Onan Elite E125V, Elite E140V Owner's Manual

El25V,

El40V

Elite Series

Printed

in

U.S.A.

965-0166

6-94

(Spec

C)

Important Safety Precautions

,

Read and observe these safety precautions when using or working on electric generators, engines and related equipment. Also read and follow the literature provided

with the equipment. Proper operation and maintenance are critical to perfor-

mance and safety. Electricity, fuel, exhaust, moving parts and batteries present hazards that can cause severe personal injury or death.

FUEL, ENGINE OIL, AND FUMES ARE

Fire, explosion, and personal injury can result from improper practices.

4

.

FLAMMABLE AND TOXIC

Used engine oil, and benzene and lead, found in some gasoline, have been identified by government agencies as causing cancer or reproductive toxicity. When checking, draining or adding fuel or oil, do not ingest, breathe the fumes, or contact gasoline or used oil.

Do

not fill tanks with engine running.

Do

not smoke

around the area. Wipe up oil or fuel spills.

Do

not leave rags in engine compartment or on equipment. Keep this and surrounding area clean.

Inspect fuel system before each operation and periodically while running.

Equip fuel supply with a positive fuel shutoff. Do not store or transport equipment with fuel in tank. Keep an ABC-rated fire extinguisher available near

equipment and adjacent areas for use on all types of fires except alcohol.

Unless provided with equipment

or

noted otherwise in installation manual, fuel lines must be copper or steel, secured, free of leaks and separated or shielded from electrical wiring.

Use approved, non-conductive flexible fuel hose for fuel connections.

Do

not use copper tubing as a

flex-

ible connection. It will work-harden and break.

EXHAUST GAS

IS

DEADLY

Engine exhaust contains carbon monoxide (CO),

an odorless, invisible, poisonous gas. Learn the symptoms of CO poisoning.

Never sleep

in

a vessel, vehicle, or room with a gen-

set or engine running unless the area is equipped with an operating CO detector with an audible alarm.

Each time the engine or genset is started, or at least every day, thoroughly inspect the exhaust system. Shut down the unit and repair leaks immediately.

u

b

Warning: Engine exhaust is known to the State of California to cause cancer, birth defects and other reproductive harm.

Make sure exhaust

is

properly ventilated.

Vessel bilge must have an operating power exhaust.

Vehicle exhaust system must extend beyond vehicle perimeter and not near windows, doors or vents.

Do

not use engine or genset cooling air to heat an

area.

Do

not operate enginelgenset in enclosed area

without ample fresh air ventilation. Expel exhaust away from enclosed, sheltered, or

occupied areas. Make sure exhaust system components are se-

curely fastened and not warped.

MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH

Do

not remove any guards or covers with the equip-

ment running. Keep hands, clothing, hair, and jewelry away from

moving parts. Before performing any maintenance, disconnect

battery (negative

[-I

cable first) to prevent acciden-

tal starting. Make sure fasteners and joints are secure. Tighten

supports and clamps, keep guards in position over fans, drive belts, etc.

If

adjustments must be made while equipment is running, use extreme caution around hot manifolds and moving parts, etc. Wear safety glasses and protective clothing.

BATTERY GAS

IS

EXPLOSIVE

Wear safety glasses and do not smoke while servicing batteries.

Always disconnect battery negative

(-)

lead first

and reconnect

it

last. Make sure you connect battery

correctly.

A

direct short across battery terminals can

cause an explosion.

Do

not smoke while servicing

batteries. Hydrogen gas given

off

during charging

is

explosive.

Do

not disconnect or connect battery cables if fuel

vapors are present. Ventilate the area thoroughly.

GSP-1

1

of2

DO NOT OPERATE IN FLAMMABLE AND EXPLOSIVE ENVIRONMENTS

Flammable vapor can be ignited by equipment operation or cause a diesel engine

to

overspeed and become diff

i-

cult to stop, resulting in possible fire, explosion, severe personal injury and death.

Do

not operate diesel equipment where a flammable vapor environment can be created by

fuel

spill,

leak, etc., unless equipped with an automatic safety device to block the air intake and stop the engine.

