Onan CCK User manual

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1

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Orton

Operators

Manual

case

GenSet

4

kW

and

5

kW

Mobile

Models

927-0120

(SPEC

U)

(Reprinted

5-82)

Printed

in

U.S.A.

Safety

Precautions

Before

operating

the

generator

set,

read

the

Operator's

Manual

and

become

familiar

with

it

and

the

equipment.

Safe

and

efficient

operation

can

be

achieved

only

if

the

unit

is

properly

operated

and

maintained.

Many

accidents

are

caused

by

failure

to

follow

fundamental

rules

and

precautions.

The

following

symbols,

found

throughout

this

manual,

alert

you

to

potentially

dangerous

conditions

to

the

operator,

service

per¬

sonnel,

or

tne

equipment.

A

DANGER

This

symbol

warns

of

Immediate

haz¬

ards

which

will

result

in

severe

personal

injury

or

death

.

lAWARNiNGl

This

symbol

refers

to

a

hazard

or

unsafe

practice

which

can

result

in

severe

personal

injury

or

death

.

1A

caution]

This

symbol

refers

to

a

hazard

or

unsafe

practice

which

can

result

in

personal

injury

or

prod¬

uct

or

property

damage

.

FUEL

AND

FUMES

ARE

FLAMMABLE.

Fire,

explosion,

and

personal

injury

can

result

from

improper

practices.

•

DO

NOT

fill

fuel

tanks

while

engine

is

running.

Fuel

contact

with

hot

engine

or

exhaust

is

a

potential

fire

hazard.

•

DO

NOT

SMOKE

OR

USE

AN

OPEN

FLAME

near

the

gen¬

erator

set

or

fuel

tank.

•

Fuel

lines

must

be

adequately

secured

and

free

of

leaks.

Fuel

connection

at

the

engine

should

be

made

with

an

ap¬

proved

flexible,

non-conductive

line.

Do

not

use

copper

pip¬

ing

on

flexible

lines

as

copper

will

work

harden

and

Become

brittle.

•

Be

sure

all

fuel

supplies

have

a

positive

shutoff

valve.

GASOLINE

AND

LPG

FUEL

MAY

BE

ACCIDENTALLY

IG¬

NITED

BY

ELECTRICAL

SPARKS,

presenting

the

hazard

of

fire

or

explosion,

which

can

result

in

severe

personal

in¬

jury

or

death.

When

installing

the

generator

set:

•

Do

not

tie

electrical

wiring

to

fuel

lines.

•

Do

not

run

electrical

lines

and

fuel

lines

through

the

same

compartment

openings.

•

Keep

electrical

and

fuel

lines

as

far

apart

as

possible.

•

Place

a

physical

barrier

between

fuel

lines

and

electrical

lines

wherever

possible.

•

If

electrical

and

fuel

lines

must

pass

through

the

same

com¬

partment

opening,

make

certain

that

they

are

physically

separated

by

running

them

through

individual

channels,

or

by

passing

each

line

through

a

separate

piece

of

tubing.

•

DO

NOT

SMOKE

while

servicing

batteries.

Lead

acid

bat¬

teries

emit

a

highly

explosive

hydrogen

gas

that

can

be

ig¬

nited

by

electrical

arcing

or

by

smoking.

EXHAUST

GASES

ARE

DEADLY

♦

Never

sleep

in

the

vehicle

with

the

generator

set

running

un¬

less

vehicle

is

equipped

with

an

operating

carbon

monoxide

detector.

♦

Provide

an

adequate

exhaust

system

to

properly

expel

dis¬

charged

gases.

Inspect

exhaust

system

daily

for

leaks

per

the

maintenance

schedule.

Ensure

that

exhaust

manifolds

are

secure

and

not

warped.

Do

not

use

exhaust

gases

to

heat

a

compartment.

♦

Be

sure

the

unit

is

well

ventilated.

MOVING

PARTS

CAN

CAUSE

SEVERE

PERSONAL

IN¬

JURY

OR

DEATH

•

Before

starting

work

on

the

generator

set,

disconnect

batter¬

ies.

This

will

prevent

accidental

arcing.

•

Keep

your

hands

away

from

moving

parts.

•

Make

sure

that

fasteners

on

the

generator

set

are

secure.

Tighten

supports

and

clamps,

keep

guards

in

position

over

fans,

drive

belts,

etc.

•

Do

not

wear

loose

clothing

or

jewelry

while

working

on

gen¬

erator

sets.

Loose

clothing

and

jewelry

can

become

caught

in

moving

parts.

Jewelry

can

short

out

electrical

contacts

and

cause

shock

or

burning.

