

lbs.

(73

kg)

ENGINE

DETAILS

Manufacturer.

Number

of

Cylinders.

Displacement

(cubic

inches)

Cylinder

Bore.

Piston

Stroke.

Compression

Ratio.

Engine

Speed.

Engine

Design.

Starting

System.

GENERATOR

DETAILS

Manufacturer.

OMAN

Design.

Revolving

Armature,

Two

Pole,

Inherently

Regulated,

3600

RPM

Rating

(in

watts)

60

Hertz.

3000

Watts

(3

kW)

Voltage

.120

Current

Rating

.25

Amperes

Phase.Single

Wire.

Two

Power

Factor..

Cranking

Current.

4

0

Amps

Break-away

Current.

225

Amps

CAPACITIES

AND

REQUIREMENTS

Oil

Capacity.

Recommended

Battery,

Electric

Start

Battery

Charge

Rate—Fixed.

Ventilation

Requirements

(total).

TUNE-UP

SPECIFICATIONS

Spark

Plug

Gap

.025

(0.64

mm)

Breaker

Point

Gap

(cold

setting).022

(0.56

mm)

Ignition

Timing

Reference

(cold

setting).22°

BTC

Valve

Tappet

Adjustment

(engine

cold)

Intake.011

(0.28

mm)

Exhaust.018

(0.46

mm)

.2

qts.

(1.89

litres)

12

Volt,

92

Amp/hr

(331.20

kC)

.

1-2

Amps

.50

sq.

in.

(323

cm^)

.

OMAN

.One

.

14.9

(244.16

cm3)

.2-3/4

in.

(69.85

mm)

.2-1/2

in.

(63.50

mm)

.6.25:1

.3600

RPM

Four

Cycle,

Air

Cooled,

L

Head

...

Exciter

Cranking

Generator

3

INSTALLATION

CHECKS

INSTALLATION

Nearly

all

Onan

electric

generating

sets

are

installed

by

the

motor

home

manufacturer.

Although

the

manufacturer

must

follow

safety

codes

when

install¬

ing,

certain

installation

problems

could

ariseafterthe

unit

is

installed

and

subjected

to

vibration.

There

are

a

few

areas

that

you

as

the

operatorshould

be

concern¬

ed

with.

If

in

doubt

aboutany

aspect

ofyourgenerator

set’s

operation

or

safety,

contact

your

nearest

authorized

Onan

Service

Center.

A

daily

inspection

of

your

installation

should

include

the

following;

•

Exhaust

•

Fuel

System

•

Electrical

•

Ventilation

EXHAUST

Check

for

leaks

around

manifolds,

gaskets

and

welds.

Make

sure

exhaust

lines

are

not

heating

surrounding

areas

excessively.

If

so,

have

corrected

immediately.

Remember

EXHAUST

GASES

CONTAIN

DEADLY

CARBON

MONOXIDE.

Be

sure

all

holes

to

the

inside

of

RV

from

set

compartment

are

sealed

to

prevent

poisonous

exhaust

gases

from

entering

vehicles.

FUEL

SYSTEM

With

set

running,

check

for

leaks.

Raw

fuel

will

cause

fumes

which

could

EXPLODE.

Check

around

car¬

buretor

and

fuel

pump

inlets.

Make

sure

fuel

lines

are

not

rubbing

against

anything

which

could

cause

breakage.

Inlet

hose

connection

to

fuel

filter

requires

a

clamp.

ELECTRICAL

AC

Output

Two

AC

leads.

Ml

(hot)

and

M2

(ground),

terminate

in

generator

junction

box.

These

wires

should

be

con¬

nected

to

distribution

box

with

multistrand

wire

enclosed

in

a

flexible

conduit.

Check

all

wires

(to

and

from

the

generator

set)

for

fraying

and

loose

connec¬

tions.

For

information

on

load

connections

refer

to

OPERATION

section

following.