HOT COOLANT CAN CAUSE SEVERE PERSONAL INJURY

0

Hot coolant is under pressure. Do not loosen the coolant pressure cap while the engine is hot. Let the engine cool before opening the pressure cap.

ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY

OR

DEATH

0

Do not service control panel or engine with unit running. High voltages are present. Work that must be

done while unit is running should be done only by qualified service personnel.

Do not connect the generator set to the public utility

or to any other electrical power system. Electrocution can occur at a remote site where line or equipment repairs are being made. An approved transfer switch must be used

if

more than one power source

is

connected.

Disconnect starting battery (negative

[-I

cable first) before removing protective shields or touching electrical equipment. Use insulative mats placed on dry

wood platforms. Do not wear jewelry, damp clothing or allow skin surface to be damp when handling electrical equipment.

Use insulated tools. Do not tamper with interlocks. Follow all applicable state and local electrical

codes. Have all electrical installations performed by a qualified licensed electrician. Tag open switches

to

avoid accidental closure.

With transfer switches, keep cabinet closed and locked. Only authorized personnel

should

have cabinet or operational keys. Due to serious shock hazard from high voltages within cabinet, all service and adjustments must be performed by an electrician or authorized service representative.

If

the cabinet must be opened for any reason:

1.

Move genset operation switch

or

Stop/AuY

Handcrank switch (whichever applies)

to

Stc

2.

Disconnect genset batteries (negative

1-1

leaa

3.

Remove

AC

power to automatic transfer switch. If instructions require otherwise, use extreme caution due to shock hazard.

.

first).

*

k'

MEDIUM VOLTAGE GENERATOR SETS (601V TO

15kV)

Medium voltage acts differently than low voltage. Special equipment and training are required to work on or around medium voltage equipment. Operation and maintenance must be done only by persons

trained and qualified to work on such devices. Improper use or procedures will result in severe personal injury or death.

Do not work on energized equipment. Unauthorized personnel must not be permitted near energized equipment. Induced voltage remains even after equipment is disconnected from the power source.

Plan maintenance with authorized .personnel

so equipment can be de-energized and safely grounded

.

Do not work on equipment when mentally or phys

cally fatigued or after consuming alcohol or drugs Carefully follow all applicable local, state and feder-

al codes. Never step on equipment (as when entering or leav-

ing the engine compartment).

It

can stress and break unit components, possibly resulting in dangerous operating conditions from leaking fuel, leaking exhaust fumes, etc.

Keep equipment and area clean. Oil, grease, dirt, or stowed gear can cause fire or damage equipment by restricting airflow.

Equipment owners and operators are solely

re-

sponsible for operating equipment safely. Contact your authorized OnanlCummins dealer or distributor for more information.

KEEP THIS DOCUMENT NEAR EQUIPMENT FOR EASY REFERENCE.

GENERAL SAFETY PRECAUTIONS

GSP-1

2

of

2

Table

of

Contents

Title

Page

Safety Precautions

....................................

Inside Cover

introduction

....................................................

2

Engine Set-Up

..................................................

4

Operation

......................................................

6

Maintenance Schedule

...........................................

9

.

Maintenance Procedures

........................................

1

0

Adjustments

...................................................

13

Troubleshooting

.......................................

;

........

14

[AWARNING

I

INCORRECT SERVICE OR REPLACEMENT

OF

PARTS CAN RESULT IN SEVERE PERSONAL iNJURY AND/OR EQUIPMENT DAMAGE. SERViCE PERSONNEL MUST BE QUALIFiED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.

1

Introduction

Valve

Clearance

(Cold)

in

0.006 0.006

Intake (mm)

(0.15) (0.15)

Exhaust

in

0.006

(mm)

(0.15)

KNOW

YOUR

ENGINE

Study this manual carefully and comply with each of

Always use this number and the engine serial number when making reference to your engine.

G

*

the warnings and cautions. Maintain the engine according to the maintenance schedule. Operating the engine properly and performing regular maintenance can result in longer engine life, better performance and

safer

operation. Regularly scheduled

maintenance lowers operating costs.

Figure 1 shows the locations

of

the components

referred to in this manual.