•

If

adjustment

must

be

made

while

the

unit

is

running,

use

ex¬

treme

caution

around

hot

manifolds,

moving

parts,

etc.

ELECTRICAL

SHOCK

CAN

CAUSE

SEVERE

PERSONAL

INJURY

OR

DEATH

•

Disconnect

starting

battery

before

removing

protective

shields

or

touching

electrical

equipment.

Use

rubber

insuia-

tive

mats

placed

on

dry

wood

platforms

over

floors

that

are

metal

or

concrete

when

around

electrical

equipment.

Do

not

wear

damp

clothing

(particularly

wet

shoes)

or

allow

skin

sur¬

faces

to

be

damp

when

handling

electrical

equipment.

•

Use

extreme

caution

when

working

on

electrical

compo¬

nents.

High

voltages

can

cause

injury

or

death.

•

Follow

all

state

and

local

electrical

codes.

Have

all

electrical

installations

performed

by

a

qualified

licensed

electrician.

Tag

open

switches

to

avoid

accidental

closure.

•

DO

NOT

CONNECT

GENERATOR

SET

DIRECTLY

TO

ANY

BUILDING

ELECTRICAL

SYSTEM.

Hazardous

volt¬

ages

can

flow

from

the

generator

set

into

the

utility

line.

This

creates

a

potential

for

electrocution

or

property

damage.

Connect

only

through

an

approved

device

and

after

building

main

switch

is

open.

Consult

an

electrician

in

regard

to

emergency

power

use.

GENERAL

SAFETY

PRECAUTIONS

•

Have

a

fire

extinguisher

nearby.

Maintain

extinguisher

prop¬

erly

and

become

familiar

with

its

use.

Extinguishers

rated

ABC

by

the

NFPA

are

appropriate

for

all

applications.

Con¬

sult

the

local

fire

department

for

the

correct

type

of

extin¬

guisher

for

various

applications.

•

Hot

coolants

under

pressure

can

cause

severe

personal

in¬

jury.

DO

NOT

open

a

radiator

pressure

cap

while

the

engine

is

running.

Stop

the

engine

and

carefully

bleed

the

system

pressure.

•

Benzene

and

lead,

found

in

some

gasoline,

have

been

iden¬

tified

by

some

state

and

federal

agencies

as

causing

cancer

or

reproductive

toxicity.

When

checking,

draining

or

adding

gasoline,

take

care

not

to

ingest,

breathe

the

fumes,

or

con¬

tact

gasoline.

•

Used

engine

oils

have

been

identified

by

some

state

or

fed¬

eral

agencies

as

causing

cancer

or

reproductive

toxicity.

When

checking

or

changing

engine

oil,

take

care

not

to

in¬

gest,

breathe

the

fumes,

or

contact

used

oil.

•

Remove

all

unnecessary

grease

and

oil

from

the

unit.

Accu¬

mulated

grease

and

oil

can

cause

overheating

and

engine

damage,

which

presents

a

potential

fire

hazard.

•

DO

NOT

store

anything

in

the

generator

compartment

such

as

oil

or

gas

cans,

oily

rags,

chains,

wooden

blocks,

portable

propane

cylinders,

etc.

A

fire

could

result

or

the

generator

set

operation*

(cooling,

noise

and

vibration)

may

be

ad¬

versely

affected.

Keep

the

compartment

floor

clean

and

dry.

•

Do

not

work

on

this

equipment

when

mentally

or

physically

fatigued,

or

after

consuming

any

alcohol

or

drug

that

makes

the

operation

of

equipment

unsafe.

RV-9

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

#927-0220.

TABLE

OF

CONTENTS

General

Information.

2

Specifications.

3

Installation

Checks.

4

Operation..

6

Engine

Troubleshooting

Guide.

11

Maintenance.

12

Periodic

Maintenance

Schedule.

16

Adjustments.

17

Control

Troubleshooting.

21

Generator

Set

Schematic.

22

Remote

Accessories.

23

Parts

Information.

25

1

warningX

TO

PREVENT

FIRE

OR

ACCIDENT

HAZARD.

.

.

THIS

UNIT

MUST

BE

INSTALLED

ACCORDING

TO

THE

MANUFACTURERS

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

you

r

generator

set.

Study

and

follow

the

instructions

carefully.

A

well-planned

service

and

maintenance

program

will

result

in

longerunit

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

yourOnan

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

preceding).

This

information

is

necessary

to

identify

your

generator

set

among

the

many

types

manufactured

by

Onan.

FIGURE

1.

TYPICAL.

CCK

FOR

RECREATIONAL

VEHICLES

RE

AKER

POINT

BOX

EXHAUST.

