- -'il00Bllil{lll$0ll

Operatorc
Manual
65
NH
GenSet
6.s ru t-t -ict/ltco 4F
Gts,.r.
_...{L
)l_Lg

RV Electric Generating Set

@1)r.rsrro @

gqHn?t
(SPEC Pl
 SAFETY PRECAUTIONS
Always use an appropriately sized- r \pro . '
The lollowing symbols in this manual signal poten-
lially dangerous conditions to the operator or equrp- double-throw transfer switch wilh an'
ment. FIead this manual carefully. Know when these generalor set. DO NOT PLUG POR I',---v
conditions can exist- Then, take necessary steps to SrnNoav sers DTREcTLY rNTo A h6usr
prolecl personnel as well as equipment. RECEPTACLE TO PROVIDE EMERGENCY
POWER. lt is possible for current to flow from
generator into the utility line. This creates ex-
treme hazards to anyone working on lines to
mARt ttcl Onan uses symbollhlr restore power.
lhroughoul thit menull lo Use extreme caution when working on electrical
warn ol po3slble 3€rlour penonal lnlury. components. High voltages cause injury ordeath.

Follow allstale and local electrical cod es. Have all

o"""'o'"
IEffi,TO ]llio?Tfl!:l:;"': electrical installations performed by a qualilied
licensed electrician.

Oo Not Snoke While Servicing B.tleries

Fuels, electrical equipment, batteries, exhaust gases
and moving parts prcsent potential hazard s th at could Lead acid balteies emit a highly explosive
result in serious, personal injury- Takecare in lollow- hydrogen gas that can be ignited by electrical
ing these recommended procedures. arcing or by smoking.

. Use Ext.eme Caution Near Gsloline. A con3tant

. Erhaust Gas$ Are Toxic
polenlial erplo3lve or llre hazard exbl8.
Provide an adequate exhaust system to propedy
Do nol till luel tank near unit with engine running. expel discharged gases. Check exhaust system
Do not smoke or use open tlame near the unit or regularly lor leaks. Ensure that exhaust manifolds
lhe fuel tank. are secure and not warped.

Be sure the unit is well ventilated.

- \::-+ \J/
Be sure all fuel supplies have a positive shutotl
Keep The Unit And Surounding Area Clean
Fuel lines must be of steel piping, adequately
secLrred and free of leaks. Use aflexible section ot Bemove all oil deposits. Remove all unnecessary
grease and oil from the unit. Accumulated 9rcase
fueltine between generator set and stationaryfu6l
line in the vehicle. This flexible section must be and oil can cause overheating and subsequent
engine damage and may prcsent a potential fire
1000,6 NON-METALLIC to prevent electrical
hazard.
currents lrom using it as a conductor.
Do NOT storc anything in the generator com-
Have a fire extinguisher nearby. Be sure ex- partment such as oil or gas cans, oily rags,
tinguisher is properly maintained and be familiar chains, wooden blocks, propane tanks, etc. A
with its proper use. Extinguishers rated ABC by fire could result or the gen€rator set operation
the NFPA are appropdate for all applicalions. (cooling, noise and vibmtion) may be adversely
Consult the local fire department lor the correct affected- Keep the compartment lloor cl€an and
type of extinguisher for various applications. dry.
. Guard Ag.lntt Elect.lc Shock Protect AgaiBt Moving Patt3
Avoid moving parts ot the !nit. Loose jackets,
Remove electric power before removing protec- shirts or sleeves should not be permitted because
tive shields or touching electrical equipment. Use ol lhe danger of becoming caught rn moving
rubber insulative mats placed on dry wood plat- parts.
lorms overfloors that are metalorconcrete wh€n
around electrical equipment. Do not wear damp Make sure all nuts and bolts are secure. Keep
clothing (particularly wet shoes) or allow skin power shields and guards in position.
surlaces to be damp when handling electrical
equipment. lladjustments musl be made while
running, use exlreme caulion a
manifolds, moving parts, etc.
Jewelry is a good conductor of electricity and
should be rcmoved when working on electrical Do not work on lhis equipment when mentally or
equipment. physically latigued.
 TO THE OWNER
Welcome to ihe growing lamily ol Onan Power users
. . . We are proud lo have you as a customer.

Bead this manual carefully and observe all safely

rules within. Operating instructions, adiuslmenls and
periodic maintenance procedures are given so that
you ... the owner, can keep your unil running like
new and expect many years of dependable service
from rt. Remember. .. any machine, regardless ol
design or type, will perform only in relation to the
services it receives.

lf your generator set needs specialattention, ask your

Onan dealer for assistance: the Onan Parts and
Service Organization has been factory-lrained to
provide up-lo-date know-how lor keeping your BV
electric generating set "on the road".

TABLE OF CONTENTS

General lnlormation 2
Specitications 3
lnslallalion Checks .............. 4
Operalion........... 6
Engine Troubleshoollng ..................... t0
Maintenance 11
Assembly Torques.. . 13
Periodic Mainlenance Schedule .. .. .. . .. . .. .. '14
Adiuslmenls......... 15
Conlrol Troubleshooting . ... . .. .. . .. ... . .. . .. 18
Remole Accessoriea 20

WARNING

TO PREVENT FIRE OR ACCIDENT HAZARD. . .

THIS UNIT MUST BE INSTALLED ACCORDING
TO THE MANUFACTUBER'S DETAILED IN-
ST ALLAT I O N PROCED URES O BSE RV I N G ALL
MINIMUM CLEARANCES.
TO AVOID POSS/ALF PERSONAI INJURY OR
EQUIPMENT DAMAGE, ANY INSTALLATION
AND ALL SERY/CE MUST BE PERFORMED BY
QUALIFIED PERSONNEL.
 GENERAL INFORMATION
- --'--./

YOTJR MANUAL MODEL DESIGNATION

This manual contains operation and other informa- The following typical model number is broken down
tion to properly maintain, service. and make ad- into code segments used by Onan.
justments on your NH generatorset. Study and follow

i 3C R
the instructions carefully. A well-planned service and 6.5 NH t6oo4 M
maintenance program will result in longer unit lifeand
better performance. Because the most importantpari
ot repair is diagnosis, a troubleshooting chart is
included. I
T 2
TTTT
3456
Throughout the manual, engine end of the generalor
set is the front. Left and right sides are determined 1. lndrcales krlowall rating.
when facing the engine (front) end.
2. Series identif ication.
When contacting your Onan dealer, distributor,
orthe Number 3 is the voltage code tor 120/240 volts
lactory about the generator set, always supply the single phase. "C" is the code for reconnectible
complete model number and serial number as shown (120 volts, 2 wiret and 120/240 volts,3 wire).
on the nameplate (see Model Designation lollowing). 4. Method of starting: R-remote electric starting.
This inlormation is necessary to identily your 5. Factory code lor designating optional equipment
generator set among the many types manufactured
il any.
by Onan.
6. Specification letter which advances when the
f actory makes production modif ication.
Onan electric sets are given a complete running test
under various load conditions and are thoroughly
checked before leaving the factory. Upon receiving
your unjt, check ii thoroughly for any damage that
may have occurred during shipping. Iighten loose
parts, replace missing parts and repair any damage
before operating the unit.

