Onan EM, EK Owner's Manual

•0(3

DO

® •

ELECTRIC

RATOR'S

MANUA

AND

FOR

EK-EM

SERIES

GENERATING

928-0302

BEGIN

SPEC.

Printed in U.S. A

C

' ..^0jS-.©^'Cf=7 5

( R e

pTa-c

e s..4 C

' t'-i

ETIC.E.T

3 )

TABLE

OF

CONTENTS

TITLE PAGE

Introduction 1
Safety Precautions 2
Specifications
Description.

4

9
Installation 13
Operation 22
General
Parts

The need for an international standard of measurement has been increased by
today's improved communication and transportation between countries.

This has prompted formation of modernized metrics known as the International
System of Units, officially abbreviated SI.

ONAN products appear on the world market, therefore both metric and the present
American system of units (CU) will be found in this manual.

To assist in familiarization, refer to the following terms.

TERM METRIC ENGLISH

Length ' millimetre (mm) Inch (in)
Pressure kilopascals pounds per square

Mass (Weight) kilogram (kg) pound (Ib)
Volume (Liquid) litre gallon (gal)

Power kilowatt horsepower (HP)
Frequency hertz (Hz) cycles per second

Energy Joules (J) BTU
Battery Capacity Coulomb (C) Ampere Hour (AH)
Revolutions per Minute
Temperature Celsius (0C) Fahrenheit (0F)

Maintenance 27

Catalog 35

(kPa) inch (PSI)

(CPS)

r/min

rpm

The customary unit of Brake Horsepower (BHP) becomes kilowatts (kW) when
converted to SI metric units. This kW rating should not be confused with the kW

rating of the generator which will always be lower due to losses inherent with any

electrical induction device.

WARNING

TO AVOID POSSIBLE PERSONAL INJURY OR

EQUIPMENT DAMAGE, A QUALIFIED ELECTRI-

CIAN OR AN AUTHORIZED SERVICE
REPRESENTATIVE MUST PERFORM IN­STALLATION AND ALL SERVICE.

INTRODUCTION

FOREWORD

This manual is applicable to the EK/EM Series electric
generating sets each consisting of an ONAN UR
generator, driven by a Ford C5PG Gas/Gaso Engine.
See SPECIFICATIONS for generator sizes.

The manual is divided into two sections.

Section 1 provides information in installation, opera-

tion and troubleshooting.

Section 2 is a Parts Catalog for ONAN optional and
standard equipment.

The manual should be used in conjunction with the

Ford engine manual, for specific engine information.

is

WARNII

warn of

Onan

iroughou

possible

uses

al injury.

symbol

manual to

MODEL

Identify your model by referring to the MODEL and

SPECIFICATION NO. as shown on the Onan

nameplate. Electrical characteristics are shown on

the lower portion of the nameplate.

1.

Indicates Kilowatt rating (30 kW).

2.

Factory code for SERIES identification.

3. 15 = 60 Hz. Reconnectible

4.

Factory code for designating optional equipment.

5. Specification letter. (Advances when factory

When contacting a dealer orthe factory regarding the
set, always mention the complete Model, Spec No.
and Serial No. as given on the Onan nameplate. This

nameplate information is necessary to properly iden­tify your unit among the many manufactured. Referto
the engine nameplate when requesting information
from its manufacturer. The Onan nameplate is

located on the right side of the generator; the Ford

nameplate is on the right hand side on the valve cover.

IDENTIFICATION

30.0 EK 15R / 1 G

1 4 5

515 = 50 Hz. Reconnectible
R—Indicates remote starting feature.

makes production modifications.)

•T

rxrr^T^r?

This/Symbol>e|ers

to

l£Ayi!ONi equ/pment damage.

possible

Left side and right side are considered when viewed from the
engine or front end of the generator set.

±4J

0

•

SAFETY

Throughout this manual
flags containing Warnings
alert

you

to

conditions that could result

you

or

the

equipment,

ONAN recommends that
become thoroughly acquainted with
equipment before
cumulated experience
available
the most efficient and safest manner possible. These

recommendations
precautions

them!

REMEMBER. Most accidents are caused

follow simple

precautions.

KNOW

to

you, enabling

are for

and

MosX accidents

YOUR

MANUAL—KNOW

and the

you

will find eye-catching

and

Cautions. These will

if

the

notice

you

you

start your unit.

of

ONAN engineers

you

your protection. Study and know

fundamental safety rules

can be

is

ignored.

read your manual

it and

to

operate your set

following safety

prevented!

YOUR

PRECAUTIONS

in

danger

The ac-

by

EQUIP-

and

your

failure

to

is

in

to

or

MENT

WARNING

personal injury. The suggested procedures should

Set forth below
hazards which could result

are a

number

in

some degree

be

of

potential

adhered

of

to.

Do

not

stand

on a

wet

floor while working
electrical equipment. Use rubber insulative mats
placed

Fuel System

•

DO

unless tanks
Fuel contact with
potential fire hazard.

•

DO NOT

the vicinity
mable.
REMEMBER—IF

POSSIBLE EXPLOSION AND FIRE CONDITION

• Make sure that oily rags are
engine.

on dry

NOT

Internal combustion engine fuels are highly flam-

EXISTS!

Oil

present hazardous walking conditions.

wood platforms.

fill fuel tanks while engine

are

outside engine compartment.

hot

SMOKE

of the

OR

YOU CAN

soaked rags

engine

USE

generator

or

AN

OPEN FLAME

set or

SMELL FUMES-A

not

left on ornearthe

are

combustible

is

exhaust

fuel tank.

on

running,

is a

in

and

General

• Keep your electric generating
rounding area clean
Remove
dry.

• Provide appropriate fire extinguishers and install
them
fire department
tinguisher
fires.

• Make sure that all fasteners on the generating
are secure. Tighten supports
guards

•

Do not

moving parts,

trical equipment. Loose clothing and jewelry can

become caught

short

burning.

•

If

running,

exhausts, moving parts,

all oil

in

convenient locations. Consult your local

to

use.

Use

extinguisher rated

in

position over fans, driving belts,

wear loose clothing

out

electrical contacts; cause shock

necessary

to

use

extreme caution when close

and

deposits; keep

for the

Do not use

or

jewelry while working

in

moving parts. Jewelry

makeadjustmentswhiletheunitis

etc.

set

and

the

sur-

free from obstructions.

the

floor clean

correct type

foam

on

ABC

by

NFPA.

and

clamps, keep

in the

and

of ex-

electrical

etc.

vicinity

on

elec-

can

to

set

of

or

hot

• Fuel lines must
secured,
should
copper piping on flexible lines as copper will work

harden

• Your engine installation should be equipped with
a means
when fuel

Fuels under pressure (e.g. natural gas

petroleum gas) should be controlled by a positive
shutoff valve, preferably automatic,
any valve integral with

regulator equipment.

Exhaust System

• Exhaust products
engine

injury,

pecially those within a confine, should
equipped with
gases
gases

• Inspect exhaust system regularly
system

and free from leaks. Piping at the engine

be

and

of

are

if

inhaled.

to the
to

heat a compartment.

is

free

be of

approved flexible line.

become brittle.

positive fuel shutoff

is

conducted from a remote source.

toxic and

an

atmosphere.

of

steel piping, adequately

Do not use

in

in

the

carburetor

of any

can

All

exhaust system

leaks.

internal combustion

cause serious personal

engine installations,

to

Do not

to

applications

or

liquefied

addition

or gas

discharge

use

exhaust

assure that

to

es­ be

Coolant

• Coolants under pressure have a higher boiling

System

point than that of water. DO NOT open a radiator
or heat exchanger pressure cap or break a system
while the engine is running, and in no case until
the system pressure has been bled off.

codes should-have been consulted and complied
with.

It is essential that all load circuit breakers
adequately protect electrical functions, all cir­cuits are properly grounded and wiring is correct
capacity.

Tag open'switches. "' '"'

• Radiator fan belts are guarded for your protec­tion.

DO NOT remove covers or guards.

•

Keep

Ventilation

• Check remote radiators frequently. Remove any

• Check ventilation louvres.frequently. Make sure

Electrical

• The electrical installation exterior to your

your

hands

System

dirt, debris, bird nests, etc.

that free-fall louvres and motor operated louvres
open and close properly and that there is no

restriction in the free-air flow.

System

generator should have been performed by
qualified licensed electricians. All local and state

away

from

moving parts.

DON'T tamper with interlocks.

Before starting work on the generating set,
disconnect batteries. This will prevent inadver­tent starting of the set.

Use extreme caution when making adjustments
on the electrical components in the control
cabinet while theengine is running. High voltages
are present and could cause serious personal,

injury.

DO NOT SMOKE while servicing batteries. Verify
correct polarity of battery cables before connec­ting.

Lead acid batteries give off a highly ex-

plosive hydrogen gas which can be ignited by

electrical arcing or by smoking. When connecting

batteries, connect the ground lead last.