If

a

major repair

or

an overhaul is necessary, Onan recommends the work be done by a Gompetent mechanic to see that all dimensions, clearances, and torque values are within the specified tolerances.

An engine service manual is available at additional cost. Contact your nearest authorized dealer or

ENGINE MODEL REFERENCE

Onan Parts ani Service Center.

Identify your model by referring to the

MODEL

and

SP€C/F/CAT/ON

number as shown on the engine

nameplate (Figure

1).

This manual contains the SI metric equivalents shown in parentheses immediately after the

U.S.

customary units of measure.

TABLE

1.

SPECIFICATIONS

Unit

of

Series

SPECIFICATION

Measure

El

25V

El

4QV

Numbers

of

Cylinders

1

~

in

3.31

I

Stroke

(70.0)

in

2.76

(mm)

(70.0)

1

Displacement

(389)

23-7

I

cu

in

23.7

(cm3) (389)

I

Compression Ratio 8.5

to

1

8.5 to

1

I

Power

at

Rated

Speed

(3600

rpm)

BHP

(kw)

(1

0.4)

12.5

(9.3)

Oil

Capacity

With Filter

QtS

(liter)

il

I

Spark

Gap

(0.89)

0.035

I

in

0.035

(mm) (0.89)

I

Ignition

Timing

~~

BTDC

230

I

2

AIR

FILTER

HOUSING

U

SPARK

PLUG

Mrn7

FIGURE

1.

ENGINE

COMPONENT

LOCATIONS

3

Engine

Set-Up

PRE-START CHECKS

Inspect the engine visually. Check for

loose

or rnissing parts and any damage that may have occurred in shipment.

~IStartIng the engine without oil will

result in severe engine damage. Add oilprior to starting the engine.

BATTERY

(If

Equipped)

The battery and battery cables used for starting the engine should be

of

sufficient size to provide prompt

starting. Use of an undersized battery

will

result in poor starter operation and a very short starter service life.

-1

lgnifion

of

explosive battery gases

can result in severe personal injuw.

Do

not smoke or allow any Ignition source near the battery.

1-1

Reversing positive and negative battery connections or allowing the engine to run without being connected to the alternator

will result in engine electrical system damage.

Do

not switch battery connections or allow the engine to run without being connected to the alternator.

CRANKCASE OIL RECOMMENDATIONS

Use

premium quality motor oil with the

API

(American Petroleum Institute) designation

SG

on

the container. Figure

2

shows the recommended

oil

weight forthe temperature range that the engine will be operated in. Make sure the engine oil weight is correct

for

the expected temperature range.

Refer to Table

1

(Specifications)

for the crankcase

oil capacity.

Single-grade oil is preferable when temperatures are consistently over

3OoF

(OOC).

Multigrade oils are best when wide temperature variations are anticipated.

-1

Crankcase pressure can blow out

hot

oil

that can cause severe personalinjury.

Do

not check the oil level while the engine

is

running.

-1

Excess oil can cause high

oil

con-

sumption, high operating temperatures, and

oil

foaming.

Do

not overfill the crankcase.

FIGURE

2.

OIL

VISCOSITY

VS.

TEMPERATURE

32

0

OF

-30

-20

-IO

o

10

20

30

40

SO

60

70

80

90

100

110

120

'c

-34

-29

-23

-18

-12

-7

-1

4

10

16

21

27

32

38

43

48

ANTICIPATED AMBIENT TEMPERATURE

I

1

*

4

Y

Oil

Level

Check the

oil

level at the intervals recommended in the Periodic Maintenance Schedule. Check more frequently on

a

new

or

reconditioned engine as oil

consumption is normally higher until the piston rings

seat properly. Make sure equipment

is

on a level

surface and screw the oil

fill

cap into the dipstick tube until it stops. Refer to the Maintenancesection for recommended oil change intervals and procedures.

When adding oil between oil changes, it is preferable to use the same brand, because different oil brands may not be compatible. Figure

3

shows the

oil level dipstick and the

FULL

mark.

L

n

k

4

Ls1192

FIGURE

3.