EIECTBIC
CHOKE COIL

PLUG

START.STOP
swtlcH
EXHAUST STAFI.STOP
MANIFOLO DC FUSES

scRoLf

OIL FILTEF OIL DRAIN

VIBRATION
ISOLATORS
(FAIL-SAFE)

TYPICAL NH FON FECFEA.rIONAL VEHICLES

 SPECIFICATIONS
Thl6 manual conlalns Sl herric equlvdenls lhal lollow immedlarely in parenlheses
6ller lhe U,S, cuslomary unils oi mea3ur,

GENERAL
Nominal Dimensions of Set
Height . . .. ... .... .. . 19.50 in. (495 mm)
Width .. ... .. . .. .... . 20.00 in. (508 mm)
Length .... ... .. .. .. . 33.37 in. (848 mm)
Weight ... . . . . .. .. .. . 305 lbs. (138 kg)
ENGINE DETAILS
Manulacturer.,,...,. .,....,,..,,. Onan
Number ol Cylinders. . .. . ... .. . ... . Two
Displacement (cubic inches) . ... ... .... .. ... ..60 inr (983 cm3)
Cylinder Bore .. . . 3-9/16 in. (90.49 mm)
Piston Stroke. ... . ... . . 3 in. (76.20 mm)
Compression Ratio ................ . . . . . . . . . . . . . . . . . . 7.0 to
. 1

Engine Speed .. .. ... . .. ... ... 1800 rpm

Engine Design....... . . .. ... ... Four Cycle, Air Cooled, L-Head
Horizontally Opposed
Starting System Exciter Cranking (Generator)
lgnition .. ... . .. .. .. . ... .. ... ... Battery
RecommendedFuel................ ................Gaso|ine(LeadFreeorRegular)
Average Fuel Consumption
\- (at rated load & speed) ... .... ... .. . .. ... . .. ... ... . 1.30 Gallons per Hour (4.92 L)
GENERATOR DETAILS
l/anofacturer..,.,,,. . ii. . . . . . . . , Onan
. .
Design .. ... ... . .. , . . Revolving Armature, Four Pole, 1800 rpm
Rating (in watts 60 Hertz) ... .. . .. .. .. ... ... .. .. 6,500 (6.5 kW)
Voltage . . . . . . . . . . . . . . . . .12O o( 120/240
Current Rating (amperes)
120 Vo|t . . . . . . . . . . . . . ...54.2 Amperes
240 Vo|t. .. . , .. . .. .. . ...27.1 Amperes
Phase . . . . . . . . . . . . . . . . ........... Single
Wire ... ... ... ... ... . 4 Wire Reconnectible
Output Rating ...... Unity Power Factor
Cranking Current. .. . 100 Amperes (Nominal)
CAPACITIES AND REQUIREMENTS
Oil Capacity. ..... .. . ... ..... 3 U.S. Quarts (2.8 lit) Plus 1/2 Quart for oil filter change
Recommended Battery... ... . .. ..... . . ... ... .. . ... .. . .12 Volt 74 Amp/Hr (266.40 kC)
Battery Charge Rate (Fixed). .... .... ... ... . ... . 1-112 Amperes
Ventilataon Requirements (Total-No Restrictions). ..... .. .. ... .. . 120 sq. in. (774 cm,)
TUNE.UP SPECIFICATIONS
Spark Plug Gap .... .. .. .... ... .. ... ... . .. . .025 in. (0.64 mm)
Breaker Point Gap (Cold Setting)... . .... .. . .016 in. (0.4'1 mm)
lgnitionTiming Reference (Cold SettinS) ,.................. . . . . . . . . . . . . . . . 20' BTC
Valve Tappet Clearance
lntake. ... .. . ... .. .. . .003 in. (.076 mm)
Exhaust ... . . .. . .... . .012 in. (0.30 mm)
Cylinder Head Bolt Torque.. ... .. .. . .....18|b.ft.(24.40N.m)
 INSTALLATION CHECKS

INSTALLATION
Oo not lermlnare erhau3t unde. vehicte, as
Neady all Onan e ectric generaling sets are installed wAtlt ritc carbon monoxide ga6 Is poisonous. Dlrecl
by the motor home manuiacturer Although the exhausr ga.es .way lrom window and door openings.
manulacturer musl iollow saiety codes when inslall-
ing, certain nstallat on problems cou d ar se aiterthe
unit is installed and subjected to vibration. There are a FUEL SYSTEM
few areas thai you as the operatorshould be concern- Wiih set running, check for leaks. Raw fuet will cause
ed with. lf in doubt about any aspect of you rgenerator fumes which coutd EXPLODE. Check around car-
set's operation or safety, contact your nearest buretor and fuei pump inlets. lrake sure fuel lines are
authorized Onan Service Center. Adaily inspection of not rJbbng againsl anytr,.o wnrch could cause
voJr i-stal'arion should incl.rde the !ollowing. breakaqe.

EXHAUST ELECTRICAL
Check for leaks around mantfolds, gaskets, and AC Outpult Al AC leads (M1, [42, [r3 and M4)
welds. Make sure exhaust lines are not heating termrnate ir] generator seis junction box. These wires
surrounding areas excessively. lf so, have corrected should be connected to distribution box with mul-
mmediately. Remember EXHAUST GASES CON- tistrand w re enclosed tn a flexible condutt. Check all
TAIN DEADLY CARBON I\,4ONOXIDE. Be sure aII w res rlo ano 'rom rae ge.erator set' for fraytng and
holes to the inside ot RV from sel compartment are loosF co'1reclions For tnlormalton on load connec,
sealed to prevent poisonous exhausl gases lrom trons refer to operation seclion fo owing.
entering vehicles.
Battery Connections: Battery positjve (+) connection
connects to slart solenoid Battery negative conneclr
WANNING All exhaLrsi shielding supplied with generator
sel MusT be properly lnstalled to prevent
to location on rear of generator. Check terninals on
overhealing ol cofiparlment walls or ihe possibit y ot tire, set and battery ior clean and tight connections.

33,37"
MIN CLEAFANCE TO TOP

I
I
19-50"
I
I/2" ORAIN HOLES IN ALL
FOUN CORNERS

OIL DRAIN
CLEAFANCE
'1-1/2"
MINIMUII/I SCBOLL FLOOR
OUILET DIAMETER
CLEANANCE 9.69" x 4-00"
1. OTMENSTONS tN ( ) ARE MTLLIMETERS 4. VACU-FLO SCFOLL EXTENDS BELOW MOUNTING PIATE
2. APPROX WEIGHT: 305 LBS MASS; 138 kg 5, FOF CUSTOMERS COMPARTMENT HOLE SIZE FOF SCFOIL|
3. A 1_00" (25) MtN CTEARANCE REOUTFED AFOUND 5,1 wlDTH:4.00 (102)
sET ANO ,50 {13) MtN ABOVE CARB TO COMPARTMENT
WALLS OR SOUND TNSUIATTON (OtL FITER UAy 5.2 LENGTH: 9.69 (246)
PROTRUOE INTO 1.0O" (25) CIEABANCE)
FIGURE I. INSTALLATION OUTLINE
4
Onan recommends using a s€parate ballery lor operalion ol lhe VENTILATION
qeneralor sel in adalilion lo lhe reqular vehicle slarring ballery.
Feler to individual inst6llalion gride or T-012 tor additional The biggest enemy of electrc generating sets n-
i.lomalion on barlery sharing. stalled in moior homes is excessive heat. Make sure
the set's air nlet and outlet are not plugged wlth dust,
dirt, bugs, leaves or anyihing that could restrict
Grounding: Generator must be effeclively bonded to cooling arr.
recreational vehicle chassis