SPECIFICATIONS

30 kW EK

ENGINE

Engine Manufacturer Ford
Engine Series * C5PG
Number of Cylinders 6
Displacement 300-in3 (4.9 litre)
BHP @ 1800
Compression Ratio 8.4:1

Bore 4.00-inch (101.6 mm)

Stroke 3.98-inch (101.09 mm)

Fuel Gas/Gaso
Battery Voltage 12
Battery Group—One 12-Volt, 74 A.H. (266 kC) Type 60
Starting Method Solenoid Shift
Governor Regulation 5% Max. No Load—Full Load
Battery Charging Current 35-Amperes

GENERATOR

Type UR15 60 Hz
Rating (Watts)

AC Voltage Regulation ±2%

Output Rating 0.8 PF
AC Frequency Regulation 3 Hz Max

DETAILS

r/min

80 (59.68 kW)

DETAILS

UR515 50 Hz

60 Hertz Continuous Standby 30 000 (37.5 kVA)
50 Hertz Continuous Standby 25 000 (31.25 kVA)

60 Hertz
50 Hertz

r/min
r/min

! 1800
1500

CAPACITIES

Cooling System, Engine and Radiator 20-quarts (19 litres)

Engine Oil Capacity (Filter, Lines, Crankcase) 7-quarts (6.6 litres)
Exhaust Connection (inches pipe thread) 2

AIR

REQUIREMENTS

Engine Combustion 100 ftVmin (0.05 m3/s)
Radiator Cooled Engine 5 335 ftVmin (2.52 m3/s)
Total for Radiator Cooled Model 5 435 ftVmin (2.6 mVs)

Alternator Cooling Air (1800 r/min) 1 000 ftVmin (0.5 mVs)

Fuel Consumption at Rated Load

Gasoline (Regular) 4.9 gal/hr (5.15 cmVs)

Natural Gas (1000 BTU/ft3 [37.25 MJ/m3]) 600-ft3/hr (0.28 mVmin)
LPG (2500 BTU/ft3[93.1 MJ/m3]) 245-ftVhr (0.12 mVmin)

GENERAL

Height 45.56-inches (1.16 m)

Width 33.00-inches (0.84 m)

Length 71.81-inches (1.82 m)
Approximate Weight (Mass) 1395-lb (633 kg)

AND

REQUIREMENTS

(1800

(1500 r/min) 833 ftVmin (0.4 mVs)

r/min)

1550-lb (703 kg)

SPECIFICATIONS

45 kW EM

ENGINE

DETAILS

Engine Manufacturer r^pr
Engine Series 6

Number of Cylinders

Displacement SOO-m3 (4 9
BHP @ 1800

r/min

Compression Ratio ;

4.00-inch (101.6 mm)

Bore

3.98-inch (101.09 mm)

Stroke

• • • • • •

98 (

• • •

•; • •; • 8- [

•;:'':' .

l.tre

^

Fuei Gas/Gaso

Battery Voltage • • •'

Battery Group-One 12-Volt, 74 A.H. (266 kC) vj**™
Starting Method •••••

Governor Regulation 5% Max. No Load-Full Load

Battery Charging Current 35-Amperes

GENERATOR

Type •

yP :

DETAILS

UR15 60 Hz

" UR515 50 Hz

"^'eo SzContinuous Standby 45 000 (56.25 kVA)

50 Hertz Continuous Standby

AC Voltage Regulation

60 Hertz
50 Hertz

r/min

r/min
Output Rating • 0^
AC Frequency Regulation

±2

1

^5°°

3 Hz Max

37 500 (46-87

So}erl0i^M

J^

°JJj

PF

'

CAPACITIES

AND

REQUIREMENTS

Cooling System, Engine and Radiator 20-quarts (19 litres)
Engine Oil Capacity (Filter, Lines, Crankcase) 7-quartsc (6.6 litres)

Exhaust Connection (inches pipe thread)

AIR

REQUIREMENTS

(1800

r/min)

2

Engine Combustion -J^T Vlo "Yfl

Radiator Cooled Engine ^f'^/T- ^ " *

Total for Radiator Cooled Model ;

5

460-ft3/min (2.6 m3/s)

Alternator Cooling Air (1800 r/min) 1000-ft3/min (0.5 m3/s)

(1500 r/min) 833-ftVmin (0.4 m3/s)

Fuel Consumption at Rated Load -

Gasoline (Regular) J^T^ T

Natural Gas (1000 BTU/ft3 [37.25 MJ/m3]).

LPG (2500 BTU/ft3[93.1 MJ/m3])

290 ft3/hr

690 ft3/hr (0-32

(O-14 mVmin)

mVmin)

GENERAL

• ' 45.56 inches (1.16 m)

Heiqht

33.00 inches (0.84 m)

Wjd^h

Length 73.19 inches (1.86 m)
Approximate Weight (Mass) 3-phase 1455 Ib (660 kg)

MM

1-phase

1610 Ib (730 kg)

5

SERIES

EK "

TABLE

1

GENERATOR VOLTAGE/CURRENT

OPTIONS

SERIES

X
X
X

X
X
X
X

VOLTS

110/220
115/230

FREQ
50 Hz 1

50 Hz

120/240 60 Hz

110/190 50 Hz
115/200 50 Hz
120/208 50 Hz
120/208 60 Hz
110/220 50 Hz
127/220

50 Hz

127/220 60 Hz
115/230 50 Hz
120/240 60 Hz
139/240 60 Hz
220/380 50 Hz
230/400

50 Hz

240/416 50 Hz
240/416
254/440
254/440
277/480

60 Hz
50 Hz
60 Hz
60 Hz

DOUBLE

PHASE AMPERES DELTA

142* X

1
1

3
3
3
3
3
3
3
3
3
3
3
3
3

3
3
3
3

136*
156* X

95
90
87 ,

104

82
82
98
78
90

90
47
45
43
52

41

49
45

x

SERIES

DELTA

X

X
X

PARALLEL

WYE WYE

X
X
X
X

X
X

X

9X

347/600 60 Hz

3

36

3

120/240 60 Hz

1

156

30 kW 37.5 kVA 60 Hz
25 kW 31.25 kVA 50 Hz

- These current values are available only from special long stack units (B125 option). When standard 3 phase
unit is connected into Double Delta configuration, maximum current is 2/3 that of value given.

REF

VOLTAGE

WIRE

(W12) TAP

H6
H6
H5

H3
H4
H4
H3
H6
H5
H4
H6
H5
H5
H3
H4

H4
H3
H5
H4

H5

H5—Not

Reconnectible

H5—Not

Reconnectible

SERIES

VOLTS

EM

FREQ

TABLE

IA

GENERATOR VOLTAGE/CURRENT

SERIES

DELTA

PHASE

DOUBLE

AMPERES DELTA

OPTIONS

PARALLEL

WYE

SERIES

WYE

REF

VOLTAGE

WIRE

(W12) TAP

110/220 50 Hz

1

115/230 50 Hz 1
120/240

110/190
115/200
120/208 50
120/208
110/220 50
127/220 50
127/220
115/230 50
120/240
139/240
220/380
230/400 50 Hz
240/416
240/416
254/440
254/440 60 Hz
277/480

60 Hz 1

Hz

50
50

60

60
60

60
50

Hz
Hz
Hz
Hz
Hz
Hz
Hz
Hz
Hz
Hz

3
3
3
3
3
3
3
3
3
3
3
3

50
60
50

Hz
Hz
Hz

3
3
3

3

Hz

60

3

213*
204*

234*

-

142 -

135 -

130

156 *

123

123 -

148

118 -

135

135 -

71 -

68 —

65

78 "

62
74

68 -

X
X
X

r

X

X
X

X
X
X
X

X
X

X

X
X
X
X
X
X
X

9X

347/600

60 Hz

3

54

3

120/240

60 Hz 1

234 Reconnectible

45 kW 56.25 kVA 60 Hz

37.5 kW 46.87 kVA 50 Hz

- These current values are available only from special long stack units (B125 option). When standard 3 phase
unit is connected into Double Delta configuration, maximum current is 2/3 that of value given.

H6

.H6

H5
H3

H4
H4
H3
H6
H5
H4
H6
H5
H5
H3
H4
H4
H3
H5
H4
H5

H5—Not

Reconnectible

H5—Not

120/240

NAMEPLATE VOLTAGE CODE

VOLT, 1 PHASE,

•TO

CONNECT LEAD
TERMINAL

63 TO H5

Tl

T2

FROM

60

3

THIS

DIAGRAM

HERTZ

APPLIES

+

TO 12

347/600

NAMEPLATE VOLTAGE CODE

VOLT,3 PHASE,

TK

.T2

•)

CONNECT LEAD

|

TERMINAI 63 TO H5

T3

LEAD GENERATORS ONLY

TO

60

HERTZ

9X

FROM

13

SIS

IS

S15

IS

515

fe:

12C/240

115/230
110/220

120/208
12^220
139/240

110/190
115/200
129/208

127/^20

240/416
254/140
277/180
22(^)80
230/400
240/416
25V440

Mm/'

60 H5

H6
H6

H3
H4

H5
H3
H4
H4

H5

H3
H4
HS

H3

H4
H4
H5

GENERATOR

CONNECTION
SCHEMATIC
DIAGRAM

GENERATOR

(WITH

Tl

T2 T6 Til T8

Tl

TIO T6 T7 T2 Til T4 TB T3 T12 TS T9

LO

Ll

T4

T6 Til

TS

TIO T12

LO

Ll

CT21

TlO

Til T12 Tl T7 T4 T2 T8 TS T3 T9 T6

CONNECTION WIRING DIAGRAM

CURRENT TRANSFORMERS

T12

T4 T9 TS T7 T3 TIO

L2

CT22

Tl

T7

CT22

T2

L2

T8

TT

n

WHEN

9BC2193

USED)

T3

T9

FIGURE

1.

OPTIONAL

VOLTAGE

8

CONNECTIONS

DESCRIPTION

GENERAL

An Onan EK or EM series electric generating set is a
complete unit consisting of an engine driven AC
generator, with standard and optional controls and
accessories as ordered.

ENGINE

The engine on these units is a Ford C5PG as
described in the engine manual. Basic measurements
and requirements will be found under
SPECIFICATIONS. For operation, maintenance and

service information, consult the Ford manual.

AC

GENERATOR

The generator is an ONAN Type UR, 12

revolving

main rotor is attached directly to the engine flywheel,
therefore engine speed determines generator output
frequency. The 60 Hz set operates at 1800 r/min, the
50 Hz at 1500 r/min. Excitation is achieved as
fol

lows-

Residual alternating current from the stator winding
is applied to the voltage regulator, where it is
compared with a reference voltage, rectified and

returned to the field winding of the exciter. Current
then induced in the exciter rotor is rectified and fed
into the generator rotor. This induces a current in
generator stator which is applied to the

CONTROL

The following is a brief description of each of the
standard controls and instruments located on the
face of the panel. See Figure 2.