Battery

Connections

Battery

positive

(+)

connection

connects

to

start

solenoid.

Battery

negative

connects

to

location

on

rear

of

generator.

Check

terminals

on

set

and

battery

for

clean

and

tight

connections.

4

Onan

recommends

using

a

separate

battery

for

operation

of

the

generator

set

in

addition

to

the

regular

vehicle

starting

battery.

Refer

to

individual

installation

guide

or

T-012

for

additional

information

on

battery

sharing.

WARNING^

discharged

cooling

air

for

com¬

partment

heating

since

it

could

contain

poisonous

exhaust

gases.

Grounding:

Generator

must

be

effectively

bonded

to

recreational

vehicle

chassis.

For

additional

information

on

installation

contact

your

ONAN

Service

Representative

or

request

In¬

stallation

Guide

#924-0611.

Vehicle

chassis

(frame)

ground

and

the

battery

and

generator

set

ground

should

all

be

electrically

connected

to

be

at

0

ground

potential.

All

Onan

units

are

designed

for

negative

ground

apollcation.

WARNING

ANSI

198.1

AND

recreational

vehicles

I

Insulation

must

not

reduce

the

minimum

I

clearances

as

specified

In

Figure

1

to

meet

CSA

#946

temperature

rise

requirements

for

Do

not

terminate

poisonous

carbon

monox¬

ide

exhaust

gas

under

vehicle.

Direct

exhaust

gases

away

from

window

and

door

openings.

Keep

all

openings

above

or

to

the

rear

of

exhaust

pipes

closed

when

generator

set

Is

operating.

WARNING

\

WARNING

DO

NOT

DISCONNECT

BATTERY

CABLES

FROM

BATTERY

WHILE

GENERATOR

SET

IS

CRANKING

OR

RUNNING;

SPARKS

MAY

CAUSE

AN

EXPLO¬

SION.

WARNING

Mount

the

battery

In

a

separate

compartment

from

the

set

or

any

spark-producing

device

to

prevent

fire

or

explosion.

WARNING

I

being

charged.

Do

not

smoke

while

servicing

batteries.

Lead

acid

batteries

give

off

explosive

gases

while

VENTILATION

The

biggest

enemy

of

electric

generating

sets

in¬

stalled

in

motor

homes

is

excessive

heat.

Make

sure

the

set's

air

inlet

and

outlet

are

not

plugged

with

dust,

dirt,

bugs,

leaves

or

anything

that

could

restrict

cooling

air.

IMPORTANT:

Certain

states

(particularly

California)

have

state

ordinances

pertaining

to

the

type

and

usage

of

exhaust

muffler/spark

arresters

on

internal

combustion

engines

or

engine

driven

equipment

when

used

In

a

recreational

vehicle

such

as

electric

generating

sets.

Be

sure

your

installation

meets

all

Federal,

State

and

local

codes

pertaining

to

your

unit.

Failure

to

provide

and

maintain

a

spark

arrester

may

be

in

violation

of

the

law.

WARNING

i

ENGINE

EXHAUST

GAS

(CARBON

MONOXIDE)

IS

DEADLY!

Carbon

monoxide

Is

an

odorless,

colorless

gas

formed

by

Incomplete

combustion

of

hydrocarbon

fuels.

Carbon

monoxide

is

a

dangerous

gas

that

can

cause

unconsciousness

and

is

potentially

lethal.

Some

of

the

symptoms

or

signs

of

carbon

monoxide

inhalation

are:

•

Dizziness

•

Vomiting

•

Intense

Headache

•

Muscular

Twitching

•

Weakness

and

Sleepiness

•

Throbbing

in

Temples

if

you

experience

any

of

the

above

symptoms,

get

out

into

fresh

air

immediately.

The

best

protection

against

carbon

monoxide

inhalation

is

a

regular

inspection

of

the

complete

exhaust

system.