For additional inlormation on installation contact Don l u3e discharged cooling anlorcomparl-
your Onan Service Representaiive or request lnstal a- fwai-Nri6-l menl healing since il could conl.ln
tlon Guide #940-0610,

f-RrrNc I Do nor r€rminare exh.ust under vehicle.

carbon monoxide qas i3 poisonous. Olrecl
63

Vehlclc ch...ir {l..he) 9rcund tnd rhe ban€ry.nd generalor tel lrom window and door openlng.,
ground rhould .ll be elecrrlcrlly connecled lo be sl 0 ground
por.nll.l, All Onln unllr are detlgned lor .eqtllve ground
On all llsled model3 wlth erhaust lhlelding
l--lWATNING 3upplled wilh unft, .hleldlns ilusT be
prope.ly in3t. ed lo prevenl overheallng ol compddmcnl w.ll! or
Mounilhe bitert In 3 sep.r.le compadmenl rhe polliblllly ol tire, Reter lo apProprlaie ifttallallon guide tot
Irom lhe.el or..y sprr*-produclngdevlcelo e.ch model lor delril3,
prevent ll.e or erylo.lon.

Do nol smoke whil.sedicinq b.tleries, Lead

acid balteries qive olt explosive qases while

DO NOT DISCONNECT BATTEFY CABIES

FROM BATTEFY WHILE GENERAIOF SET
IS CRANKING OR RUNNING:SPARKS MAY CAUSEAN EXPLO-
sroN.

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

odlnan.$ perlllnlhg ro ihe lyPe .nd u.!ge ot erhau3i
multler/!pErk ar€3teB on inlemal combutllon englne. orengine
driven equipmenl when u3ed In . recresllon.l vehicl. luch rs
elecrric gener.llng !e1.. Be !ore you.ln.l!llallon mels rll Federal,
sl.tesnd locrl cod6perl.lningloyourunil,FailureloProvld.and
malnrrh a 3park are.ler mry be in viol.llon ol lh. hw,

IwmNrNGl
ENGINE EXHAUST G AS (CARBON MONOXIDE) IS DEADLY!

Crrbon monoxlde l! an odo e!3, colode.! ga3 lormed by lncofiplele

cohbu3tlon ol hydroca.bon lu€13. Calbon monoxlde l! a drngerous gai lhtl
- l!polenllally lethal. Some olthe 3ymplom3or
csn c!u3e uncon3ciou3ne!3 .nd
3ign3 ot carbon monoxlde inhalallon are:

. Olzzlne.! . Vomlllng
. lnten3e Headsche . Mu3cular Twltchlng
. weakness and Sleepiness ' Th.obblng ln TemPles

llyou erperlence any ol lhe ebove symPlom!,get oul lnlo lresh air
lmnedlately.

The b€31p.otectlon again!l ctrbon monoxlde inhslstlon l3a regulat lnspecllon

ot lhe complete 6xhau3l 3yslen, ll you nollce a change ln lhe 3ound or
appe.rrnce ot ethautt rytlem, 3hut lhe unlt down lmmedlately and heve ll
in3pecled and repaired at once by a comPelenl mech.nic.
 OPERATION

BEFORE STARTING
lnspeclion: inspect the engine vrsua ly be{ore star-
lingCheck lor loose or missing parts orany shipp ng
damaoe.

CRANKCASE OIL
The set o I capacity s3U.S quarts(2.8 lit) plusl/2
quart lor oi fi ter change. FilL the crankcase uniil the
o I reaches the FULL markontheolevelrndicator
(F gure 2). Do NOT OVERFILL. (Overli ling may
cause ioam ng and engine shutdown.) Always 0244060
change the o I fiter when changing oil. Refer 10 .c -30 -20 1n 0 10 20 30 4q
Periodrc Maintenance Schedule I l\'IAINfENANCE TEMPEiATUNE RANGE YOU EIPECI B€FOF€ NEIT OIL CHANGE
section lor serv ce lnterval.
Check oil evel dailyand changeoil every 100norma]
CAP ANO OIL operating hours. See Figure 3 ior location of o I drain.
IEVEL INDICAIOR It operating n extremely dusty ordirty conditions, the
oil mrght have to be changed sooner. When adding oil
belween changes, use the same brand as in the
crankcase. Vafous brands of oi miqht not be com-
KEEP OIL pat ble when mixed.
_- FULL
AT THIS IEVEL --- - olL
LEVEL
OIL FILL
NEVEF OPERATE--LgY-
ENGINE WITH OII CAP TIGHTLY, ON
BELOW THIS IEVEL OIL LEAKAGE MAY
occuF.

FIGIJRE 2 CHECKING OIL LEVEL

Be sure to f ll lhe crankcase with oil to the "FULL"

mark on the oil leve indicator. Use oll with the API
(American Petroleum lnslituie) designation SE or
SE/CC Oil should be labeled as having passed MS FICUFE 3 OIL ORAIN ANO FILL
Sequence Tests (also known as having passed
AST.4G-lv Sequence Tests). Refer to oil chart for RECOMMENDED FUEL
recommended viscoslty and temperatu re Use clean, fresh, unleaded or regular grade gasoline
Do not use highly leaded premium fuels. Using
O I consumption may be higher with a mult grade oil unleaded gasoline results in reduced valve and
ihan with a single grade oil ii both oils have com- catbon cleanout maintenance,
parabe viscosities ai 210'F (99"C). Therefore,
single grade oils are generally more desirable, un ess
dntrcrpalrng a wrde'ar9e of lenpe'alL'es lf the use oi unleaded gasoline rs desired, use regular
gasoline for the flrst 25 hours to allow the ringsto seat
wel for best performance. Then use unleaded gas-
Use ol the same grade and quality oi o I asthai Lrsed in
your recreational vehicle engine is acceptable as long oline therealter.
as Lrnit is serviced regularly and oil meets re-
quirements shown in chart. lfregular gasoline rs used continually, carbon afd
ead deposits must be removed trom the cylinder
Do Nor check oll while lhe seneralor sel is heads as required because ol engine powet loss.
hA-ttt[,tc I Unleaded gasoline may be used safely alter lead
\-l opet.llng. Hol oil could cau3e burn. by
blowing our ol oil lill robe due lo crankcase presure. deposils have been removed.
 Leakage ol gasoline rn or arou.d lhe com- EXERCISE
WAN NING
parlmenr is a deiinile hazard. The venlilafton lnfrequenl use results in hard slartrng. Operale iFe
syslem should provide a conslanl llow ol air lo erpel any generator sei one 30-minute period each week Run
accumulalion ol luel vaoor while lhe vehicle is in l,ansil. Com- onger 11 battery needs charging. Exercising lor one
parlmenis musi be vapor lighi lo lhe inlerior to *eep lumes lron ong perod each week rs better than several shorl
Periods