DC

Pai^y§fofr«nd-SwHehUWujnjm

field,

reconnectible, brushless unit. The

PANEL

Panel Q_

lead,

load.

4-pole

Warning Light: Indicates "Fault" in engine operation.

AC

Panel

AC Voltmeter: Indicates ACgeneratoroutput voltage.
Dual range instrument: measurement range in use

shown on indicator light.
Voltage Regulator: Rheostat, provides approximately

plus or minus 5% adjustment of the rated output

voltage.

Exciter Circuit Breaker Provides generator exciter
and regulator protection from overheating, in the
event of certain failure modes of the generator,
exciter and voltage regulator.

Running Time Meter: Registers the total number of
hours,
record for periodic servicing. Time is accumulative,
meter cannot be reset.

Voltmeter Phase Selector Switch: Selects phases of

generator output to be measured by the AC voltmeter.

OPTIONAL
DC

Warning Lights: Eliminates the one "Fault" light and
substitutes five indicator (see Figure 3) lights to give
warning of—

Operation of these lights will be discussed in

junction with engine monitor panel.

to 1/10th, that the unit has run. Use itto keep a

EQUIPMENT

Panel

a. Overcrank

b. Overspeed
c. Low oil pressure
d.

High engine temperature

e. Low engine temperature

con-

Oil Pressure Gauge: Indicates pressure of lubricating
oil in engine (wired to a sensor unit located on the
engine).

Water Temperature Gauge: Indicates temperature of
circulating coolant in engine. (Wired to a sensor unit

located on the engine.)
Battery Charge Rate DC Ammeter:.Indicates battery

charging current.
RunStop/Reset-Remote Switch: Starts and stops the

unit locally or transfers control to a remote location.
Resets engine monitor relay in Stop/Reset position.

Reset Switch: Manual reset for engine monitor after

shut-down.
Lamp Test: Press to test warning lamp bulbs (when

engine is running only), on five light panels.

AC

Panel

•/AC Ammeter:, Indicates AGvgene.rator output-current. /
Dual range in use shown on indicator lights.

Frequency Meter: Indicates the frequency of the

generator output in hertz. It can be used to check
engine speed. (Each hertz equals 30 r/min.)

RUNNING TIME

METER

INDICATE UPPER AND LOWER SCALE

INDICATOR LAMPS

ON VOLTMETER AND AMMETER—,

% TURN FASTENERS- TURN BOTH

SCREWS TO OPEN HINGED CONTROL

P&yELiXI.G.HXAND SWITCH

PANEL DOORS

DUAL RANGE

AC VOLTMETER

VOLTAGE

ADJUSTING

RHEOSTAT

PHASE SELECTOR

SWITCH

FIELD CIRCUIT BREAKER

FIGURE

DUAL RANGE AC AMMETER

INDICATE UPPER AND LOWER SCALE

INDICATOR LAMPS

ON VOLTMETER AND AMMETER—,

2.

TYPICAL

CONTROL

PANEL

(ONE

OIL PRESSURE

GAUGE

WATER TEMPERATURE

DC AMMETER

•RUN-STOP-REMOTE SWITCH
(ALSO A RESET SWITCH FOR

FAULT LAMP

FAULT

LAMP)

VS TURN FASTENERS- TURN BOTH

SCREWS TO OPEN HINGED CONTROL

PANEL DOORS

I

Et-bl G-HT-A'N-D-SWTTtm*.

GAUGE

ENGINE MONITOR)

DUAL RANGE

AC VOLTMETER

VOLTAGE

ADJUSTING

RHEOSTAT

FREQUENCY

METER

RUNNING TIME

METER

FIELD CIRCUIT BREAKER

PHASE SELECTOR SWITCH

FIGURE

3. OPTIONAL

CONTROL

10

PANEL

OIL PRESSURE

GAUGE

WATER TEMPERATURE

DC AMMETER

RUN-STOP-REMOTE SWITCH
(ALSO A RESET SWITCH FOR

FAULT LAMPS

TEST LAMP BUTTON AND

ENGINE MONITOR RESET SWITCH
USED ONLY ON CONTROL PANELS

WITH FIVE FAULT LAMPS

(FIVE

FAULT

LAMPS)

GAUGE

ENGINE MONITOR)

CONTROL

PANEL

INTERIOR

The only equipments discussed in this section will be
those which the operator may have reason to adjust or

inspect for service.

Terminal Board (TB) 21: Connection of wire W12 to
terminals H3, H4, H5, and H6 is made at this point, to

change reference voltage when reconnecting
generator for different voltages. Refer to Figure 1.

Voltage Regulator, Begin Spec F: Solid state unit,
consisting of printed circuit board VR21; an SCR
bridge CR21, with a commutating reactor L21 are

located in the control panel as part of the voltage
regulator system. AC output from generator is

trolled at predetermined level regardless of

con-

load;
regulation is plus or minus 2% from no load to full
load,

at 0.8 P.F.

Voltage Regulator, Prior to Spec F: Solid state unit
consisting of printed circuit board VR21.

An exciter-regulator assembly designated VR22 containing an SCR
bridge circuit and commutating reactor is mounted on the
generator end bell (see Figure 4) and works in conjunction with
VR21.

Engine Monitor: Printed circuit plug-in modules
provide the following functions:

1.

A 75 second cranking period.

2.

Approximately a 12.5-second time delay for oil

pressure buildup.

3. An external alarm contact to light a fault lamp ahd
shut down the set for alarm conditions such as:

a. Overcrank (failed to start after cranking 75

seconds).

b. Overspeed (enginespeed reaches2100 r/min).
c. Low oil pressure 14 psi (96.
d.

High engine temperature|fT5°F (102oC).

p^^^JJ^ High Engine Temperature (
L^x^^^-^Z^J' down engine in an overheat i

coolant level is sufficiently high to physically contact shutdown
switch.

Loss of coolant will allow engine to overheat without
protection of shutdown device, thereby causing severe damage to
the engine. It is therefore imperative that adequate engine coolant
levels be maintained, to ensure operational integrity of cooling
system and engine coolant overheat shutdown protection.

On standard control panels, all four alarms are wired into one
common fault lamp; on units with five fault lamps, four have
shutdown alarms, the fifth (low engine temperature) lights a fault
lamp only. Refer to Table 2.

i engine in an overheat condition only if

Cutoff will shut

EXCITER-REGULATOR

CHASSIS ASSEMBLY

\

OVERSPEED SWITCH

FIGURE 4. REGULATOR ASSEMBLY

ROTATING EXCITER
WITH RECTIFIERS

(Prior to Spec F)

NDBELL

Standard Cranking Module: Limits engine cranking
time to 75 seconds. If engine fails to start after 75
seconds the engine monitor lights a fault lamp and
opens the cranking circuit.

OPTIONAL

MODULES

Cycle Cranker: Plug-in 'module replaces standard
cranking circuit. Automatically provides a 15-second
crank time and a 10-second rest time forth

ree

ON and
two OFF cycles in 65 seconds. If engine fails to start,
after 75 seconds the engine monitor lights a fault lamp
and opens the cranking circuit. The ON and OFF
cycle times are nominal and can be adjusted at

potentiometers on the cranker module board.
Pre-Alarm:

Gives advance warning for low oil

pressure or high engine temperature. Requires two

sensors each for engine temperature and oil pressure.

11

TABLE

2.

FAULT

LAMP OPTIONS

SYSTEM

PENN STATE

SINGLE LIGHT '

Overcrank
Overspeed

FAULT

Low Oil Pressure
High Engine Temperature

STANDARD

SINGLE LIGHT

Overcrank
Overspeed
Low Oil Pressure
High Engine Temperature

5 LIGHT

Overcrank
Overspeed
Low Oil Pressure
High Engine Temperature
Low Engine Temperature

5 LIGHT

PRE-ALARM

Overcrank
Overspeed
Low Oil Pressure

High Engine Temperature

Low Engine Temperature

* - With additional optional sensors.

ENGINE

SENSORS

Resistance units and switches in the engine
temperature and oil pressure monitoring and shut­down systems are sealed units and are not repairable.

FAULT STOP EXTERNAL

LAMP

X
X
X X
X X

X
X
X X X
X X X

X X
X X X
X X
X X
X

X X
X
X
X
X

ENGINE TEMPERATURE

CUT-OFF SWITCH

(HETCO)

ENGINE

X X
X

X
X X

X X

*
*

HIGH

ALARM ALARM

X

X

X

X
X

X

X
X

PRE-

X
X

For location, referto Figures 5 and 6. When replacing

a sensor, do not substitute, use recommended items.

Resistance units are matched to the gauge they

supply, and cut-off switches are close-tolerance

actuation parts, made for a specific application.

LOW OIL

PRESSURE

SWITCH

(LOPKO)

B374

OIL PRESSURE

GAUGE SENDER

FIGURE 5. OIL PRESSURE MONITORS

FIGURE 6. ENGINE TEMPERATURE MONITORS

12

INSTALLATION

GENERAL

Installations must be considered individually. Use

these instructions as a general guide. All installations

must meet regulations of state and local building
codes, fire ordinances, etc., which may affect installa­tion details. See Figures 7 and 8. Refer to ONAN

Technical Bulletin T-030 for further installation infor-

mation.

Requirements to be considered prior to installation:

1.

Level mounting surface.

2.

Adequate cooling air.

3. Adequate fresh induction air.

4.

Discharge of circulated air.

5. Discharge of exhaust gases.

6. Electrical connections.

7. Fuel installation.

8. Water supply (city water cooling).

9. Accessibility for operation and servicing.

10.

Vibration isolation.

11.

Noise levels.

VENTILATION

Generator sets create considerable heat which must
be removed by proper ventilation. Outdoor in­stallations rely on natural air circulation but indoor

installations need properly sized and positioned vents
for the required air flow. See SPECIFICATIONS for
the air required to operate with rated load under

normal conditions at 1800 r/min.