If

you

notice

a

change

in

the

sound

or

appearance

of

exhaust

system,

shut

the

unit

down

immediately

and

have

it

inspected

and

repaired

at

once

by

a

competent

mechanic.

5

OPERATION

GENERAL

inspection:

Inspect

the

engine

visually

before

star¬

ting.

Check

for

loose

or

missing

partsorany

shipping

damage.

The

unit

may

be

tilted

during

operation

to

any

maximum

angle

not

exceeding

vehicle

operation

limitations.

Rust

inhibitor

oil

has

been

placed

In

the

engine

combustion

chamber

at

the

factory

and

may

foul

the

spark

plug.

If

the

plug

should

foul,

remove

it

and

clean

thoroughly.

Then

dry

and

replace

in

engine.

RECOMMENDED

FUEL

Use

ciean,

fresh,

unleaded

or

regular

grade

gasoline.

Do

not

use

highly

leaded

premium

fuels.

Using

unleaded

gasoline

results

in

reduced

valve

and

carbon

cleanout

maintenance.

If

the

use

of

unleaded

gasoline

is

desired,

use

regular

gasoline

for

the

first

25

hours

to

allow

the

rings

to

seat

well

for

best

performance.

Then

use

unleaded

gas¬

oline

thereafter.

If

regular

gasoline

is

used

continually,

carbon

and

lead

deposits

must

be

removed

from

the

cylinder

heads

as

required

because

of

engine

power

loss.

Unleaded

gasoline

may

be

used

safely

after

lead

deposits

have

been

removed.

Leakage

of

gasoline

in

or

around

the

com¬

partment

is

a

definite

hazard.

The

ventilation

system

should

provide

a

constant

flow

of

air

to

expel

any

accumulation

of

fuel

vapor

while

the

vehicle

is

in

transit.

Com¬

partments

must

be

vapor

tight

to

the

interior

to

keep

fumes

from

within

the

vehicle.

OIL

Check

oil

level

daily

(see

Figure

2).

Be

sure

unit

is

level

when

checking

oil.

Add

oil

to

top

of

fill

hole

if

required.

See

MAINTENANCE

section

of

this

manual

for

type

of

oil,

oil

viscosity

and

crankcase

capacity.

Do

NOT

check

oil

while

the

generator

set

is

operating.

Hot

oil

could

cause

bums

by

blowing

out

of

oil

fill

tube

due

to

crankcase

pressure.

STARTING

Push

the

start-stop

switch

to

the

start

position.

Release

the

switch

when

engine

starts.

If

engine

fails

to

start,

inhibitor

oil

used

at

the

factory

may

have

fouled

the

spark

plugs.

Remove

the

plugs,

clean

in

a

suitable

solvent,

dry

thoroughly

and

re-install.

Heavy

exhaust

smoke

when

the

engine

is

first

started

is

normal

and

caused

by

the

inhibitor

oil.

OIL

DRAIN

FIGURE

2.

OIL

LEVEL

STOPPING

Push

the

start-stop

switch

to

the

stop

position

and

hold

until

unit

stops

completely.

Automatic

Choke

An

electric

choke

provides

proper

choking

for

star¬

ting

and

running

the

generator

set.

BREAK-IN

PROCEDURE

Controlled

break-in

with

the

proper

oil

and

a

con¬

scientiously

applied

maintenance

program

will

help

to

assure

satisfactory

service

from

yourOnan

electric

generating

set.

Break-in

as

follows:

1.

One

half

hourat1/2load

(with

oneairconditioner

running).

2.

One

half

hour

at

3/4

load

(with

one

air

con¬

ditioner)

and

approximately

500

watts

additional

load.

3.

Change

crankcase

oil

after

the

first

25

hours

of

operation.

APPLYING

LOAD

If

practical,

allow

set

to

warm

up

before

connecting

a

heavy

load.

Continuous

generator

overloading

may

cause

high

operating

temperatures

that

can

damage

the

windings.

Keep

the

load

within

nameplate

rating.