BATTERY CHARGING
STARTING The battery charge rate is conlrolled by a lixed value
Push the start-siop switch lo the slart posrtion. res stor ihat allows a irickle charge .ale ol 1 - 1-1/2
Reiease the switch when engrne slarts. lf engine larls amPs underal conditions.
to siarl, inhrbrtor oil used al the lactory may have
touled the spark plugs. Remove the p ugs. clean rn a
suitable so vent. dry thoroughly and re-inslall Heavy HIGH OPERATING TEMPERATURES
exhaust smoke when the engine is iirst started is
normal and caused by the inhibrtor o I 1. See that noihing obstructs arr l ow lo and trom the

STOPPING 2 Keep coo rng f ns clean Air housing should be

properly installed and undamaged
Push the start-slop sw 1ch to the stop position and
hold unlil unil stops complelely 3. Keep ignilron I ming properly adiusied.

BREAK.IN PROCEDURE
Control ed breakrn with the proper oil and a con- LOW OPERATING TEMPERATURES
scientiously applied maintenance prograrn will hetp 1 Use correct SAE orl lor ternperature condilions.
lo assure satrsfaclory service from you r Onan eleclric Changeol only when engine rs warm. lf an
generaling set Break-tn as Jolows: unexpecled lemperature drop causes an
1 OnF lari loJt al 1t2 .oao (w,tr one a r con- emergency move vehicle to a warm location.
ditioner) and approximately 500 watts additionat 2 Use iresh gasoline Protecl againsi moisture
load condensalion. Below 0'F (-18"C), adjUst car-
buretor main jel lor a slig ht y richer tuel mixture.
2 O.e l_al' hour at 3,4 load {wrt5 one arr con- Keep ignition syslem clean, properly adiusted
ditioner) and approximately 1500-2000 watts ad- and balteries in a wel charged cond tion.
dllional load.
Partially restr!cl cool airilow, but use care 1o avoid
3 Change crankcase oil atler the first 50 hours of overhealing.
oPeration.

A carbu r.lor .ir pr6hqter llt ls afl!ll!bl€ lor cold wearhe, opedlion
APPLYING LOAD -below 45' F (7'C), whlch helF prevenl carbur.lorlclng Order
ll practical, allow sel to warm Lrp before connecting a Kit No. 140-1673.
heavy load Continuous generator overloading may
cause high operaling lemperalures that can damage
lhe windings. Keep lhe load within nameplate rating.
EXTREMELY DUSTY OR DIBTY
LOAD CONNECTIONS 1 Keep unit clean Keep cooling su'aces :::_
2 Servrce all c ealer as f'eqJent / E-i ':::i--.
1. Generator set load wires l\,41, and lv12 terminale
within the junction box. Connect and join wires 3 Change crankcase orl every a:
within junction box in an approved manner for 4. Keep oil and gaso ne rn cus:-:
desired voltage code. See Figure 4. 5. Keep governor rnkage c ea-
6 Clean generator brijs-:s sa
2 Wrres must be adequate size, properly insulaled mulator do nol rera': _:-:
and sLrpported. Do not polish
3 Mount swrlches and conlrols secure y lo prevent
damage lrom vibratLon and road shocks All HIGH ALTITUDE OPEFATTO"
swilches must be vibration proof to prevenl For operalion a: al: :-:- :':51: E=, -: - -rr.=
accidenlal operling or closing whrle the vehicle is -:-
sea level. close ca-a-'=_:- -a- F al,-,stre__ -rE
in motron. ly tO marntai' .':a=- .':E-a.E _6lr: r+E E :-€
4. All winng musl meet applicable locai eleclricaL ADJUSTT'IEN-S o---.-- *-t ,-* :c-' .'rl :€
codes. Have a qualrtied eeclrician nstall and reduced aaa.a: -z'=. 'a-l. :v)tr \'-. *: ".l|Ja
rnsPecl the wrrlng. fee! ,3': - ::.:.: :tr3 tlF:'* 1s':CC r=l
--:
 POWER REOUIREMENTS FOB APPLIANCES
Appllance or Approximale
Tool Running Watlage
Refrigerator ......600-1000
Etectiic broom .. . . 200-500
Cottee percolator . . . . . . . . . . . . . . . . . . . . . . . . 550-700
Electric frying pan . ... ... . ... ... ... .. 1000-1350
Hair dryer... ... .. .. .. ... ... .... ... .. .. 350-500
Electric stove (perelement) ...... . . .. 350n000
Electric iron .. ... . .. .. .. ... .. . ... . .. 500-1200
Radio .. ... ... ... ... .. .. .. .. . . ...... ... ... 50-200
Electric water heater.. ... .... ... ... ... 1000-1500
Space heater ... .. .. . . .. , ... ... .... ... 1000-1500
Eiectric blanket...................,....... 50-200
Tetevision ... . . .. ... .. .. ... ...... ... ... .. 200-600
Electric drill .. ... .. 250-750
Battery charger.. . . . .. .... ... ... ... ... . Up to 800
Electric water pump .. ... ... .... ... ... .. 500-600
Air Conditioner . . . . . . . . . . . , . . . . . . . . , . . . .14OO-220O
converter .. .. .... .. .... ... .... .... . .... . 300-350
Microwave oven .. .700-1500

JOII{ BOTII SL CK IE DS
IIEBE FOB FULI N TIXG
sfl{otEctRcull I20 YOIT
cB2
AL CK
outPtll.

UiGNOUTDED LOAD WIBE (

G
cBt
E BL CK TO YEHICLE
LL LOAD
EE
nl
D
t3 wHttE
o OMUXDED IOAD STIBE
B
t 20 voLT LOAD WIRE COI{}aECrlors

G
TI
.--------------- UXGNOUXDEO IOAD WIRE
E
IL
EE VtNlClE
R GROUXDED IOAD WIRE
TO
IO D
D
t3
o
R

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

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

 Operate slart switch.

Enerqizes start solenoid.

Solenoid contacls closi.

Current fed to Current fed to eleclric

Battery currenl fed to choke operates
generator series field,
ignition coil and fuel pump carburetor choke.
cranks engine.

Engine starts.

Operate slart switch until generator speed builds up

Generalor DC current AC output current produced

Release start switch. prod uced. and ted to load.

Generator supplies current to Recharges bdllery.

ignition, coil and fuel pump.

FICUFE 5. SEOUENCE OF OPEFATIOI{

SEOUENCE OF OPERATION
Figure 5 shows the operation sequence of the NH
"RV" electric generating set.
 ENGINE TROUBLESHOOTING
\_,

TR O U BI- ES H O OT IN G
o{ GUIDE
""f,, CAUSE
,,1.

' '.cooLrNc sYsrE|l (ArR cooLED)

LUBRICATION sYSTEM

THROTTLE AND GOVERNONJi]iii]]]]'.