Radiator set cooling air travels from the rearof theset
and is removed by a pusher fan which blows out
through the radiator. Locate the air inlet to the rear of
the set.

Locate the cooling air outlet directly in front of the
radiator and as close as possible. The opening free

area must be at least as large as the radiator area.

Length and shape of the air outlet duct should offer
minimum restriction to air flow. Use a duct of canvas

or sheet metal between the radiator and the air outlet
opening.
air.

The duct prevents recirculation of heated

LOCATION

Provide a location that is protected from the weather

and is dry, clean, dust free and well ventilated. If

practical,

tion from extreme weather conditions.

install inside a heated building for protec-

MOUNTING

Generator sets are mounted on a rigid skid base
which provides proper support. The engine­generator assembly is isolated from the skid base by
rubber mounts which provide adequate vibration
isolation for normal installations. For installations
where vibration control is critical, install additional
spring-type isolators between skid base and founda­tion.

For convenience in general servicing and changing
crankcaseoil, mount set on raised pedestal at least 6­inches (150 mm) high.

For operation outside a building, a shelter housing
with electrically operated louvres is available as an
option.
output supply current to the motors.

When the generator is operating, current in the
transformers actuate the motors and open the

louvres. The louvres are held open for the duration of
the set operation, then are closed by return springs

when the set is shut down.

City water cooled sets do not use the conventional

radiator. A constantly changing water flow cools the

engine. Sufficient air movement and fresh air must be
available to properly cool the generator, disperse heat
convected off the engine and support combustion in
theengine. • • • - "v.- •

Installations require an auxiliary fan (connected to

operate only when the unit is running) of sufficient
size to assure proper aircirculation and evacuation of
fumes.

Transformers connected across the generator

13

FILL PIPE

HOODED VENT

^^^"^FUEL LINE

.^"'-Jf"'

(FROM DAY TANK IF USED)

FUEL RETURN LINE

FIGURE

• OAS FUEL REGULATOR
ELECTRIC FUEL SOLENOID

7.

TYPICAL

INSTALLATION

FUEL STORAGE TANK

DRY FUEL FILTER

SHUT OFF VALVE

FIGURE

8.

TYPICAL

1

|f

INSTALLATION OF LPG WITHDRAWAL

14

SYSTEM

COOLING

SYSTEM

Standard Radiator Cooling, uses a set mounted

radiator and engine driven pusher type fan to cool
engine water jacket. Air travels from the generator
end of the set, across the engine and out through the

radiator. An integral discharge duct adapter flange

surrounds the radiator grille.

Heat Exchanger Cooling (optional), uses a shell and

tube type heat exchanger instead of the standard

radiator and fan. Engine jacket coolant circulates
through the shell side of the heat exchanger, while
raw cooling water is pumped through the tubes.
Engine coolant and raw water do not mix. This type of
cooling separation is necessary when the raw water
contains scale forming lime, or other impurities.

This system reduces set enclosure airflow re­quirements and noise levels. Proper operation

depends upon a constant supply of raw waterfor heat
removal.

The engine coolant side of the system may
be protected from freezing; the raw waterside cannot.
See Figure 9 for typical installation.

EXPANSION

TANK

This system reduces set enclosure airflow re-

quirements and noise levels. Proper operation is
dependent on a constant supply of cooling water. The
system cannot be protected from freezing. See Figure

10.

ANTI-SIPHON — r

DRAIN

FROM

ENGINE

• TO ENGINE

MIXING

TANK -

SOLENOID VALVE

(OPEN WHEN

SET IS RUNNING)

WATE

I

STAND

PIPE

• ADJUSTABLE VALVE
(RATE OF FLOW)

STRAINER

FROM

-»—

HEAT EXCHANGER

(OPENS WHEN

J

DRAIN

ADJUSTABLE

VALVE

(RATE OF FLOW) ase

FIGURE

9.

TYPICAL

SET IS RUNNING)

HEAT

Tn ENGINE

SOLENOID

VALVE

EXCHANGER

STRAINER

ENGINE

I^- CRATER

IN

SYSTEM

Standpipe Cooling (optional) substitutes a mixing

(tempering) tank for the standard radiator and fan.

Cooling water circulating through theenginejacket is

mixed with raw water in the tank. Because raw water
flows through the engine jacket, it must not contain
scale forming impurities or fouling of the engine
water passages will occur. Fouling results in engine

overheating and costly repair bills.

FIGURE

10.

TYPICAL

STANDPIPE

SYSTEM

Remote Radiator Cooling (optional), substitutes a
remote mounted radiator and an electrically driven

fan,

for the set mounted components. Removal of the

radiator and fan from the set reduces set enclosure

airflow requirements and noise levels without forcing

dependence on a continuous cooling water supply.

The remote radiator system can be completely

protected against freezing.
This system must be designed to meet specific

requirements of the application.
Water Jacket Heater, (optional) may be installed to

keep engine coolant warm while engine is shut down.
It heats and circulates the coolant within the engine,

which reduces start-up time and engine wear caused

by cold starts. It is electrically operated and ther­mostatically controlled.

15

Oirect

Flow Installation

With this system, a city or raw water cooling supply

under pressure forces water directly into the engine,
through the engine and to the outlet. An adjustable
valve controls the incoming water flow rate to obtain
correct engine water temperature, as measured at

engine coolant water outlet while the generator set is

operating under full

load.

A solenoid valve is coor­dinated with the generatorset system to open during
set operation.

CAUTION

and seals will leak.

Restrict inlet water pressure to a maximum of
7 psi or 48.3 kPa, otherwise engine gaskets

Raw water cooling is often undesirable because:

1.

The water supply must be very clean or engine

deposits will result.

2.

A high temperature differential between the cold

incoming water into the engine and warm dis-

charged water can put damaging stresses on

engine components (no overall uniform engine

temperature).

COOLING

CONNECTIONS

The radiator cooled (standard) set does not require
any external connections except as discussed under

Ventilation. Allow clearance around the set for access

to service the radiator and fan belts. See Figure 7.

Heat Exchanger and Standpipe cooled sets must be

connected to a pressurized supply of cold water.

Make connections to the set with flexible pipe to
absorb vibration. On the cool water line install a
solenoid valve to shut off the flow when the set is shut
down and a rate of flow valve to control engine
temperature. This valve can be either manual or
automatic. Actual rate of flow will depend on inlet
water temperature and applied

load.

Adjust the flow to maintain water temperature

between 1650Fand 195° F (73.9° C and 90.6° C) while

viewing the water temperature gauge.

Before filling cooling system check all hardware for security. This
includes hose clamps, capscrews, fittings and connections. Use
flexible coolant lines with heat exchanger, standpipe or remote
mounting radiator.

Remote radiator plumbing will vary with installation.
All systems must comply with the following
conditions—

1.

Make all connections to the set and to the radiator

with flexible pipe.

2.

Install an auxiliary circulating pump if the

horizontal distance between the engine and
pump exceeds 15-feet (4.65 m).

3. Install a hot-well system to relieve excess engine
water jacket pressure if the top of the radiator is

more than 15-feet (4.65 m) above the center-line

of the engine crankshaft.

16

EXHAUST

I WARNING

Inhalation of exhaust gases can result in

death.

Engine exhaust gas must be piped outside building
enclosure.
vents

(Figure
through walls
downward

Do not

or

combustible materials.

11)

must

or

terminate exhaust pipe near inlet,

be

used where exhaust pipes pass

or

partitions. Pitch exhaust pipes

install a condensation trap (Figure

An

approved thimble

or

12)
at the point where a rise in the exhaust system begins.
Avoid sharp bends; use sweeping long radius elbows.

Provide adequate support
pipes.

Refer

to

Figure 7 for a typical exhaust installa-

tion.

Shield

or

insulate exhaust lines
of personal contact. Allow
of clearance
wall

or

inch

(50 mm)

Suspend
attach

to

if the

pipes

partition. Use a pipe

pipe size outlet

the

pipe from

engine with a flexible section. Place muffler

for

mufflers

if

at

least 9-inches (230

run

close

to a

at

least as large as the

of the

the

enclosure structure

engine.

and

exhaust

there is danger

mm)

combustible

2-

and

as close to engine as possible to reduce condensation
damage

and

carbon fouling.

IF EXHAUST LINE MUST

• CONSTRUCT A TRAP

FIGURE

12. EXHAUST CONDENSATION TRAP

POINT

OF

DRAIN CONDENSATION TRAP

BE

PITCHED UPWARD.'

OF

PIPE FITTINGS

RISE

PERIODICALLY

AT

HOLES

IN END OF

INNER SLEEVE

WALL

OR

PARTITION

FIGURE

RAIN

11.

CAP

-"Jl

TYPICAL

DRIP

CAP

INNER SLEEVE

EXHAUST THIMBLE

Minimum diameters

(with critical muffler[s])

and

maximum lengths

are as

follows:

of

pipe

Single Exhaust system:

2.5-inch

3.0-inch

3.5-inch

(67

mm) pipe 9-feet

(76

mm) pipe 89-feet

(90

mm) pipe ...... / 168-fee't (51

(3 m)

(27 m)

m)

Maximum permissible exhaust restriction (back
pressure)

is

20.4-inches (508

mm)

H2O manometer,

or 11.8 ounces (5.1 kPa) gauge.

17

FUEL

SYSTEM

Ford engines used on EK/EM sets are designed to
operate on gasoline (average regular grade of 93
octane),

natural gas with thermal rating of 1000

BTU/ft3 (37.25 MJ/m3) or liquefied petroleum gas

(LPG) Propane at 2500 BTU/ft3 (93.13 MJ/m3).

FUEL

CONNECTIONS

Before starting any type of fuel installation, ONAN

recommends that the regulations described in
Pamphlet 58 of the National Fire Prevention Associa­tion (NFPA) be studied. All pertinent state and local
codes, most of which are governed by NFPA 58, must

be complied

with,

and the installation must be

inspected before the unit is put in service.