BATTERY

CHARGING

The

battery

charge

rate

is

controlled

by

a

fixed

value

resistor

that

allows

a

trickle

charge

rate

of

1

-

2

amps

under

all

conditions.

6

SET

EXERCISING

Establish

an

exercise

program

if

unit

is

not

used

for

long

periods

of

time.

Start

and

run

unit,

with

a

full

load

connected

if

possible,

for

at

least

30

minutes

every

week.

This

exercise

program

will:

•

Lubricate

internal

engine

parts.

•

Assure

proper

starting

when

set

is

needed.

•

Remove

moisture.

•

Keep

carburetor

filled

with

fuel.

•

Bring

engine

up

to

operating

temperature.

•

Recharge

battery.

ELECTRICAL

OUTPUT

The

generator

set’s

wiring

provides

for

120

volts,

with

the

total

electrical

load

not

to

exceed

25

amperes.

install

any

outlets

between

generator

^distribution

panel.

120

VOLT.

2

WIRE

UNGROUNDED

LOAD

WIRE

30

AMP

^

BLACK

120

V

(FULL

NAMEPLATE

RATING)

y

WHITE

GROUNDED

LOAD

WIRE

IM1

GENERATOR

LEADS

M2

FIGURE

3.

SINGLE-PHASE,

“1R”

VOLTAGE

CODE

GENERATOR

CONNECTIONS

POWER

REQUIREMENTS

FOR

APPLIANCES

Appliance

or

Tool

Approximate

Running

Wattage*

Refrigerator.

600-1000

Electric

broom

.

200-500

Coffee

percolator.

550-700

Electric

frying

pan.

1000-1350

Hair

dryer.

350-500

Electric

stove

(per

element).

350-1000

Electric

iron.

500-1200

Radio.

50-200

Electric

water

heater.

1000-1500

Space

heater.

1000-1500

Electric

blanket.

50-200

Television.

200-600

Electric

drill.

250-750

Battery

charger.

Up

to

800

Electric

water

pump

.

500-600

Air

Conditioner.

1400-2200

Converter.

300-350

Microwave

oven.700-1500

'

-

Starting

wattages

for

motors

can

be

three

to

four

times

more

than

the

approximate

running

wattages.

HIGH

OPERATING

TEMPERATURES

1.

See

thatnothingobstructs

air

flow

to

and

from

the

set.

2.

Keep

cooling

fins

clean.

Air

housing

should

be

properly

installed

and

undamaged.

3.

Keep

ignition

timing

properly

adjusted.

LOW

OPERATING

TEMPERATURES

1.

Use

co;

•

:t

SAE

oil

for

temperature

conditions.

Change

oil

only

when

engine

is

warm.

If

an

unexpected

temperature

drop

causes

an

emergency,

move

vehicle

to

a

warm

location.

2.

Use

fresh

gasoline.

Protect

against

moisture

condensation.

Below

0°

F

(-18°

C),

adjust

car¬

buretor

main

jet

for

a

slightly

richerfuel

mixture.

3.

Keep

ignition

system

clean,

properly

adjusted

and

batteries

in

a

well

charged

condition.

4.

Partially

restrict

cool

airflow,

but

use

care

to

avoid

overheating.

EXTREMELY

DUSTY

OR

DIRTY

1.

Keep

unit

clean.

Keep

cooling

surfaces

clean.

2.

Service

air

cleaner

as

frequently

as

necessary.

3.

Change

crankcase

oil

every

50

operating

hours.

4.

Keep

oil

and

gasoline

in

dust-tight

containers.

5.

Keep

governor

linkage

clean.

6.

Clean

generator

brushes,

slip

rings,

and

com¬

mutator:

do

not

remove

normal

dark

brown

film.

Do

not

polish.

HIGH

ALTITUDE

OPERATION

For

operation

at

altitudes

of

2500

feet

(775

m)

above

sea

level,

close

carburetor

main

jet

adjustment

slight¬

ly

to

maintain

proper

air-to-fuel

ratio

(refer

to

the

ADJUSTMENTS

section).