START-STOP

SWITCH

SOLID

STATE

CONTROL

UNIT

NAMEPLATE'

GENERATOR

COOLING

AIR

■

E

L

ECTRIC

FUEL

PUMP

OIL

DRAIN

VIBRATION

ISOLATOR

2

SPECIFICATIONS

(Dimensions

in

parenthesis

are

metric

values)

ENGINE

DETAILS

Manufacturer.

Number

of

Cylinders.

Displacement

(in

)...

Cylinder

Bore.

Piston

Stroke.

Compression

Ratio

..

Engine

Speed.

Engine

Design.

Starting

Method.

.

Onan

.

T

wo

.

49

8

(816

cm

)

.

3.25

inch

(82.5

mm)

...

3.00

inch

(76.2

mm)

..

5.5

to

1

...

1800

i

pm

Four

Cycle,

Air

Cooled,

L-Head,

Horizontally

Opposed

.

Exciter

Cranking

(Generator)

GENERATOR

DETAILS

Manufacturer.

Onan

Generator

Design.

Revolving

Armature,

Four

Pole.

1800

rpm

Rating

(Watts)

4.0

CCK.

4000

5.0

CCK.

5000

Voltage

(AC).

120/240

Volts

Current

Rating

(Amperes)

4.0

CCK

120

Volts.

33.3

240

Volts.

16.7

5.0

CCK

120

Volts.

41.6

240

Volts.

20.8

Phase.

Single

Output

Wires.

Four

Wire,

Reconnectible

Output

Rating.

Unity

Power

Factor

Cranking

Current..

75-100

Amperes

Break-away

Current.

300-350

Amperes

CAPACITIES

AND

REQUIREMENTS

Oil

Capacity.

Recommended

Battery.

Battery

Charged

Rate

Fixed

.

Average

Fuel

Consumption

@

Rated

Load

4.0

CCK.

5.0

CCK.

Air

Inlet

Size

Required

(Minimum)

4.0

CCK.

5.0

CCK.

.

4

Quarts

(3.78

Litres)

12

Volt,

74

Amp/hr

(266.40

kC)

.

1-1-1/2

amperes

.0.88

gph

.1

05

gph

.

100

in

2

(645

cm

2

)

.

100

in

1

'

(645

cm

2

)

TUNE-UP

SPECIFICATIONS

Spark

Plug

Gap.

Breaker

Point

Gap.

Ignition

Timing.

Valve

Tappet

Adjustment

Intake.

Exhaust.

.025

inch

(0.64

mm)

.020

inch

(0.51

mm)

.

19°

BTC

.007

inch

(0.18

mm)

.016

inch

(0.41

mm)

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

arise

after

the

unit

is

installed

and

subjected

to

vibration.

There

are

a

few

areas

that

you

as

the

operator

should

be

concern¬

ed

with.

If

in

doubt

about

any

aspect

of

your

generator

set’s

operation

or

safety,

contact

your

nearest

authorized

Onan

Service

Center.

A

daily

inspection

of

your

installation

should

include

the

following:

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

CON¬

TAIN

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.

WARNING

Ail

exhaus

*

shielding

supplied

with

unit

MUST

be

properly

installed

to

prevent

overheating

of

compartment

walls

or

the

possibility

of

fire.

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.

ELECTRICAL

AC

Output:

All

AC

leads

(Ml,

M2,

M3

and

M4)

terminate

in

generator

sets

junction

box.

These

wires

should

be

connected

to

distribution

box

witi.

mul¬

tistrand

wire

enclosed

in

a

flexible

conduit.

Check

all

wires

(to

and

from

the

generator

set)

for

fraying

and

loose

connections.

For

information

on

load

connec¬

tions

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.

WARNING

I

Separate

installation

area

or

compartment

from

living

quarters

by

a

vapor-tight

wall

to

prevent

entrance

of

noxious

fumes

to

interior.

3

MOUNTING

HOLES

FOR

4

MOUNTING

HOLES

FOR

MOUNTING

PLATE

EXH

MANIFOLD

AND

EXTENSION

Pf>E

OPTIONAL

LOCATION

REMOTE

TERM

BLOCK

iNTROL

PANEL

-AIR

CLEANER

OUTPUT

BOX

a

KNOCKOUTS

■

8ATT

POS

TERM

-FUEL

INLET

Vq

NPTF

AIR

-BATT

NEG

TERM

MODEL

NO.

MODEL

NC.W/PLATE

DIM

A

DRY

WT.