OIL

LEVEL

DIPSTICK

FUEL

RECOMMENDATIONS

1-1

Ignition of

fuel

can

result

in

severe

personal injury or death.

Do

not smoke or allow any spark, pilot light, or arcing equipment near the fuel system.

Use clean, fresh, unleaded gasoline. Use of unleaded gasoline results in less maintenance.

-1

Gasoline de-icers and fuel containing alcohol can cause poor engine performance and engine damage.

Do

not use fuelsystem de-

icers.

Do

not use gasoline containing alcohol

concentrations greater than ten percent.

-1

Ignition of fuei can result in severe

personal injury or death. Thoroughly clean up

any spilled fuel.

EXHAUST

SYSTEM

Exhaust products of any internal combustion engine are toxic and

can

cause injury

or

death

if

inhaled.

All

engine appliktions, especially those

within

a

confined area, must be equipped with an

exhaust system to discharge gases to the outside

atmosphere and away from windows doors and

vents.

-1

Exhausf gas Is deadly. Breathing ex-

haust

gases can result in severe personalinjury or death, Use exfreme care during lnsbllafion to ensure a leak-free exhaust system.

5

0

perat

ion

IAWARNING

I

EXHAUST GAS

IS

DEADLY!

Exhaust gases from ail fuels (including diesel, gasoline, //quid propane, naturai gas) contain carbon monoxlde, an odorless and coioriess gas. Carbon monoxide

is

poisonous and

can

cause unconsciousness and death.

Symptoms of carbon monoxide poisoning

can

include;

Dizziness Nausea Muscular Twitching Headache Vomiting

Weakness and Sleepiness

Throbbing

in

Temples

Inability to Think Coherently

IF

YOU

OR

ANYONE

ELSE

EXPERIENCE ANY

OF

THESE

SYMPTOMS,

GET

OUT

INTO

THE FRESH AIR iMMEDlATELY. if symptoms persist, seek

medical attention. Shut down the unit

and

do not operate untii

it

has been

inspected and repaired. Protection against carbon monoxide inhalation includes proper instaliation,

ventiiation and regular, frequent visual and audible inspections

of

the

complete exhaust system.

STARTING

1.

Move the speed control to the choke position.

2.

Engage the electric starter

for

up to

30

seconds

or pull the recoil starter until the engine starts.

3.

When the engine starts, move the speed control from the choke position to the fast or high

position as the engine warms up, usuallywithin

10

seconds..

4.

If

the engine does not start, wait

30

seconds

and repeat steps

2

and

3.

In very

cold

temperatures

it

may

be

necessary

to

partlaily open the choke when the engine

be-

gins

to

fire.

BREAK-IN

PROCEDURE

Controlled break-in

is

the ideal fitting

of

all

internal

moving metal parts. Using the proper oil and apply-

ing 'a conscientious maintenance program during this period helps to obtain satisfactory service from the Onan engine.

Maintain the proper cooling and lubrication during

break-in. Run the engine at half load for the first

1-1/2

hours with intermittent periods of

full

load to

control engine break-in.

-1

Using the wrong grade and weight

of

oil

with high engine operating temperatures during break-In can cause engine damage. Use the correct

oil

grade and weight and provide ad-

equate engine cooling during engine break-in.

Check the oil level at least every five operating hours during break-in. Add oil to keep it

at

the proper

level, but never overfill, because overfilling may

cause the oil to foam and enter the breather system,

resulting

in

high

oil

consumption and

oil

accumula-

tion

in

the air cleaner houshg.

6

U OPERATION

Always be careful when operating power equipall warnings and cautions.

-1

Contact wlth mtating machinery

and hot parts can result In severe personal

injury

or death.

Shy

clear of rofating components and hot parts. Make sure that protective shlelds and guards are secured In place before operating power equSpment.

”

ment. Followthe operating procedures and observe

Hot Weather Operation

When operating the engine in temperatures above

100°F

(38OC), pay particular attention to the follow-

ing items to prevent equipment damage:

1.

Keep the engine cooling fins clean and free of obstruction.

racAuTIoN7

Piuggeti or clogged cooling

fins

or a dltty flywheel Intake fiRer can cause overheatlng and englne damage. Make sure the cooling flns and infake filter are kept clean.