Fuels under pressure (e.g. natural gas or LPG) must
be controlled by a positive shut off valve, preferably
automatic, in addition to any valve integral with the
carburetor or gas regulator equipment.

Connection of gasoline fuel inlet line requires a 1/8­inch pipe fitting to an adapter on skid base.

Lift to fuel pump should not exceed 6 feet (2 m),
horizontal distance between set and fuel tank should

not exceed 50 feet (15 m). Use 3/8-inch tubing up to

25 feet (12.5 m),

1/2-inch

up to 50 feet (15 m).

Optional Day Tank: The engine may be equipped with
a one quart reservoir tank to replenish fuel lost from

the carburetor by evaporation during shutdown. See

Figure 13. Connect a 5/16-inch return line between

the reservoir upper side fitting (this fitting has a

restricted orifice and must be used) and the main
supply tank. Be sure the return line has a continuous
drop to the main supply tank with no dip-and-nse
where fuel could collect and form a vent

seal.

Seethat

the top center opening of the tank is tightly plugged.

Natural or Manufactured Gas: On sets equipped with
an Impco carburetor, gas pressure atthe carburetor
must be set at 3-ounces (1.3 kPa) gauge, or 5-inch

(127 mm) water column, manometer, with the engine
running at 1800

Thermae regulator is designed for a maximum line pressure of 6­ounces(2.6 kPa) gauge, or 10.38-inches (263.6 mm) water column,

manometer.

r/min

on no

load.

If line pressure is excessive, install asuitable pressure
reducing regulator. Be sure to comply with all local

regulations such as:

• Recommended electric shutoff valve.

• Hand shutoff valve at the fuel source.

• Supply line filter.

Use a short length of approved flexible connection

between the supply pipe and the set regulator inlet.
Combination Gas-Gasoline: Combination gas-

gasoline sets are designed for normal operation on
gas

fuel,

with provision for emergency operation on
gasoline. Both gas and gaso procedures must be
followed.

A reservoir tank is sometimes provided, so a

fuel return line may be necessary as described for

gasoline

fuel.

BATTERY

Starting the unit requires 12-volt battery current. Use
one 12-volt (see specification) battery for a normal

installation. Connect the battery as in Figure 14.
Necessary battery cables are on unit. Service battery
as necessary. Infrequent set use (as in emergency
standby service) may allow battery to self-discharge
to the point where it cannot start the unit. If installing
an automatic transfer switch that has no built-in
charge circuit, connect a separate trickle charger.

Onan automatic transfer switches include such a
battery charging circuit.

WARNING \

^HMi^M^i acid batteries give off explosive gases while

being charged.

Do no, snloke while

servicing batteries. Lea«S

RESERVOIR (DAY) TANK INSTALLATION

RESERVOIR TANK

RESTRICTED

OUTLET

RETURN_UNE TO

UNDERGROUND

FUEL TANK

FIGURE 13. DAY TANK INSTALLATION

LINE FROM

FUEL PUMP

LINE TO

CARBURETOR

18

STARTER

(AUTOMOTIVE)

12 V. BATTERY (TYPE 3EE)

72 A.H. (25g kc)

FIGURE 14. BATTERY CONNECTION

ENGINE
GROUND

REMOTE

CONTROL

CONNECTIONS

Provision is made foraddition of remote starting. This
is accomplished on a 4 place terminal block situated
within the control box. Connect one or more remote
switches across remote terminal and. B+ terminal as
shown in Figure 15. If the distance between the set

and remote station is less than 1000-feet (305 m), use
No.

18 AWG wire; between 1000- and 2000-feet

(305 m and 610 m), use No. 16 AWG wire.

FIGURE 15. REMOTE START CONNECTION (TB12)

Control Box Connections: The factory ships these 12
lead generators with load connection wires NOT
connected together in the control box. These 12 wires
are labeled Tl through T12 and must be brought
together before making load connections. Proceed as
follows:

1.

Remove either right, left or top panel from control

box. See Figure 17.

2.

Connect wires together as shown on panel draw-

ing and in Figure 1 according to voltage desired.

3. Open hinged control panel doors. Connect lead
from terminal 63 to correct terminal for voltage
desired.

These terminals are labeled H2, H3, H4,

H5 and H6. See Figure 18.

WIRING CONNECTIONS

Most local regulations require that wiring connec­tions be made by a licensed electrician and thatthe
installation be inspected and approved before opera­tion.

All connections, wire sizes, etc. must conform to
requirements of electrical codes in effect at the
installation site.

Generator set grounding must be in accordance with
National Electrical Code (NFPA 70-1975) Article 250.

If the installation is for standby service, a double
throw transfer switch must always be used. Connect
this switch (either automatic or manual) so that it is

impossible for commercial power and generator
current to be connected to the load at the same time.
See Figure 16. Instructions for connecting an
automatic load transfer control are included with
such equipment.

LINE

LOAD

GEN.

FIGURE 17. CONTROL BOX (SIDE PANEL REMOVED)

4.

Close front panel and secure with 1/4 turn

fasteners.

5. Connect load wires to generator leads.

Preceding instructions do not apply to models designated Code 3
or 9X; this connection is made at the factory. The installer must only
connect load wires.

(W12 WIRE)

CONNECT LOOSE WIRE

FROM TERMINAL #63

TO EITHER H3,H4,H5 OR

H6 DEPENDING ON
VOLTAGE SELECTED.

NOTE:

SHOWN WITH LINE CONNECTED TO LOAD.

FIGURE 16. LOAD TRANSFER SWITCH

(TYPICAL FUNCTION)

FIGURE 18. REFERENCE VOLTAGE CONNECTION (TB21)

19

120/240 Volt, Single Phase, 12 Lead: Terminal

con­nection LO can be grounded (neutral). For 120 volts,
connect the hot load wires to either the L1 or L2
connection, Figure 19. Connect the neutral load wire
to the grounded LO connection. Two 120 volt circuits
are thus available, with not more than 1/3 the rated
capacity of the set available on either circuit. If using

both circuits, be sure to balance the load between
them.

For 240 volts, connect one load wire to the L1
connection and the second load wire to the L2
connection. Terminal connection L0 is not used for

240 volt service.

Only 2/3 of rated current is available from this connection.

v

-

-£^00 NOT USE THIS
CONNECTION FOR ANY

120 VOLT LOADS.

FIGURE 20. 120/240 V. 3-PHASE DELTA

3 Phase, Wye Connected Set: The 3 phase, 4 wire set
produces line to neutral voltage and line to line
voltage. Line to neutral voltage is the lowervoltageas

noted on the unit nameplate, line to line voltage isthe
higher nameplate voltage.

For 3 phase loads, connect separate load wires to
each of the set terminals

L1,

L2 and L3. Single phase
output of the higher nameplate voltage is obtained
between any two 3 phase terminals as shown in

Figure 21.

FIGURE 19. 120/240 V.

1-PHASE

DOUBLE DELTA

120/240 Volt, 3 Phase, Delta Connected Set; 12 Lead:
The 3 phase Delta connected set is designed to
supply 120 and 240 volt, 1 phase current and 240 volt,
3 phase current, Figure 20. For 3 phase operation,
connect the three load wires to generator terminals

Ll,

L2 and L3—one wire to each terminal. For3 phase

operation the L0 terminal is not used.

For 120/240 volt, 1 phase, 3 wire operation, terminals
Ll and L2 are the "hot" terminals. The L0 terminal is

the neutral, which can be grounded if required. For

120 volt service, connectthe black load wire to either

the Ll or L2 terminal. Connect the neutral (white) wire

to the L0 terminal. Two 120 volt circuits are available.
Connect between any two 3-phase terminals for 240
volt

1-phase

loads.

The terminal marked LOcan be grounded. For 1 phase

loads,

connect the neutral (white) load wire to the L0

terminal.

Connect the black load wire to any one of

the other three terminals—Ll, L2 or L3. Three

separate 1 phase circuits are available, with not more

than 1/6 the rated capacity of the set from any one

circuit.

If using 1 phase and 3 phase current atthesametime,
use care to properly balance the 1 phase

load,

and not

to exceed rated line current.

Figure 21 shows load connections for 120/208 voitage. Other
voltages are available from either parallel wye or series wye-

illustration in Figure 1.

Ll

> «

V

<NL3-^

\ 120

1

208 V

2(j8 V

T

208 V L2

Vo-i

Any combination of 1 phase and 3 phase loading can

be used at the same time as long as total current does
not exceed the NAMEPLATE rating of the generator.
If no 3 phase output is used, usable 1 phase output is
2/3 of 3 phase kVA.

FIGURE 21. 120/208 V. 3-PHASE WYE

20

120/240

Terminal post TO is the grounded (neutral) terminal.

For 120 volt current, connect the "hot" load wire to
either the Tl or T2 terminal. Connect the neutral load
wire to the TO terminal. Two 120 volt circuits are thus

available, with not more than 1/2 the rated capacity of

the set available on each circuit. Balance the load as

closely as possible (Figure 22).

For 240 volt current, connect one load wire to terminal

Tl and the second load wire to terminal T2. Terminal

TO is not used for 240 volt service.

Volt, 1

Phase, 3 Wire

Unit (3R Units):

CAUTION

circuit.

If using both 120 and 240 volt current at the

same time, use care not to overload either

Tl

o

TO

o

T2

o

FIGURE 22. 120/240 V.

1-PHASE

>

o

(CODE 3)

21

OPERATION

GENERAL

ONAN EK/EM Series electric generating sets are
given a complete running test under various load
conditions and are thoroughly checked before leav-

ing the factory. Inspect your unit closely for loose or
missing parts and damage which may have occurred

in transit. Tighten loose parts, replace missing parts
and repair any damage before putting set into opera­tion.

PRESTART

Lubrication System: Engine oil was drained prior to

shipment. Fill engine to capacities shown. After

engine has been run, check dipstick, add oil to bring

level to safe mark (see Figure 23). Record total

capacity for future oil changes. Do not mix brands nor

grades of lubricating oils.