 MAINTENANCE

BATTERY CARE
To increase battery life, the operalor can perform a
number of routine checks and some preventive
maintenance,

1. Keep the battery case clean and dry.

2. Make sure the battery cable connections are
clean and tight. Use a terminal puller when
rcmoving cables for any reason.
3. Coat the battery terminals with a mineral grease
or petroleum ielly to reduce corrosion and oxjda-
tion.
4. ldentify each battery cable to be posjtive or
negative before makrng any connection. Always
connect the ground (negative) cable lasl. ELEMENT
5. Nlaintain the electrolyte level by adding water
(drinking quality or bette.) as needed for f illing to
split level marker. (The water ingredient of the
electrolyte evaporates, but the sulphuric acid
ingredient remains- Thercfore, add water, not
electrolyte.
6. Avoid overcharging when recharging. Stop the
boost charge when the specific aravity is 1.260
and the electrolyte is 80'F (26.7'C).

FIGUFE 6. ONAN FUEL PUMP

AIR CLEANER ELEMENT

Check and clean element at least every 100 hours.
ELECTRIC FUEL PUMP Loosen wing nut to remove. Clean by tapping base
Service of the fuel pump is limited to cleaning the lightly on a flat surface. Replace elementat least every
filter. Every 100 hours, drain the fuel pump and check 200 operating hours; clean or replace more often in
the filter element. Turn the hex nut on the base of the dusty conditions. See Figure 7.
pump to gain access to the filter element- lf ihe
element appears dirty, rcplace it. Be sure to replace
gaskets when reassembling (Figure 6).

COOLING SYSTEM
The generator set is cooled by a flywheel blower tan
which pulls air over the cylinders and cooling fins.
The air path is directed by sheet metal shrouds and
plates. These shrouds and plates must always be
installed properly so unit does not overheat-

Check and clean (rf necessary) the cooling lins at

least every 200 hours ol operation. Remove any_Check
dust,
dirt or oil which may have accumulated.
compartment air inlet and generator set air ou et for
buildup of dirt, chaff, etc.

FIGURE 7, AIB CLEANEN ELEMEN1

SPARK PLUGS the engine stops to help drain the carburetor
Replace spark plugs every 100 hours orat least once a comPletely.
year. A badly leaded plug will cause misfiring. poor
operation or stopping when a load is applied.
3.
i:?';'i"" ;,1 J:" T.:'
"i"ii,I,,'
li
::':1",l;;'i I at
tag -
. Black deposits indicate a rich mixture. Replace drain plug and relill. Atlach a warning
stating type and viscosity of oil used.
. wet plug indicates misfiring. Remove spark plugs. Pour 1 ounce of rust in_
. Badlyorf requently louled plug indicatesthe need hibitor oil (or SAE #'10) into each cylinder. {Spray
tor a major tune-up. cans work well for lhis applicalion). Turn engine
over by hand at least 2 complete revolutions.
Each time the spark plugs are removed, Inspect, clean Replace the spark plugs.
and regap (Figure 8). lf the plug looks discolored or 5. Replace the air cleaner at least on an annual
has fouled, replace it.
basis.
6. Plug the exhaust outlet to prevent entrance of
moisture, dirt, bugs, etc.
7. Clean and oilallexposed engine parts including
carburetor and governor linkage.
L Wipe generator brushes, slip rings, housing, etc.
Do not apply any lubricant or preservative.
9. Bemove the battery and store in a cooldry place.
Coat the battery terminals and cable connections
vrith vasolrne or grease lo prevent any corrosion.
Recharge the battery at least monthly or maintain
with a trickle type battery charger.
10. Provide a suitable cover il the unii is exposed to
the elements.
FIGURE 8. CHEC(ING SPAFK PLUG GAP
RETURNING THE UNIT TO SERVICE
GOVERNOR LINKAGE
I Remove the cover and all prolective wrapping.
Wipe the oil film off all exposed engine parts.
The linkage must be able to move freely through its Remove the plug ,rom the exhaust outlet.
entire travel. Every 50 hours of operation, clean the
2. Visually inspect the unitforany damage. Check to
ioints and lubricate as shown in Figure L Also inspect be sure the carburetor and governor linkage are
the linkage for binding, excessive slack and wear.
free. Bemove the generator end bell band and
check to be sure the brushes work lreely in their
holders.
3. Check the tag to ensure oil of the proper brand
and grade has been installed. Check the oil level.
lnstall the battery (be sure battery is fully charg-
ed), observing proper polarity. Ground is
negative.
5. Bemove spark plugs, clean and gap. Turn the
engine overby hand several times. Reinstall spark
KEEP COVERNOR plugs.
LINKA6E LUBRICATEO
AND LUBRICATE W TH WiTH GRAPHITE 6. Turn on luel, disconnect electric fuel pump lead
and electric fuel solenoid shuFofl lead if unit is so
eqoipped. Jumpea the fuel pump and eleclric fuel
FIGUFE 9. GOVEFNOF LINKAGE solenoid shut-off leads to the battery to primethe
unit. Reconnect the leads.
OUT-OF.SERVICE PROTECTION 7. Remove all load and start the generalor set at the
Prolect a generator set that will be oul of service lor unit. lnitial stan may be slow due to oil or rust
more than 30 days trom damage caused by rust or inhibitor in the cylinders. Excessive smoke and
corrosion. Use the following procedure to properly rough operation will occur until the oil or rust
protect the set. inhibitor is burned olf.
1. Run the generatorsetwith at leasta 50% load until Apply a 500/0 load after the set runs smooth. Allow
thoroughly warm (usually about'1 hour). the generalor set to warm up (1 hour) with the
2. Turn off fuel supply and allow the engine to run load connected. Check speed and voltage.
out of fuel. Also operate the choke manually as L Unit is now ready tor service.
 GENERATOR MAINTENANCE
_ The qeneralor normailv needs little careotherlhan a
Iqt perio.-oic check ot th; brushes, commutator and
;ollector rings. lf a major repair job on the generator
should become necessary, have the equipment
checked by a competent eieclrician who isthorough-
ly familiar with the operation of electric generator
equipment.

Brush Replacement
lnstall new brushes when the old ones are worn to the
dimensions shown in Figure 10. Remove the end bell
band to expose the brush holders. Remove the three
screws holding each brush holder in place (Figure
10). Remove the old brushes and clean the holders so
the new brushes can move easily in their holders.
lnstall the new brushes in the same manner as theold
ones. Always use the correct brush as listed in the
PARTS CATALOG. Never substitute a brush which
may appear to be the same for it may have different
characteristics. New brushes are shaped lo fit and
seldom need sanding to seat properly. It some brush
sparking occurs after replacing brushes, run th'e set
under a light load until the brushes wear to a good
seat,

Collector rings acquire a glossy brown finish in

normal operation. Do not attempt to maintain a bright
newly machined appearing surface. Ordinary clean-
ing with a dry, lint lree cloth is usually sufficient. Very
fine sandpaper (#200) may be used to remove stight
roughness.