2.

See that nothing obstructs the air flow to and

from the engine.

3. Make sure the crankcase is

full

of the proper oil weight for the ambient temperatures. Check the oil level each time you fill the fuel tank.

4.

Change the crankcase oil and oil filter more frequently than scheduled.

Cold

Weather Operation

When the engine is being used in temperatures

below

32°F

(O°C),

check the following items to pre-

vent equipment damage:

1.

Make sure the crankcase is full of the proper oil weight forthe ambient temperatures. Warm the engine up before changing the oil. If an unexpected temperature drop occurs when the en-

gine is

filled

with summer weight oil, move the

equipment to

a

warm location before starting

the engine

so

the oil will flow freely.

4

2.

Use fresh fuel. Fill the fuel tankafter each day’s use to protect against moisture condensation.

3.

Keep the battery in a well-charged condition.

4.

After each use, place the speed

control

in the

low

speed position. This

will

prevent engine

overspeed

if

ice

forms

on the linkage during

storage.

Operation in

Dusty

Conditions

1.

2.

3.

Keep the cooling system and the equipment clean.

Service the air cleaner more frequently than listed

in

the

Mainfenance schedule.

Change the crankcase

oil

and oil filter more

frequently than listed in the

Maintenance

schedule.

OUT-OF-SERVICE PROTECTION

1.

2.

3.

4.

5.

6.

7.

a.

9.

10.

Protect an engine that

will

be out-of-service for

more than

30

days as follows:

Run the engine until

it

reaches normal operat-

ing temperature. Turn

off

the fuel supply and run the engine until

it stops.

Drain the

oil

from the oil base while the engine is still warm. Refill with fresh oil and attach atag stating the oil viscosity used.

Remove the spark plug. Squirt

1

ounce (2

tablespoons

or

28

grams) of rust inhibitor

or

SAE

50

oil into the cylinder. Crank the engine

over

a

few times. Reinstall the spark plug.

Service the

air

cleaner as outlined in the

Main-

tenance

section.

Clean the governor linkage and protect it by wrapping

it

with a clean cloth.

Plug the exhaust outlet to prevent the entrance

of moisture, dirt, bugs, etc. Wipe the entire unit clean. Coat bare metal

parts with

a

light

film

of grease or oil.

Provide

a

suitable cover

for

the entire unit.

If

the equipment is equipped with a battery, disconnect it and follow the manufacturer’s battery storage procedure.

7

RETURNING ENGINE

TO

SERVICE

1.

Remove the cover and

all

protective wrapping.

Remove the plug from exhaust outlet.

2.

Check the tag

on

the oil base and verify that oil

weight is

stili

correct for the existing ambient

temperatures.

4.

Check the fuel filter and lines

to

make sure they

5.

Check that the carburetor throttle lever and

6.

Connect the battery cables, positive

(+)

cable

first.

7.

Start the engine. Exhaust smoke

is

normal

when the engine is started, due to the

rust

inhibitor oil.

are secure and have no cracks

or

leaks.

.l

.

governor linkage move freely.

3.

Clean and check the battery (if equipped).

8

Maintenance

Schedule

I

Clean

Cooling

Fins

Y

PERIODIC

MAINTENANCE

SCHEDULE

engine more frequently. Neglecting routine maintenance can result

in

premature engine failure.

For

any

abnormalities

in

operation,

unusual

noises

Center.

Refer to the following

Maintenance

Procedures

section for routine maintenance procedures.

Following the maintenance schedule and using the

each maintenance procedure after the number of operating hours indicated. These service intervals are recommended

for

normal operating conditions.

For operation in hot

or

dusty conditions, service the

b

engine properly will result

in

longer engine life,

better

performance

and

safer

'peration-

Perform

from fie engine oraccessofies,

loss

of power, over-

heating, etc., contact your nearest Onan Service

Replace Air Cleaner Paper Element

Reolace Fuel Filter

TABLE

2.