ENGINE OIL LEVEL DIPSTICK

SERVICING

1.

CAUTION

initial starting of set to allow coolant chambers to
and damage to the engine could result from non-compliance.

2.

If engine is equipped with a cooling system filter, do not use
antifreeze with an anti-leak formula. The stop leak element can
prevent or retard the coolant flow through the filter, thereby
eliminating the filtering process completely.

WARNING

and bleed off pressure before removing pressure cap. Severe bums
could result from contact with hot coolant.

Fuel:

If the set uses gasoline

Verify that the electric solenoid valve used

with city water cooled sets is open before

Be careful when checking coolant under
pressure. It is advisable to shut engine down

fuel,

fill.

Overheating

see that the fuel

supply tank is properly filled with automotive

"regular" gasoline. Do not use highly leaded premium

grade gasoline. Check with the fuel supplier for
assurance that the fuel supplied meets the
specifications. Make every effort to keep the fuel

supply clean.

If the set is equipped for gas

fuel,

see that the fuel

supply is turned on. Observe all safety precautions

regarding the use of gas

fuel.

FIGURE

•10° F +10° F +32° F +60° F +90° F

-5W30-*-

-10W-

23. OIL

-10W30-

-10W40-

-2OW20-

LEVEL

-20W40-

-30-

DIPSTICK

-40-

Oil capacities (nominal)
Oil Pan and Filter — 7-quarts (6.6 litres)

Cooling System: Cooling system was drained priorto
shipment. Fill cooling system before starting.
Nominal capacity is 20-quarts (19 litres). For units
using either a radiator or heat exchanger (city water
cooled),

fill the system with clean soft water. Use a
good rust and scale inhibitor additive. If a possibility
exists of a radiator cooled set being exposed to
freezing temperatures use anti-freeze with an
ethylene-glycol base. During initial engine run, check
the coolant level several times and replenish if

necessary to compensate for air pockets which may
have formed during filling. Refer to Ford engine
manual for additional information.

Combination Gas-Gasoline: A set designed for nor­mal operation on gas fuel with provision for emergen­cy operation on gasoline

fuel,

is equipped with a gas­gasoline toggle switch. Throw the switch to the
appropriate position according to the type of fuel in
use.

Check all connections in fuel system for security, to
ensure that pressure will not bleed off when engine is

not in use. Pressure should be maintained for im­mediate starting if unit is on standby service.

BATTERIES

Ensure that the cable.connections to the batteries are

secure. Coat connections with petroleum based or

non-conductive grease to retard formation of cor­rosive deposits.

Check level of electrolyte to be at split ring mark.
Measure specific gravity of electrolyte: SG 1.280 at

80° F (26.7°C). If distilled water has been added cr
specific gravity is less than

charge until desired reading is reached. Do not over
charge.

1.280,

place batteries on

22

STARTING

When the preceding service functions have been

performed,

1.

Crankcase filled.

2.

Cooling system filled.

3. Batteries charged and connected.

4.

Fuel solenoid valve open.

To start, move the "run-stop/reset-remote" switch to
the "run" position. The engine should start after a few
seconds of cranking. Immediately after start, observe
the oil pressure gauge. Normal oil pressure is

between 30- and 55-psi (207- and 380 N»m). Check

the following gauges:

1.

DC Ammeter—10 to 30 amperes.

2.

AC Voltmeter—AC generator output voltage.

3. Frequency Meter—AC generator output
frequency.

After running 10 minutes under load the water
temperature gauge should have stabilized at 180° to

1950F (82° to 90°C). On city water cooled units an
adjustable valve is connected in thewatersupply line.
Adjust the hand wheel valve to provide a water flow

that will keep the water temperature gauge reading

within the range of 1650F to 195°F (74°C to 90°C).

recheck to verify unit is ready to start.

EXERCISE

Generator sets on continuous standby service are

required to be operative at essential loads from a cold
start in a short period of time in the event of a power
outage.

This imposes severe conditions on the engine. Fric­tion of dry piston rings upon dry cylinder walls causes
scuffing and rapid wearing. These can be relieved by
exercising the set at least once a week for a minimum
time of 30 minutes per exercise period. Preferably,

run the set under at least 50 percent load to allow the

engine to reach normal operating temperature. This
will keep engine parts lubricated, maintain fuel prime,

prevent electrical relay contacts from oxidizing and
insure easy emergency starts. ONAN automatic
transfer switches contain an optional exercise switch
which,
period and shut down a set on a weekly frequency.

After each exercise period, top up fuel tank, check
engine for leaks and unit for general condition.

by pre-selection, will start, determine run

For example, the switch can be set for time of start,

length of run, A.M. or P.M. and day of week.

Locate cause of leaks (if any) and correct.

PERIOD

Break-In Note: Run set at 50 percent rated load forthe
first half-hour of initial operation after reaching
operating temperature.

Non-Start: If after a few seconds of cranking engine

fails to start, or starts and runs then stops and fault

lamp lights, refer to appropriate troubleshooting
chart, Table 3 or Table 4.

STOPPING

To reduce and stabilize engine temperatures, run the
engine at no load for three to five minutes before

shutting down.
Move the run-stop/reset-remote switch to stop posh

tion to shut down the set.

NO

LOAD

Periods of no.load operation should be,.heldvto.a'

minimum.

for long periods of time when no electric output is

required,
by connecting a "dummy" electrical
could consist of heater elements, etc.

OPERATION

If it is necessary to keep theengine running

best engine performance will be obtained

load.

Such a load

HIGH

standard cooling, normal ambients and specified
fuels.
distributor for operating characteristics under other
conditions.

Engine horsepower loss is approximately 3 percent for each 1000
feet (304 m) of altitude above sea level for a naturally aspirated
engine. Use lower power requirement at high altitudes to prevent
smoke, over-fueling and high temperatures.

• A. •Partially restrict cool.airf low but use care to avoid

ALTITUDE

Ratings apply to altitudes up to 1000 feet (304 m)

Consult factory or nearest authorized Onan

HIGH

LOW

TEMPERATURES

1.

See that nothing obstructs air flow to-and-from

the set.

2.

Keep cooling system clean.

3. Use correct SAE No. oil for temperature
ditions.

con-

TEMPERATURES

1.

Use correct SAE No. oil for temperature

ditions. Change oil oniy when engine is warm.

2.

Use fresh

sation.

3. Keep fuel system clean and batteries in a well
charged condition.

overheating.

5. Connect water jacket heater when set is not
running.

6. Refer to Ford manual for further information.

fuel.

Protect against moisture conden-

con-

• #

23

•

TROUBLESHOOTING

(Engines

with

TABLE

3.

ENGINE

only one

SHUTDOWN

fault

lamp)

SYSTEM

SYMPTOM

1.

Engine stops cranking and fault

lamp lights, after cranking
approximately 75 seconds.

2.

Fault lamp lights immediately

after engine starts.

3. Fault lamp lights and engine
shuts down after running for
a period.

CORRECTIVE

1.

See engine service manual for

troubleshooting fuel system, ignition
system,

After correcting problem, reset engine
monitor relay by placing Run-Stop/
Reset-Remote switch to Stop/Reset,
then back to the required running
position.

2.

Check for:

Overspeed condition as engine starts.

3. Check the following:
a. Oil level. Engine will shut down

b. Check engine manual for

c. High engine temperature. Check

d.

etc.

if sensor is closed.

troubleshooting oil system.

coolant level; check water flow

(city water cooled systems);
check radiator for free air flow,
and fan belts for tightness. See

engine manual for troubleshooting

cooling system.

Check for faulty oil pressure

sensor or faulty high engine
temperature sensor.

ACTION

4.

Engine runs, shuts down and

cranks for 75-seconds. Cranking
cycle stops; fault lamp lights.

5. Fault lamp lights, no fault
exists.

4.

Check fuel supply. Check ignition

system.

5. To check a no-fault condition,
disconnect !eadssfrom TBll terminals
29,

30 and 31. If fault lamp lights
with leads disconnected, replace
engine monitor board. Reconnect leads.

24

TROUBLESHOOTING

(Units

with

TABLE

4.

ENGINE

five

fault

SHUTDOWN

lamps)

SYSTEM

SYMPTOM

1.

Overcrank fault lamp lights and

engine stops cranking after
approximately 75-seconds.

2.

Engine runs, shuts down, cranks

for 75-seconds, cranking cycle stops,
overcrank light ON.

3. *Low oil pressure shutdown.

4.

'High engine temperature shutdown.

CORRECTIVE

1.

See engine service manual for

troubleshooting fuel system, ignition
system,

After correcting fault, reset engine

monitor relay by placing Run-Stop/
Reset-Remote switch to Stop/Reset
position,
then to the required running position.

2.

Check fuel supply, check ignition.

3. Check —
a. Oil level. Replenish if necessary.
b. Sensor. Faulty sensor will shut

c. Refer to engine service manual for

4.

Check—

a. Coolant level. Replenish if

b. City water cooled sets. Check

c. Check sensor; check thermostat.
d.

etc.

depressing Reset button,

down engine.
troubleshooting guide for oil

system.

necessary.
water flow, valves, etc.

Radiator model, check fan belts,

radiator for obstructions, etc.

ACTION

5. Overspeed shutdown.

6. Overspeed light on, no shutdown.

7. *Low oil pressure light ON.
No shutdown.

8. "High engine temperature light ON.
No shutdown.

*NOTE:

Not applicable on Pennsylvania State models.

5. Check governor and throttle linkages
for freedom of movement.
Check overspeed switch.

6. Disconnect wire at TB11-29. Light en
after reset; replace engine monitor
board.

7. Disconnect wire at TB11-30. Light
ON after relay reset. Replace engine
monitor board.

8. Disconnect wire at
ON after relay reset. Replace engine
monitor board.

TB11-31.

25

Light

OUT-OF-SERVICE

PROTECTION

Generator sets removed from service for extended
periods of time should be protected from rust and
corrosion.

Onan recommends the following protec-

tive procedure—

For One Month

1.