ASSEMBLY TORQUES
BOLT TORQUE FT..LB.
Gearcase Cover 8-10
Cylinder Head Slud Nuts (Cold). .... ... .. 17-19
Rear Bearing Plate Screws .. . ... .... ... .. 25-28
Connecting Rod Bolt ... .. . ... .. ,... ... .. 27-29
Flywheel Cap Screw. 35-40
Other 5/16" Cylinder Block
Stud and Nuts...... . 8-10
Oil Base Mounting Screws .. .. ... .. . ... 18-23
[4anifold l\,,lountin; Scrers . . . . . . . . . . . . . . . 18-23
7-9
Exhaust [,,lanifold '18-23

EXHAUST SPARK ARRESTER

Erhaust spark arreslers are necessary tor SAFE EASURE FiOfl IOP FTCE Of
OPERATION. All require periodic clean-out (every 50 Btusfl rL0c( I0 T0P 0t 8nusfi
to 100 operating hours) to maintain maximum ef-
ficiency. Some state and lederal parks require them. s.9 AE
5 tB"

To clean spark arrester remove pipe plug in bottom ol 1 1/16

muffler. Run set under load for 5 minutes. Replace
plug.
FIGUFE 10. BFTISH LENCTH

13
 PERIODIC MAINTENANCE SCHEDULE

Regularly scheduled mainlenance is lhe key lo lower the cond tion of the crankcase oil, the fillers eic
operating costs and longer servlce life lor the unit. irequent y until lhe proper service time periods can be
The following schedule can be used as a guide. established.
However, actual operating conditions under which a
unit rs run should be the determining factor in For any abnormalities in operation, unusual noises
establishing a ma ntenance schedule. When from engrne or accessories, loss of power,
operating in very dusty or dirty conditions, some of overheating, etc., contact your nearest aulhorized
lhe service periods may have to be reduced. Check Onan dealer.

wArNtN;-| Arway. alrow generaror ser ro coot ort

belo.e perlorfrhg .ny n.lnlen.nce or
inslallaiion work on lhele|, Working on a hoi Bel colld calse

AFTER EACH CYCLE OF INDICATED HOURS

SERVICE THESE ITEMS I 50 100 200 400

General inspectron X1
Check Oil Level X
Check Batlery Electrolyte Level X
Change Crankcase Oil x2
Check Air Cleaner x2
Check Spark Plugs x4
Check Breaker Points X3
Change Oil Filter x2
Clean Cooling Fins x2
Replace Breaker Points x4
Clean Crankcase Breather x2
Replace Arr Cleaner x2
Remove Carbon Deposits from Heads X
Adiust Tappets X
Replace Fuel Filter X4
Clean Carburetor X

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

x1 - wirh ser r!nnrnq. vrs!a ly and audibly check exhausl sylem tor leaks
X2 - Pedorm more oflen n exlremely dusly condrlions
X3 - qep a' p _.ces(drt
Yr' qpo'dce 'la.1ual y o' o or io $orage

;^Dxrr6t All erhault lvltom connection! IIUST be checked regularly fo. any leeks and
lryl tlghtened aa;ece!3a.y. Do NOTterminate erhau3t pipe underYehicle or neat any
window or dooiopenings. tnlpect the yapor tight 3ealr around all openings made in lhe-3et'5
compartment for wiring; conduitr etc,, to Prevent entrance of any noxioua fumes to motor home
inlerior.
14
 ADJUSTMENTS
Salislactory gonerator s€t performance depends on
correct adjustments. lf trouble develops, tollow an
orderly procedure to determine the cause betore
making changes in adjustments. Refer to ENG/NE
TROUBLESHOOTING and PERIODIC SERVICE
GUIDES for additional h6lp.

CARBURETOR
The NH "RV" gen€rator set carburotor has two
mixture adiustmenls, an idle mixture which aftects
operation mainly at no load and a main (power)
adiustment which affects operation at maximum load
(Figure 11). lf your generutor set has a "hunting"
(sudden surges and drops in speed) condition at no FIGURE 11, CABEURETOR FUEL MIXTIJFE ADJUSTIIIENTS
load or lull load and cannot be corrected by car-
buretor adjustm€nts, check governor, linkage and THROTTLE STOP SCREW
adfustment (see Govehot Adiustmerts). A hunting
condition at no load can usually be corrected by an The throttle stop scr6w is located on the base of lhe
idle mixture adjustment. carburetor (opposite side frcm main power adjust-
ment needle) near the cGnkcase breather valve. lt
When del.inlnlng lu.l mlrlure .€ttlng., must be adjusted to obtain 56hertzatno load with the
n.vlr lorc. lh. tu.l mlllult dlurtn.nl throttle closed as far as possibl€ (throttle shaft lever
n.dl.. !g.ln.l th.k...t (d.m.g.! th. ..d..nd n..dl.r). touching adjustment screw). See Figur€ 12.

CARBURETOR ADJUSTMENTS .
ADJUST THIS DISTANCE
BY ADIUSTING LENGTH
Start generator sel and allow it to warm up for at leasl OF GOVERNOR CONTROL
'10 minutes before making any adiustments. Remove
all AC loads and connect a plug-in-typeAC voltmetor
into one of the receptacles in the coach. When
procedure below callsforfull load, turn on appliances
or use an onan load test panel. The first two
adjustments are made with the set not running. Turn
unit off-proceed as followsl
1. Turn idle mixture screw out (counterclockwise)
1/2lo 3/4lwn from seated position.
2. Turn main mixture screw 1-1l4 to 1-1l2 turns out
(counterclockwise) f rom seated position.
3. Start set and adjust governor sp ng setting so
engine speed is 1860 RPM at no load (62 hertz or
130 volts). cLcEo PostTtoN
Hold back governorarm sothatthrottle lever Gsts
on throttle stop screw. Adiust idle stop screw to FIGUFE 12. THFOTTLE STOP SCFEW SETTING
1500 RPM (50 hertz or 100 volts). Reloase gover-
CARBURETOR FLOAT ADJUSTMENT
5. Adiust idle mixture screw to highost RPN.4 or
voltage. Readjust governor spring setting so 1. Normal operation seldom requires any adjust-
engine speed is 1860 RPN4 at no load (62 hertz or ment of the float level. Disconnecl throttle con-
130 volts). trol, choke leads, air cleaner inlet hose and tuel
line from carburetor.
6. Apply full Ioad to generator and adiust main
mixture screw lo highest RPIVI or voltage. Read- 2. Remove the tour bolts that hold the intake
manilold assembly in place and remove lhe.
iust governor spring setting so engine speed is complete carburetor and intake manifold
1770 RPM at full load (59 hertz or'1'10 volts).
assembly as one unil. Then remove carburelor
7. Remove and add load sevemltimesto checkfora lrom intake manifold lor easier handling wheo
governor hunting condition. Readjust governor checking float level.
spring setting if required.
 3. Remove the four phillips head screws on the top A binding in the bearings of the govemor shaft, in the
ot the carburetor and lift it ofi. ball ,oinl, or rn the carburetor throttle assembly will
4. lnvert the carburetor and check lhe lloat seiling
(see Figure l3). Thetloat should havea 0.0710.02 ::;d:":":1':""?""$T"Ti,",jiruii'iJff ':#",ffi?o
adjuslmenl may also cause hunting. Springs of all
lnch (1.8 1 0.5 mm) clearance from the machined
mating surface (without gasket). Bend the float kinds have a tendency to lose their calibrated tension
tab as required. through latigue alter long usage. lf all governor and
carburetor adjustments are properly made, and the
5. lf it is necessaryto reset thefloat level,loos€nthe governor action is still erratic, replacing the spring
scrcw nearfloatvalveaxle (pin) and bend thelloat with a new one and reselting the adiustments will
arm near float valve axle (pin) to posiiion tloat usually correct the trouble.
flush with top edge ol carburetor float bowl. See
Figure 13. 1. Adjust the carburetor idle needle with no load
connected,
It llolt ..l,u.lddt l. n.c.trrry, b.
c.rdul nol lo lo|e llr. buoy&cy rprlnt 2 Adjust the carburetor main jet for the best luel
or th. hn.lon lDrinq on th€ vlion llp llo.t n..dl€ md ..d mixture while operating the set with a full €ted
load connected.
Adjust the length of the governor linkage and
6. Reassemble carburelor and reinstall carburetor check linkage and throltle shaft for binding or
on intake manilold assembly and then replace excessive looseness,
complete assembly on the engine.
4. Adjust the governor spring tension for rated
7. Check carburetor for prop€r operation. speed at no load operation.
NEEOLE
5. Adjust the governor sensitivity.
6. Recheck the speed adiustment.
7. Set lhe carburctor throttle stop screw.