PERIODIC MAINTENANCE SCHEDULE

x3

SERVICE THESE ITEMS

X

x4

Inspect the Engine Check Oil Level Service Air Cleaner Foam Wramer Chanae Crankcase Oil and Oil Filter

Check

or

ReDlace

%ark

Plug

Check Valve Clearance

AFTER EACH CYCLE

OF

INDICATED HOURS

8

I

25

I

50

I

100

I

200

I

X'

X

X2

X

1

-

Check

for

fuel leaks.

With

engine running, visually and audibly check exhaust system

for

leaks.

2-

Perform more often when running under severe operating conditions.

3-

Required

for

initial break-in only.

4-

For detailed maintenance, contact

an

Onan Service Center or refer

to

the

SeMce

Manual.

Shut down the engine and repair any leaks immediately.

TABLE

3.

MAINTENANCE PARTS

ENGINE MAINTENANCE

PARTS

Part

No.

Filter

122-0737

Fuel Filter

149-2356

Air

Cleaner Paper Element

140-2672

Spark Plug

167-0263-02

-1

Breathing exhausf gases can

result

in severe personal injury

or

death.

Do

not use air cleaner, exhaust elbow, or connecflng parts as a supporting step. Damage

fo

fbese and con-

necting

parts

can cause an exhausf leak

9

Maintenance Procedures

I-Accldental starting

of

the engine can result In severe personal injury or death. Disconnect the negative

(-)

battery cable and the spark plug wlre whlle servicing the engine, controls, or associated equipment.

CHECK DAILY

OR

EVERY

a

HOURS

The operator should make a complete visual and

audible inspection

of

the engine daily. Check the fol-

lowing before starting the engine for the first time

each day:

1.

Check

all

fuel lines and fittings for possible

leakage. Repair all leaks immediately.

2.

Inspect exhaust system for possible leakage and cracks. Locate leaks in muffler and piping while the engine is operating. Repair all leaks immediately.

3.

Inspect the air cleaner system for leaks. Make certain all clamps and fittings are tight and free

of potential leaks.

4.

Check crankcase oil level with the engine

off

and the equipment on a level surface.

If

the en-

gine has been nrn, allow a minimum of

10

min-

utes for the oil to drain down before checking.

To

check the oil level, screw the oil fill cap into

the dipstick tube until

it

stops.

If

the oil level is

belowthe

FULL

mark on dipstick, add sufficient

oil

of the proper viscosity as specified in

Engine

Set-Up

section. Maintain the oil level at the

FULL mark.

Do

not operate the engine with oil

level above the FULL mark.

5.

Check the engine cooling system to makesure the cooling fins and ducting are clean. Remove dust, dirt or oil from the cooling surfaces.

CRANKCASE

OIL

AND

flLTER

CHANGE

1-1

Hot crankcase oilcan cause burns

if

it contacts the skin. Wear protective clothing

and keep hands clear when draining oil.

Refer to the

Periodic Maintenance

Schedule

for oil

change intervals. Refer to Figure

1

for oil filter and

oil

drain locations.

1.

Run the engine until it is warm. Stop the engine

and place a pan under the oil drain outlet.

2.

Remove the oil drain plug. After the

oil

is com-

pletely drained, securely install the drain plug.

3.

Spin off the oil filter element. Drain the oil and discard the filter.

4.

Thoroughly clean the filter mounting surface.

5.

Make sure the new gasket is inserted in the

element. Apply

a

thin film

of

oil to the gasket.

6.

Spin the new element on by hand until the gasket just touches the mounting pad, then turn it down an additional

1/2

to

3/4

turn.

Do

not

overtighten.

7.

Refill with

oil

of the correct API classification and the appropriate SAEviscosity grade for the temperature conditions (refer to Figure

2).

Re-

fer to Table

1

(Specifications)

for the oil capac-

ity.

8.

Start the engine and run

it

for a short time to check for oil leaks around the drain plug and oil filter. Retighten only as much as necessary to eliminate leaks.

Do

not overtighten.

Used oil is harmful to theenvironment. Pour

used

oil into a sealed container and deliver it to the nearest recycling center or automotive service station.

J

10

Y

AIR

CLEANER

Refer to the

Periodic

Maintenance

Schedule

for air

cleaner element wrapper and

air

filter service and replacement intervals. Service or replace more often when operating the engine under severe operating conditions.