4L0CCK-3CR/I6000S

4.0CCK-3CR/

29.06(738)

290

LBS

(131

kg)

5.0CCK-3CR/I6000S

5.0CCK-3CR/

31.44(799)

315

LBS

(142

kg)

ARE

MILLIMETRES

FIGURE

2.

INSTALLATION

OUTLINE

4

Do

NOT

use

maintenance

free,

unvented

batteries

with

this

generator

set.

Malfunction

of

the

starting-charging

system

can

produce

high

charging

currents,

causing

excessive

gassing.

An

unvented

battery

can

build

up

sufficient

pressure

to

explode.

Grounding:

Generator

must

be

effectively

bonded

to

recreational

vehicle

chassis.

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

application.

Mount

the

battery

in

a

separate

compartment

from

the

set

or

any

spark-producing

device

to

prevent

fire

or

explosion.

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.

Don’t

use

discharged

cooling

air

for

compart¬

ment

heating

since

it

could

contain

poisonous

exhaust

gases.

Do

not

terminate

exhaust

under

vehicle,

as

carbon

monoxide

gas

is

poisonous.

Direct

exhaust

gases

away

from

window

and

door

openings.

I

wad|ji||/;

On

all

listed

models

with

exhaust

shielding

supplied

with

unit,

shielding

MUST

be

property

installed

to

prevent

overheating

of

compartment

walls

or

the

possibility

of

fire.

Refer

to

appropriate

installation

guide

for

each

model

for

details.

DO

NOT

DISCONNECT

BATTERY

CABLES

FROM

BATTERY

WHILE

GENERATOR

SET

IS

CRANKING

OR

RUNNING;

SPARKS

MAY

CAUSE

AN

EXPLO¬

SION.

FIGURE

3.

BATTERY

AND

GROUND

CONNECTION

5

OPERATION

[BEFORE

STARTING

[Crankcase

Oil

Oil

capacity

of

the

CCK

generator

set

is

4

U.S.

quarts

(3.79

lit).

Fill

the

crankcase

until

the

oil

reaches

the

“FULL”

mark

on

the

oil

level

indicator

(Fiqure

4)

DO

NOT

OVERFILL.

WARNING

|

Do

NOT

check

oil

whi

*e

t

he

generator

set

is

hhhhmhJ

operating.

Hot

oil

could

cause

bums

by

:

blowing

out

of

oil

fill

tube

due

to

crankcase

pressure.

CAP

AND

OIL

LEVEL

INDICATOR;

KEEP

OIL

AT

THIS

LEVEL

NEVER

OPERATE

ENGINE

WITH

OIL

BELOW

THIS

LEVEI_

ALWAYS

REPLACE

CAP

TIGHTLY,

OR

OIL

LEAKAGE

MAY

OCCUR.

Check

oil

level

daily

and

change

oil

every

100

normal

operating

hours.

See

Figure

5

for

location

of

oil

drain.

If

operating

in

extremely

dustyordirtyconditions,

the

oil

might

have

to

be

changed

sooner.

When

adding

oil

between

changes,

use

the

same

brand

as

in

the

crankcase.

Various

brands

of

oil

might

not

be

com¬

patible

when

mixed.

TEMPERATURE

fiBinc

Below

0°F

(-18°

C)

.5W

or

5W-30

0°

to

32°

F

(-18°

C

to

0°C)

.lOW

or

10W-40

Above

32°

F

(0°C)

.

30

Oil

consumption

may

be

higher

with

a

multigrade

oil

than

with

a

single-grade

oil

if

both

oils

have

com¬

parable

viscosities

at

210°F

(99°

C).

Therefore,

single

grade

oils

are

generally

more

desirable

unless

an¬

ticipating

a

wide

range

of

temperatures.

Use

the

proper

grade

oil

for

the

expected

conditions.

Use

of

the

same

grade

and

quality

oil

as

that

used

in

your

recreational

vehicle

engine

is

acceptable

as

long

as

unit

is

serviced

regularly

and

oil

meets

API

designation

SE

or

SE/CC.

Other

factors

(primarily

temperature)

should

also

be

considered

when

selec¬

ting

appropriate

engine

oil.

FIGURE

4.

CHECKING

OIL

LEVEL

Use

a

heavy

duty

oil

with

the

API

(American

Petroleum

Institute)

designation

SE

or

SE/CC

(gasoline

operation

only).

If

this

oil

is

not

available,

SD

or

SD/CC

designated

oil

can

be

used.

FIGURE

5.

OIL

DRAIN

AND

FILL

Recommended

Fuel

All

Onan

AC

electric

generating

sets

for

recreational

vehicles

use

gasoline

fuel.

Because

any

AC

electric

generating

set

runs

at

a

constant

speed,

lead

deposits

tend

to

build

up

in

the

combustion

chambers.