Maximum

power

will

be

reduced

approximately

four

percent

for

each

1000

feet

(310

m)

above

sea

level

after

the

first

1000

feet.

Do

not

use

discharged

air

from

blower

scroll

for

compartment

heating.

Poisonous

gas

fumes

may

be

present.

OUT-OF-SERVICE

PROTECTION

Protect

a

generator

set

that

will

be

out

of

service

for

more

than

30

days

from

damage

caused

by

rust

or

corrosion.

Use

the

following

procedure

to

properly

protect

the

set.

1.

Run

the

generator

set

with

at

least

a

50

percent

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

the

engine

stops

to

help

drain

the

carburetor

completely.

warning!

7

3.

Drain

the

oil

from

oil

base

while

engine

is

still

warm.

Replace

the

oil

filter

if

so

equipped.

Replace

drain

plug

and

refill.

Attach

a

warning

tag

stating

type

and

viscosity

of

oil

used.

4.

Remove

spark

plug.

Spray

1

ounce

of

rust

in¬

hibitor

oil

(or

SAE

#10)

into

the

cylinder.

(Spray

cans

work

well

for

this

application.)

Turn

engine

over

by

hand

at

least

2

complete

revolutions.

Replace

the

spark

plug.

5.

Replace

the

air

cleaner

at

least

on

an

annual

basis.

6.

Plug

the

exhaust

outlet

to

prevent

entrance

of

moisture,

dirt,

bugs,

etc.

7.

Clean

and

oil

all

exposed

engine

parts

including

carburetor

and

governor

linkage.

8.

Wipe

generator

brushes,

slip

rings,

housing,

etc.

Do

not

apply

any

lubricant

or

preservative.

9.

Remove

the

battery

and

store

in

a

cool

dry

place.

Coat

the

battery

terminals

and

cable

connections

with

vasoline

or

grease

to

prevent

any

corrosion.

Recharge

the

battery

at

least

monthly

or

maintain

with

a

trickle

type

battery

charger.

10.

P

r

ovide

a

suitable

cover

if

the

unit

is

exposed

to

the

elements.

RETURNING

THE

UNIT

TO

SERVICE

1.

R

e

m

o

v

e

the

cover

and

all

protective

wrapping.

Wipe

the

oil

film

off

all

exposed

engine

parts.

Remove

the

plug

from

the

exhaust

outlet.

2.

Visually

inspect

the

unit

for

any

damage.

Check

to

be

sure

the

carburetor

and

governor

linkage

are

free.

Remove

the

generator

end

bell

band

and

check

to

be

sure

the

brushes

work

freely

in

their

holders.

3.

Check

the

tag

to

ensure

oil

of

the

proper

brand

and

grade

has

been

installed.

Check

the

oil

level.

4.

Install

the

battery

(be

sure

battery

is

fully

charg¬

ed),

observing

proper

polarity.

Ground

is

negative.

5.

Remove

spark

plugs,

clean

and

gap.

Turn

the

engine

over

by

hand

several

times.

Reinstall

spark

plugs.

6.

Remove

all

load

and

start

the

generator

set

at

the

unit.

Initial

start

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

off.

7.

Apply

a

50

percent

load

after

the

set

runs

smooth.

Allow

the

generator

set

to

warm

up

(1

hour)

with

the

load

connected.

Check

speed

and

voltage.

8.

Unit

is

now

ready

for

service.

GENERATOR

MAINTENANCE

The

generator

normally

needs

little

care

other

than

a

periodic

check

of

the

brushes,

commutator

and

collector

rings.

If

a

major

repair

job

on

the

generator

should

become

necessary,

have

the

equipment

checked

by

a

competent

electrician

who

is

thorough¬

ly

familiar

with

the

operation

of

electric

generator

equipment.

8