Air

Cleaner Foam Element Wrapper

With the engine stopped, remove the outer air cleaner nut and plastic outer cover. When servicing

the foam wrapper only, do not remove the inner

air

cleaner nut and cover.

Remove and wash the foam wrapper in water and

detergent and squeeze it

dry

like a sponge. Rinse

with clean water and allow it to dry. Coat the wrap-

per evenly with one tablespoon

(14

grams) of SAE

30

engine oil. Knead the oil into the wrapper and

wring out

the

excess oil.

Failure to adequately wring out excess oil from the

wrapper may cause a drop in engine power due

to

a

k.

Install the foam wrapper over the paper air cleaner

element by stretching it over the inner cover.

Com-

pletely cover

all

exposed paper pleats on the air

cleaner paper element.

If

the foam wrapper has

stretched

or

become torn, replace the foam

wrapper.

Air

Cleaner Element

With the engine stopped, remove the outer air cleaner nut and plastic outer cover. Wipe away loose dirt and chaff from the

air

cleaner assembly and remove the inner air cleaner nut and inner air cleaner cover. Remove the air filter paper element and foam wrapper from the engine. Wipe

off

excess

dirt from the air cleaner base.

Install the new paper element and secure with the inner cover and inner mounting nut. Tighten the inner nut one and a half turns after seating on the inner cover. Service the foam wrapper perthe instructions given. Assemble the outer air cleaner cover

restriction

of

inlet air.

and nut.

AIR

CLEANER

S

INNER COVER

MOUNTING NUT

AIR

CLEANER

ASSEMBLY

BASE

OUTER

COVER

MOUNTING

NUT

CLEANER

COVER

CLEANER COVER

M-lg203

FIGURE

4.

AIR

CLEANER

ASSEMBLY

11

IGNITION

Spark

Plug

Refer to the

Periodic Maintenance Schedule

for the

spark plug service interval. Replace the spark plug

if

it

shows

signs of fouling or electrode erosion.

Refer to

Specifications

(Table

1)

for the spark plug

gap.

Solid

State

Ignition

Ignition timing is set at the factory, and it is not

adjustable. The solid state ignition components do

not require any routine maintenance.

COOLING SYSTEM

Refer to the

Periodic Maintenance Schedule

for the

cooling system

service

interval. Clean the cooling

fins sooner if required. Remove dust, dirt

or

oil from

the cooling surfaces.

-1PIugged

or cfogged inlet screens and recoil starter can cause overheating and engine damage. Remove chaff and debris from air inlets.

EXHAUST SYSTEM

LaWAR"GIA

hot exhaust system can cause

severe burns.

Allow

the engine time

fo

cool

down before Inspecting or servicing fhe ex-

hausf

sysfem.

,J

Make regular visual and audible inspections of the exhaust system. Locate leaks in the muffler and piping while the engine is operating. Repair all leaks immediately after they are detected for personal safety. Keep the area around the muffler and ex-

haust manifold clear of chaff and debris.

1-1

Breathfng exhaust gas can result In

severe personal lnjufy

or

death. Inspect the exhaust system audibly and visually for leaks daily, and repalr leaks immediateiy.

[aWARNINGIAccumuIatlon of chaff and debrls

around the muffler can result in a potentlal ffre hazard. Remove chaff and debris from around exhaust system.

12

Ad

j

u

st

m

e

n

t

s

ENGINE

SPEED

ADJUSTMENT

PROCEDURE

b

The carburetor mixture adjustments are preset at the factory for maximum efficiency.

No

mixture

ad-

justments are required. The engine speed specified

by your equipment manufacturer

is

preset and should only be adjusted by a competent mechanic. The service manual outlines the speed and choke adjustment procedure

for

this engine.

The speed control cable must be properly installed for proper engine performance. Poor starting,

fouled spark plugs and poor equipment performance may be symptoms of an improperly adjusted speed control cable. Adjust the speed control cable as follows:

1.

The engine must not be running during this speed control cable adjustment.

2.

Loosen the speed control cable clamp located on your engine’s throttle control plate. (See

Figure

5.)