Link.g€: The engine starts at wide op€n throtlle. The

length of the linkage connecting thegovernorarm to

007!0 02 tN.
(1 8i 0.5 mm)
the throttle shaft assembly isadiusted by rotaling th€
ball loint. Adlust this length so that with the engine
stopp€d and tension on thegovernorspring, the stop
on the throttle shaft assembly almost touches the
throttle gtop screw housing on sideot calburetor (one
o
more turn of govemo. ball joint would allow throttle
shaft linkag€ to rest against stop screw housing) See
BOOY Figure 12.
FIGUAE 13. CARBURETOR FLOAT SETTING
Speed Adtustment With the warmed-up unit
GOVERNOR ADJUSTMENTS operaling at no load, adjust the tension ol the
It carburelor and lh. tollowing gorerno.adjutheni. h.vealt6.dy governor spring. Refer to the Voltage Chart and the
b€en mad€ and lhe govornor acilon b stlll e rtlc, replace the Speed Chart. Turn the speed adjusting nutto obtain a
qovemor .pri.s (Fisurc 14) wlth a new one .nd reldju.i the voltage and speed reading within the limits shown.
gov.nor. spdngs lo8e theh c.libEr.d teBion lhrough l.llgue
Sensitivity Adiustment: Refer to the GovernorAdiust-
Before making governor adjustments, run the unit ment illustration, and to the Voltage and Speed
about 15 minutes under,ight to reach normal Charts. Check the voltage and speed, first with no
operating temperature. (11 governor
'oad is completelyout load connected and again with a full load. Adiustthe
of adiustment, make a preliminary adjustment at no sensitivity to give the closest regulation (least speed
load to first attain a sale voltage operating range). and voltagedifference between no load and tull load)
without causing a hunting condition.
Engine speed determines the output voltage and
cuffent trequency olthe generator. By increasingthe To increase sensitivity (closer rcgulation), shift the
engrne speed, generator voltage and frequency are spring toward the governor shaft.
increased, and by decreasing the engine speod,
generator voltage and frequency are decreased. An
accurate voltmeter or frequency meter (preferably
both) should be connected to the generator output in
order to correctly adjust the governor. A small speed
drop not noticeable without instruments will result in
an obiectionable voltage drop. The engine speod can
be checked with a tachometer.

16
 VOLTAGE CHART t20 YoL.'
FOR CHECl(IIIG I PHASE
GOVERNOR FEGULA'ION 2 rraE

'---l------ -Et I32

r08
FULL-LOAO VOLIACE

SPFIING TENSION
SPEED CHART FOR CHECKING
GOVEFNOR RECUIATIOT{
MAX]MUTI NO LOAD SPE€D (RPM)
HERTZ ICURRENT FREQIIENCY) 63

MINIMUI1 FULL.LOAO SPEED (RPM)

FIGt'RE 14, GOVERNOR ADJUSIMENTS

ELECTRIC CHOKE
ll extremes in starting temperatures require a read-
iustment of the choke, loosen slightly the two cover 2. To set the point gap turn the engine crankshaft
retaining screws- See Figure 15. For less choking with rotation until the maximum breaker point
action, turn the cover assembly a few degrees in a gap is obtained.
clockwise direction. For more choking action, turn
counterclockwise. Fletighlen the cover screws. 3. Using an allen head wrench, adjust set screw (B)
Choke may be closed manually if desired to adjust for.016 (0 41 mm). Ivleasure point gap with a ftat
choke settings or for troubleshooting purposes. thickness gauge.
llthe engine sl..ls and runs roughty .tier a mtnute o. lwo ot
operalion, lh€ choke is set too rlch. tl th. ongi.. 3ians, and Mak€ sure lelergauEe l! clean dnd lFe ot anygrca*, oll or
a3suming lhatJuel, ignilion and compre$ion are.dequ.te bullhe dirt. See Fiquro 16.
engine spuneB or stoF belorc ii wams Ltp, the choko is s6t roo

The timing is adjusted during initiat engine

assembly and is fixed by the point gap adjust-
ment. No other adiustment or alignment is
necessary. A.016 point gap is equivalent to
approximately 20o BTC.

4. Beplace point box cover.

The ignltion adiushenrs 3houtd bem.dewirh rheengineina
slallc condirion and cold,

AVERAGE CHOKE SETTING

AMB ENT TEMP IFA CHOhE OPENING
58 (14 c
66 (19 c
12 (22 c
76 124 c
e2 ea c
FIGURE 15. CHOKE AOJUSTMENT

BREAKER POINTS AND IGNITION TIMING

The correct point gap setting is .016 cold (0.41 mm)
and should be adjusted as follows:

1. Remove cover by loosening screw and lift off. FTGURE 16. IOP AOJUST FO$aTS
 CONTROL TROUBLESHOOTING
PROBLEM PROBABLE CAUSE BEMEDY
1 Bad Batlery Con.ectron ' a ed dno thl.. al b"rrerv d^d (dbla ron .Llro )
2A Check specric qravrly Fecharge or rep ace baltery i e"
2A Feverse curenl drode {CFr )may be shorted or open ca!sr.9
a d.a n on lhe banery B2 may be open

3 Fauxy Srarr 5ole.o,d (Kl) 34. Check lor Ballery Voltage at Kl l termrnal
38 pushslarlswrlch Checkslarlsoenod Sl lermrna vollagelo
qround when barlery vo laqe al stan solenord B_ term nalrs
presenr barrery volrage sho! dasoappearal sl lermLnal rl
.oi rF. a.e qran so eno d
4 Faulty Starl Swrich 4. Jeunpq $rlch (i3 termrnal) lo ground rf so enoid enerqEes,

1 Bad Balrery Conneclron 1 See 1 above(FATLSTOCFANK)

2 2 See 2 above {FAILS TO CFANK)