Run the engine at 1800

r/min

and treat the upper

cylinders by spraying an engine preservative oil

(SAE 10) into the carburetor air intake for about
two minutes. Open the throttlefora short burst of
speed,

then shut off the ignition and allow the

engine to come to a stop while continuing to

spray the oil into the carburetor air intake.

Disconnect and remove battery.

2.

Leave the Spark plugs installed and cover all

engine openings with dust-proof caps or shields.

3. Drain the oil, water and gasoline.

For Indefinite Period

1.

Drain the crankcase completely and refill with an

engine preservative oil (SAE 10).

2.

Run the engine until it is completely out of

gasoline, then restart and. run it on an unleaded,
undyed gasoline for at least 10 minutes. Run the
engine at 1800

r/min

and treatthe upper cylinders
by spraying an engine preservative oil (SAE 10)
into the carburetor air intake for about two
minutes. Open the throttle for a short burst of
speed,

shut off the ignition and allow the engine

to come to a stop while continuing to spray theoil

into the carburetor air intake.

3. Disconnect and remove battery. Follow standard
battery storage procedure. Apply film of non­conductive grease to terminal lugs.

4.

Drain the oil and gasoline. Drain the water at the

bottom of the radiator and side of the block.

5. Remove all grease and oil from the exterior
surfaces of the engine.

6. Leave the spark plugs installed.

7. Seal all engine openings and accessories with
water resistant adhesive tape. Mask off all areas to

be used for electrical contact.

8. Make sure all surfaces are dry, then spray all

taped openings, all engine accessories including
ignition wiring, and all exterior surfaces of the
engine with an ignition insulation compound.

9. Fill fuel tank to prevent condensate contaminates.

10.

Provide suitable cover for entire unit.

RETURNING

1.

Remove cover and all protective wrapping.

UNIT

TO

SERVICE

Remove.plug from exhaust outlet.

2.

Refill crankcase with correct viscosity oil.

3. Clean and check battery. Measure specific gravity
(1.260 at 25° C (77° F) and verify level to be at split
ring.

If specific gravity is low, charge until correct
value is obtained. If level is low, add distilled water
and charge until specific gravity is correct. DO

NOT OVERCHARGE.

WARNING j

batteries in operation. Ignition of these gases can cause
serious personal injury.

4.

Connect batteries.

Oo not

smoke while servicing batteries.

Explosive gases are emitted from

5. Fill coolant system as described under
PRESTART SERVICE.

6. Verify that no loads are connected to the
generator.

7. Start engine.

After engine has started, excessive blue smoke will be
exhausted and the engine will run rough until the rust inhibitor
or oil has bumed away.

8. After start, apply load to at least 50% of rated
capacity.

9. Check all gauges to be reading correctly. Unit is
ready for service.

BATTERY,

HOT LOCATION

Batteries will self discharge very quickly when in­stalled where the ambient temperature is consistently
above 90°F (32.2°C), such as in a boiler room. To

lengthen battery life, dilute the electrolyte from its

normal 1.275 specific gravity reading at full charge to
a 1.225 reading. The cranking power is reduced

slightly when the electrolyte is so diluted, but if the
temperature is above 90° F (32.2°C), this shouid not

be noticed. The lengthened battery life will be worth,
the effort.

1.

Fully charge the battery.

2.

With the battery still on charge, draw off the

electrolyte above the plates in each

cell.

DO NOT
ATTEMPT TO POUR OFF; use an hydrometer or
filler bulb ahd dispose of it in a safe manner. Avoid
skin or clothing contact with the electrolyte.

3. Refill each cell with distilled water, to normal
level.

4.

Continue charging for 1 hour at a 4- to 6-hour

rate.

5. Test each

1.255,
reduced to

cell.

If the specific gravity is still above

repeat steps 2, 3, and 4 until the reading is

1.225.

Usually, repeating steps twice is

sufficient.

26

GENERAL

MAINTENANCE

GENERAL

Establish and adhere to a definite schedule of

maintenance inspection and servicing, application
and environment being the governing factors in
determing such a schedule. If your set is a prime
power application, base your schedule on operating
hours.

Use the running time meter to log hours run;

maintain an accurate record of hours and service for
warranty support.

A set on stand-by duty will need servicing at times
other than those recommended by Onan and the
engine manufacturer. Refer to Ford manual for
engine services and maintenance procedures. Adjust
your schedule to satisfy the following conditions—

TABLE

Inspect Complete Set for Leaks, etc.
Check Engine Oil Level
Check Radiator Coolant Level
Check Fuel xl
Check Governor Oil Level*
Check Air Cleaner (Clean or Replace as Necessary)
Check Electrolyte Level of Battery

Stop-Solenoid Linkage, Lubricate Governor Linkage*

Change Engine Oil & Filter

Check All Hardware, Fittings, Clamps, Fasteners, etc. x4
Adjust Drive Belt Tension
Change Governor
Clean Fuel Lift Pump
Clean Sediment Bowl & Filter
Check Starter
Clean & Inspect Battery Charging (DC) Alternator X
Check AC Generator
Inspect Spark Plugs, Replace if Necessary X
Replace Fuel Filter Element
Adjust Valve Clearances X
Inspect Ign. Points, Replace if Necessary*

xl - After every run or exercise period.
x2 - Perform more often in extremely dusty conditions.
x3 - Adjust to

Refer to Ford engine manual.

x4 - Or every 3 months.

x5 - Oil front bearing sparingly; check brushes. ' • ••

x6 - Check brushes (if installed), replace if worn to 5/8-inch (15.9 mm)

or if damaged. DO NOT LUBRICATE.

x7 - Or every two weeks.

* - See Figure 36.

NOTE:

The above schedule is a minimum requirement.

Oil*

1/2-inch

5.

OPERATOR

MAINTENANCE ITEMS

MAINTENANCE ITEMS

(12.5 mm) depression between pulleys.

Continuous duty (prime power)
Standby power
Extremes in ambient temperature
Exposure to elements
Exposure to salt water or sea air
Exposure to dust, sand, etc.

Consult with your ONAN distributor or dealer for a
schedule of maintenance and service more suitable to
the unique environment and application of your set.

WARNING

automatic transfer switch or associated wiring, disconnect
batteries. Failure to do so could result in damage to the unit or
serious personal injury in the event of inadvertent starting.

MAINTENANCE

~k Before commencing any maintenance work
J on the engine, generator, control panel,

SCHEDULE

OPERATIONAL HOURS

10 50 200 400

xl
xl

xl

X

x2
x7
x2
x2

x3

X
X
X

x5

x6

x2

27

ENGINE

General:
tained within the Ford manual, which should be used
in conjunction with the set manual, except in such
cases where instructions state otherwise. Then, the

new information unique to the EK/EM set shall take
precedence.

Air Filter: Remove wing nut in center of filter cover.

See Figure 24. Remove cover and filter. Tap f ilteron a
flat surface to remove adherent dirt. Place a light
source inside the filter and inspect for free air

passage. If necessary, apply a low pressure air source

(30-psi [207 kPa] OSHA) to the inside of the filter to

remove as much dirt as possible. Inspect interior
housing.
and wipe clean.

Basic maintenance procedures are

con-

Vacuum clean if dirty, or remove housing

COAT GASKET WITH ENGINE OIL

FIGURE 25. OIL FILTER ASSEMBLY

CAUTION

carburetor or engine.

Oo not clean filter housing while still installed.
Loose dirt entering intake could damage

Replace air filter every 50 hours of operational time;
more often in extremely dusty conditions.

WING NUT

FILTER COVER

FIGURE 24. AIR CLEANER

Fuel Filter Replace filter every 200 operational hours
or as conditions require. Unscrew the filter housing
from the fuel pump (Figure 26) and remove the filter
element and gasket. Discard the element and gasket.

Clean the filter housing in a petroleum cleaning
solvent.

Place a new filter element over the spout in the fuel
pump valve housing cover.

Be sure to use the proper type element for the installation.

Coat a new gasket with a light engine oil and position
the gasket on the filter housing. Screw the filter

housing onto the fuel pump. Hand tighten the filter
housing until the gasket contacts the pump, and then
advance it 1/8

turn.

Start the engine and check for

leaks.

Engine Oil Filter: Spin-off type, should be replaced
with every oil change, at 50 hours of operational time.

Remove and discard old filter, wipe oil from exposed
adapter recess. See Figure 25. Coat gasket of new

filter with clean lubricating oil and place in position on

adapter. Hand-tighten filter until gasket contacts
adapter face then advance one-half

turn.

DO NOT

OVERTIGHTEN.
Clean all oil residues from engine, then fill crankcase.

Refer to Prestart Servicing. Run engine and check for
oil leaks; make necessary repairs. Note oil change in
engine logbook.

FIGURE 26. FUEL FILTER ASSEMBLY

Crankcase Ventilation (PCV) Valve: Push fit in valve
rocker cover. Remove and clean at every oil change.
After cleaning, shake valve to ensure ball is free, then
reinstall.

28

CARBURETORS

The following carburetors were installed
a specific application

instructions
preference

and

to

those given

and

engine output.

adjustment procedures

in the

Ford engine manual.

Carburetor, Gasoline: Carburetors have main and idle
adjusting needle valves.
the bottom

of the

heavier load conditions.

the side

and
see Figure

of the

no

load conditions.

27.

carburetor, affects operation

The

main adjusting needle,

carburetor, affects operation

The

idle adjusting needle,

For

location

Under normal circumstances, factory carburetor
justments should

have been changed,

turn.open

for

not be

an

idle needle

disturbed.

approximate setting

and one
needle will permit starting. Adjust temporarily
smoothest running. Allow engine

up before making final adjustment.

by

ONAN

Use

these

at

of

adjustments,

If

adjustments

of 1-1/2

turn open

to

thoroughly warm

for

for

in

at

at

at

light

ad-

main

for

fluctuates
slightly.

original full load setting.
obtained

at any

Do not

by

load,

turn main adjusting needle

turn

out

more than

If

stable speed cannot

1/2

turn beyond

such carburetor adjustment, a change
governor sensitivity adjustment will probably
necessary.