3.

Place the speed control lever on the equipment to the high speed position. On equipment without a separate choke control, be sure the speed control lever is not in the start or choke position.

4.

Move the throttle control lever

so

a

pin can be

inserted through the

3.5

mm hole

in

the throttle

control plate and the throttle control lever.

5.

Remove the slack from the speed control cable

and tighten the speed control cable clamp. Re-

move the pin from the

3.5

mm hole.

6.

Start the engine per the equipment manufacturers instructions and observe all safety precautions.

If

the engine performance problem is

not corrected, take the equipment

to a compe-

tent mechanic for proper adjustment of the gov-

ernor, high idle speed, low idle speed, and

choke.

See your equipment manufacturer’s owners manual for high idle speed and

low

idle speed settings

for optimum performance from your equipment.

SPEED

CONTROL

CABLECIAMP

TYPICAL

SPEED

CONTROL

REMOVE SLACK

BY

MOVING

CABLE

IN

THIS

DIRECTION

CABLECLAMP

POSKION

FIGURE

5.

SPEED

ADJUSTMENT

13

Troubleshooting

The following chart is a basic troubleshooting guide. If these recommendations

fail

to

resolve the problem,

contact

an

authorized

Onan

service center.

4

-1

Many troubleshooting procedures present hazards that can result In severe personal in-

jury

or death. Only quallffed service personnel wlfh knowledge of fuels, electriciw, and machinery

hazards should

perform

service procedures. Review the safe

fy

precautions

on

the inside cover page.

LQWAR"GIA

hot engine can cause severe burns. Always allow the engine time

fo

cool down before

performlng any maintenance or service procedures.

TABLE

4.

TROUBLESHOOTING GUIDE

~~~~~~~~ ~

Problem

FAILS TO CRANK

CRANKS SLOWLY

OR

HARD TO PULL

RECOIL STARTER

CRANKS BUT WON'T START

UNIT RUNS THEN STOPS

EXHAUSTING BLACK SMOKE

UNIT RUNS, THEN SURGES

Probable

Cause

1.

Bad battery cable connection.

2.

Lowbattery.

3.

Defective

start

switch.

4.

Defective starter or start solenoid.

1.

Bad battery cable connection.

2.

Oil

is too heavy.

1.

Fuel supply valve closed.

2.

Carbon deposits on spark plug.

3.

Low oil level.

4.

Dirty air cleaner.

5.

Dirty fuel filter.

6.

Fuel or ignition system problem.

1.

Low on fuel.

2.

Low oil level.

3.

Excess oil.

1.

Dirty

air

cleaner.

2.

Choke stuck or misadjusted.

3.

Rich fuel

mixture.

1.

Loose or

worn

spark

plug

lead.

2.

Faulty spark plug.

3.

Ignition coil, wiring, or control

components defective.

4.

Governor

out

of

adjustment.

5.

Fuel mixture

out

of

adjustment.

Solution

1.

Check battery cable connections.

2.

Check electrolyte level.

3.

Contact

an

Onan service center.

4.

Contact an Onan service center.

1.

Clean and tighten

all

battery

cable connections.

2.

Change to proper weight oil.

1.

Fully open fuel supply valve.

2.

Clean or replace spark plug.

3.

Add oil

if

low.

4.

Clean the air filter.

5.

Replace fuel filter.

6.

Contact

an

Onan service center.

1.

Refill fuel tank.

2.

Add oil

if

necessary.

3.

Reduce engine oil level.

1.

Clean the air filter.

2.

Contact

an

Onan service center.

3.

Contact

an

Onan service center.

1.

Check

security

of spark plug

lead

at

spark plug and ignition

coil.

2.

Remove and clean or replace.

3.

Contact

an

Onan service center.

4.

Contact

an

Onan service center.

5.

Contact

an

Onan service center.

14

c

Onan Corporation

1400 73rd

Avenue

N.E.

Minneapolis, MN

55432

612-574-5000

international Use

Telex:

275477

Fax:

61

2-574-8087

Onan

is

a

registered trademark

of

Onan Corporation

1-800-888-ON AN