CRANKS BUT 1 Feprace luse (F2) on control

2 Fauliy FuelSolenord Or 2 Fue so eno d mlsl open dur nq cranking and r!nn ng check
by removrng steel ne lrom carburelor and crank eng .e ll
lue soreno'drsopen.luelwl pulsaleoulollhrslrne lLtdoes
nol rhe iuel solenord and llel p!mp musl be checked
o; tarer moders. tuet separately lo deierm ne deleclrve part
solenoid is an inlegr.l part lJie erlreme cate lorlh,s 16r Dit.crluel
wArNtN;l llow rnlo . suil.ble conlai.er .nd Frke
:l
sure are, is well venlllaled lo prevenl accumulation ol

3 Che.k to see pornrs open a.d closedunnq crankrng llhey

't c ose. adlusi and sel pornls Prug and pl!9
do not open and
wrres musr be rn qood condrlron voltage al rgn I on corl
negar ve termrnal(-)musl a lernaleJrom ' l2volrslozerovolls
as pornls open and close d!nng engrne cranki.9
,1 W'lh eng.e nol runn.q check choke vane movemenl by
plsh n9 choke lever arm chokemoslbe nclosedposlon
w lh co d e.g .e and mlsl be free lo move aga nsl b'metal
sp nq Aseng newarmsup b -melalspnngre axesa.da lows
choke vane lo ope. luly The lever w'lpulsale as e.gr.e
warms up See ADJUSTMENT secl o.

s Fau ly Cra.k qn,l on Be ay (K2) 5 Checkvollagelromreaylermnar 4 logro!ndwhlecrankrng

un I Ballery vollage should appear al lh s term nal ll nol
check Jor vo lage al relay lerm.als r a.d 2 ll ballery
vorlage s presenl al lerm'nals I a.d 2. but nol al4. replace
reay linolvolageappearsatlermL.asland2onrelaywhile
cra.k.g check wL.ng belween starl sole.od (K1)andcrank

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

UNII STARTS. BIJT 1 Fes stor Fr may be ope. shou d be 24 32 vo ts OC
STOPS IMMEDIATELY 2 Fu. lqn('on Felay K3 2 Check vo laqe on bolh s des ol K3 Sholld be 12 vo ls
AFIER FELEASING 3 Check o I leve I row or empty. rijl rl to proper leve
STAFT SWITCH S1 4 53 Low or presslre sw 1ch may be 4 Check 53 Swrlch shoud close wlh sel rlnnrng al 10 bs
mrnmufrolpressure

IJNITS FUNSTHEN 1 Check oi reve. li low or empty reliil to proper level

UN TS RUNS BI-IT 1 See 4 above (CRANKS BUT WON.T STAFTI

SURGES
2 Governor Nol Adlusled Properly

UNiTS STOPS 1 See 3 above (CRANKS BUT wON l START)

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

'efi
BEMOTE BUNNING T]ME I Fep ace F1 iuse on co.lrol
METER OF GENERATOR
LAMP INOPERATIVE
 6ll-1146 1rI

I L,

.*f ; - --l

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

;is[i#
A1 . .. ... ... Control Assembty E4 .. ... .. . . Electric Fuel Pump
A2 . .. . . . ... Deluxe Remote Control F1, F2.. .... Fuse (s-amp, 32 volt)
A3 .. .. . . ... Standard Remote Control G1 .. ... .... Generator
BT1 . ... .. ..12 Volt Battery K1 ... ... ... Start Solenoid
CB1 ... .. .. Circuit Breaker K2 ... .. . ... Crank lgnilion Flelay
CB2 ... .. .. Circuit Breaker K3 ... ... ... lgnition Run Relay
(when used) R'l ... ... ... Battery Charging Resistor
CR1,......Fleverse Current Diode (fixed value)
(prevents battery discharge 51 . ... . .. .. Start-Stop Switch
when unil is shut down) 52 . ... . .. .. Breaker Points Assembly
E1 ... ... ... Onan Choke 53 . . ... .. .. Low Oil Pressure Switch
E2, E3 .. ... Spark Plugs - T1 . .... ... .lgnition Coil

19
 REMOTE ACCESSORIES

INSTALLING STANDARD OR DELUXE REMOTE START CONTROLS

300-0985 AND 300-0986

The standard control includes a start-slop switch and 3. lnsert remole control in hole cutout and secure
indicalor lamp. The deluxe control conlains these with woodscrews supplied with switch.
items plus a running time meter and a battery Seal all hole. rhal might .llow noxiou6
condition meter. lnstall as tollows: ga3esro enlermolor home,

1. Select control location. Using Figure 17 or 18 as a

guide, drill screw holes and cut hole to accom- Ensure that leads kom remole swllch
modate remote switch in dash panel. connecl walh coresponding terninals

2. Following national local electrical codes and

using #18 or larger insulated wires ol predeter- For sers wilhoul remore conrcclo. plug, con nEl lemlnal3 I,
mined length, connect remote control lo 2, and 3lo coresponding lemlnals on qeneralor.sll6rmin.l
generator set. Ensure that leads trcm remote block. Connecl term inal ,5 (ll !s€d) lo B+ (on leminal block)
or lo battery connedlon on 3lart 3olenoid. Thb connelion
control connect to corresponding terminals on should be prorecred with 6 5 anPl$e, connecl lerminal*6lo
generalor set. Refer to Figure 19 for wiring posilire lermhal on iqnilion coil .nd protecl with a 5 amp tuse
connections,
Do.ot route Dc wirFlorrefr oleconl.ol When wiring is complete, checkforproperopera-
lhrouqh conduil conlainlng AC loadwn- tion by stading and stopping set atlhe set control
ing. hduced volrages day cause er.nc operalion. and by the remote start swiich.

FIGURE 17, MOTOE HOIIE CUTOUT FIGUF€ I8. MOION HOME CUTOUT FOR
FOF 300.0985 STANOARD 300-0986 DELUXE CONTnOL
CONI'FOI PANEL PANEL

20
 NOIE: Use 18 gruge or
larqe, sare lor in.l.rling lhe

{GLOWS WHEN SET

S RUNN]NG)

FEMOTE SwlTCH WIRE COLOR

SET TEFMINAL FTJNCTION COD€

2
3 3
5
;;;-'l
- "i::J
6 6

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

CALL FOR SERVICE

GENERATOR POWER SYSTEMS
2315 Griffrn Road Unit #6
LEESBURG, FLORIDA 32748
(904) 325€542 (305) 331.0095

@ @
\
-!
21
 NOTE: U3e 18 g.!ge or
larqer wire lor i.3r.Iang lhe

GENEFAIING LAMP
(GLOWS WHEN SET
]S RUNNlNG)

S€T TEFMINAL FUNCTION

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

CALL FOR SERVICE

GENERATOR POWER SYSTE]IIS
2315 criffin Road Unit #6
LEESBURG. FLORIDA 3274A
(904) 326€542 (305) 331-0095

@ @

21
 ' ,|:

Onan Corpoblion 612 574-5{100

at
A Substdtaty lelex 29 0476 {U,S.)
Canpany Telex 23 0856 (ouGide U.S.)
^4cctaw-Edtsan
1400 73rd Avenue N.E. fWX 91057G2833
Minneapolis, MN ss432 Cable ONAN