Forthis

reason,

use

clean,

fresh,

lead

free

or

low-lead

gas¬

oline.

Regular

grade

gasoline

may

also

be

used,

but

DO

NOT

use

highly

leaded

premium

types

of

fuel.

For

new

engines,

the

most

satisfactory

results

are

obtained

by

using

nonleaded

gasoline.

For

older

engines

that

have

previously

used

leaded

gasoline,

the

cylinder

heads

must

be

taken

off

and

all

lead

deposits

removed

from

engine

before

switching

to

nonleaded

gasoline.

leaded

gasoline,

if

damage.

Lead

deposits

must

be

removed

from

an

engine

before

switching

from

leaded

to

non-

not,

preignition

can

occur

causing

engine

|

WARNING

\

^

a

so

*

s

n

e

leakage

to

or

around

the

compart-

ment

is

a

definite

hazard.

The

ventilation

system

should

provide

a

constant

flow

of

air

to

expei

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.

8

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.

CONTROL

FUSES

A

5

amp.

32

volt

fuse

(F2)

is

connected

in

the

ignition

circuit

of

the

control.

If

unit

cranks

but

fails

to

start

when

switch

SI

is

pushed,

ch»*ck

fuse

F2.

It

remote

battery

condition

meter

does

not

operate.

<

h«

c

k

fuse

FI.

STOPPING

Push

the

start-stop

switch

to

the

stop

position

and

hold

until

unit

stops

completely.

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.

O

n

e

half

hour

at

1/2

load

(with

one

air

conditioner

only).

2

One

half

hour

ai3/4

load

(with

one

air

conditioner

and

approximately

1000

watts

additional

load).

3.

Change

crankcase

oil

after

the

first

50

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.

VOLTAGE

SELECTION

Voltage

selection

on

reconnectible

single-phase

generators

is

for

use

as

120/240

volts,

3

wire;

or

120

volts,

2

wire.

Use

the

connection

for

two-wire

service

when

one

load

exceeds

one

half

the

rated

capacity.

Balance

the

load

when

connecting

for

three

wire

service.

Current

for

any

one

output

lead

must

not

exceed

nameplate

rating.

When

two

or

more

single¬

phase

circuits

are

available,

divide

the

load

equally

between

them.

See

Figure

6.

LOAD

CONNECTIONS

1.

Generator

set

load

wires

Ml,

M2,

M3

and

M4

terminate

within

the

junction

box.

Connect

and

join

wires

within

junction

box

in

an

approved

manner

for

desired

voltage

code.

See

Figure

6.

2.

Wires

must

be

adequate

size,

properly

insulated'

and

supported.

3.

Mount

switches

and

controls

securely

to

prevent

damage

from

vibration

and

road

shocks.

All

switches

must

be

vibration

proof

to

prevent

accidental

opening

or

closing

while

the

vehic

e

is

in

motion.

4.

A

ll

wiring

must

meet

applicable

local

electrical

codes.

Have

a

qualified

electrician

install

ano

inspect

the

wiring.

EXERCISE

Infrequent

use

results

in

hard

starting.

Operate

the

generator

set

one

30-minute

period

each

week.

Run

longer

if

battery

needs

charging.

Exercising

for

one

long

period

each

week

is

better

than

several

short

periods.

BATTERY

CHARGING

The

battery

charge

rate

is

automatically

controlled

by

a

solid-state

voltage

regulator.

The

high

charge

rate

was

set

at

the

factory

for

average

operating

con¬

ditions.

HIGH

OPERATING

TEMPERATURES

1.

See

that

nothing

obstructs

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

TEMPERA’’

URES

1.

Use

correct

SAE

oil

for

tempera

e

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

richer

fuel

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.

OPERATION

IN

DUST

AND

DIRT

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

ALTITUDES

For

operation

at

altitudes

of

2500

feet

(775

m)

above

sea

level,

close

carburetor

main

jet

adjustment

slight¬

ly

to

maintain

proper

air-to-fue!

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.

POWER

REQUIREMENTS

FOR

APPLIANCES

Appliance

or

Approximate

Tool

Running

Wattage

Refrigerator..

600-1000

Electric

broom

.

200-500

Coffee

percolator.

550-700

Electric

frying

pan.

1000-1350

Hairdryer.

350-500

Electric

stove

(per

element).

350-1000

Electric

iron.

500-1200

Radio.

50-200

Electric

water

heater.

1

0

0

0-1500

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

FIGURE

6.

SINGLE-PHASE,

“-3C”

VOLTAGE

CODE

GENERATOR

CONNECTIONS