Combination Carburetor,

engine

closed.

(Figure

is

equipped with a combination carburetor

28), see
The

that

electric choke must

the adjustable cover
counterclockwise from

adjusted,
even

at

the

electric choke will

very

low

temperatures.

Gas fuel main adjustment should

Gas

the

gasoline shut-off valve

is

turned

the "*"

Operation:

be

adjusted

10 to 12

mark. When properly

be

completely open

be

made

If the

so

notches

at

full load

only.

out

be

m

be

is

that

To adjust "idle"
connected

needle

out

needle

in

(no

load) needle, seethat no loads

to

the generator. Slowly turn idle adjusting

until engine speed drops slightly. Turn

just

to the

point where speed returns

normal.
To adjust main needle, apply a full electrical

Turn

the

main needle

drop.

Slowly turn needle

rises.

Try

various, electrical loads.

in

until enginespeed begins

out

until speed

no

If

engine speed

are

to

load.

to

longer

Carburetor,
operation

regulator. Carburetor adjustments

Gas:

Engines equipped

use a gas

for

natural

carburetor with combined

are the

the combination gas-gasoline carburetor.

Conversion kits

(Figures

30 and 31).

representative

Spec

No. and

are

available

for LPG

Contact your local Onan

for

information. Give complete Model,

Serial

No. of set

when requesting

conversion information.

-GAS REGULATOR

GAS FUEL

ADJUSTMENT

gas

same

as

operation

ELECTRIC

CHOKE

FIGURE

ADJUSTMENT-

27.

GASOLINE CARBURETOR

MAIN

29

ZENITH ELECTRIC CHOKE

SETTING

FIGURE

FOR

WITH

28.

RUNNING

GAS

FUEL

COMBINATION CARBURETOR

-CARBURETOR

Electric Choke: A 12 volt electric choke (Figure 29)
with vacuum booster is used on all engines. The
adjustable choke cover is held in place by three
screws. Perimeter of the cover is divided into sections

by small raised marks. One mark is labeled zero and

the twelfth mark from zero is labeled with an asterisk

(*), which indicates normal adjustment setting. Along

raised line on top of the choke housing is used as the
reference mark. Normal setting for the choke is made
when the asterisk mark lines up with reference line.

If overchoking occurs, loosen three locking screws
and turn choke cover slightly to the left

(counterclockwise). Do not turn very far. One or two

notches will usually be sufficient. Tighten locking

screws. To increase choking action, turn choke cover

slightly to the right (clockwise). Retighten cover

screws.

LONG RAISED LINE

LOCKI

SCREWS (3)

FIGURE 29. ELECTRIC CHOKE

Anti-Dieseling Control: Normally factory adjustment
should not be changed. Adjustment procedure is

included with governor adjustment.

The anti-dieseling control is a device to hold the
throttle closed during engineshutdown. This ensures

prompt stopping and prevents backfiring. A spring
and linkage hold the throttle closed during shutdown.
A solenoid is energized to overcome spring tension
and permits the governor to open the throttle for
engine running.

Governor (Includes Anti-dieseling Control): The
governor controls the speed of the engine, and

therefore the frequency of the voltage. Engine speed

affects AC output voltage. Use either a tachometer or

frequency meter to check engine speed for proper

governor adjustment.

1.

Governor linkage—With engine stopped, throttle

held wide open, and tension on governor spring,

adjust the governor linkage length by rotating the

ball joint on the link so that the throttle stop lever
clears the stop pin by not less than

2.

Anti-diesel control—Move override and no load

1/32".

stops (set screws on wire link, Figure 32) away
from override lever so that they have no effect on
engine speed.

3. Warm up—Start the engine and allow it to reach
operating temperature.

4.

Speed—With no electrical load connected, adjust

the speed adjusting screw to obtain 1890

(63 hertz) for a 60 hertz set or 1590

r/min

for a 50 hertz set. Apply a full electrical

r/min

(53 hertz)

load."

The

speed drop from the no load figure should be no

more than 90
r/min

(1-1/2 hertz). An incorrect speed drop frorr:

r/min

(3 hertz) and no less than 45

no load to full load necessitates a sensitivity
adjustment.

30

, CARBURETOR

PIPE

SUPPORT

TO CONTROL

GROUND)

TO CONTROL TERM.B

(PARALLEL WITH

IGNITION COIL)

"J^ ^ CARBURETOR

Nj

WATER LINE

ENGINE BLOCK DRAIN

TO

m

^-

SOLENOID VALVE

COOLING WATER

LINE

DRY FUEL FILTER

FIGURE

ANTI-DIESELING

SOLENOID

«- SOLENOID VALVE

30. LPG VAPOR

OVER-RIDE

STOP

| O 1

MANUAL SHUT

WITHDRAWAL

NO LOAD (IDLE)

STOP

AND SET

SCREW

OFF

SPRING TENSION

'ADJUSTING STUD

ADJUSTING

V

NUT

GOVERNOR

CONVERTER

VAPORIZ
TO CARB

' CONTROL

LINKAGE

ED GAS \ THT

URETOR—L

FIGURE

31. LPG

LIQUID

GOVERNOR SPEED ADJUSTING SCREW.

TURN

IN TO

TURN

OUT TO

,..,/..,•.,,'"' •..-J-.^jSte.-V/,',..

TURN THIS

TO INCREASE

SENSITIVITY

WITHDRAWAL

INCREASE SPEED.

DECREASE SPEED.

WAY ,

J-

//' •v,.

FIGURE

32. ANTI-DIESEL CONTROL

31

GOVERNOR

SPRING

SENSITIVITY

SCREW

FIGURE

-TURN THIS

WAY

TO DECREASE

SENSITIVITY

33. GOVERNOR ADJUSTMENT

5. Sensitivity—If engine tends
increase

and

decrease speed) under load

ditions, increase sensitivity screw

to

hunt (alternately

on

which

con-

the

spring link pivots.
Any change

will require correcting

ment. Turning
causes a slight speed increase which
corrected
counterclockwise

by

in the

the

turning

setting

of

the sensitivity screw

the

speed screw adjust-

sensitivity screw clockwise

can be

the

speed screw slightly

to

decrease spring tension.

6. General—Be sure that all lock nuts are tightened
as adjustments are completed. Governors cannot
operate properly
or excessive looseness

if

there

is any

in

binding, sticking,

the connecting linkage

or carburetor throttle assembly. A lean fuel

mixture,

7. Output—Check

8. Throttle Stop—With
that

or a

cold engine

the AC

the

throttle stop lever screw (attaching

may

cause hunting.

output voltage.

the

engine stopped,

see

the

override lever, Figure 34) engages the carburetor

throttle stop

done

by
the stop pin, then tuming
provides1 a
starting characteristics.

pin by 1/4 to 1/2

backing

off the

screw until

in 1/4 to 1/2

"cracked open" throttle

Do not

turn.

adjust

This

can be

it

just clears

turn.

This

for

good

the

screw
so faras to cause the engine to "diesel" and refuse
to stop, thus defeating

the

purpose

of the

anti-

dieseling control.

9. Anti-dieseling control—
a. See that

to

the
lengthen this connection unless
tension
adjusted

b.

Set the

solenoid)

inch from
carburetor
wide open throttle when
engaged (plunger all-the-way
engine

the

wire linkage

solenoid plunger.

is

securely attached

Do not

shorten

the

at the

by its

opposite

stud.

See

end

Figure

cannot

32.

override stop (located nearer

on the

the

so

wire linkage

to

about

slotted override lever

that

it

does

not

interfere with

the

solenoid

in, as

is

running).

spring

be

on the

is

c. See that anti-dieseling control spring tension

is just enough
jointed lever
stopping.
also

to

rotate spring

linkage stops horizontally

to

positively bend governor's

and

hold throttle closed during

Spring tension adjusting stud serves

as

necessary

to

to

engage flat

against override lever.

d.

Set

no

load stop (setscrew, located nearer the
spring)
override lever while
speed with electrical load removed
Start

Be sure that
adjustments

on

and

wire linkage

stop

set to

all

lock nuts

are

completed.

1/32

inch away from

set is

running

at

(no

check adjustment.

are

tightened

or

fully

the

1/32

fully

when

hold

rated
load).

as

CRANKING POSITION

NO LOAD POSITION

THROTTLE PLATE

FIGURE 34. THROTTLE STOP

32

STOPPED POSITION

SOLENOI^

OVIR^~

RIDE

STOP

PISENGAr.rn.^

HT

^-

' ANTI-DIESEL

CONTROL WIRE

LINKAGE

•THROTTLE
PLATE

_

Drive Belt Adjustment: Separate belts are used to
drive fan, governor and alternator (Figure 35). Main­tain correct adjustment of these belts to provide

proper engine cooling and alternator output. Check

belts for cracks and wear occasionally, and replace
when necessary.

To adjust fan belt, loosen fan bracket screws, then

move bracket up or down until adeflection of 1/2 inch

(13 mm) is obtained between crankshaft pulley and

fan pulley, with light thumb pressure on the belt.

To adjust alternator or governor belt, loosen link

clamp screw and the mounting bolts, move alternator

or governor toward or away from engine until a

deflection of 1/2 inch (13 mm) is obtained between

pulleys, with light thumb pressure on belt.

.GOVERNOR

PULLEY

'WATER PUMP

PULLEY

1/2 • DEFLECTION

WATER PUMP

PULLEY

ALTERNATOR

PULLEY

1/2 DEFLECTION

BATTERIES

Check the condition of the starting batteries at least
every two weeks. See that connections are clean and..
tight. A light coating of grease will retard corrosion ar
terminals. Keep the electrolyte at the proper level

above the plates by adding distilled water.

CRANKSHAFT

PULLEY

FAN .

PULLEY

WATER PUMP

PULLEY

-4 — 1/2 DEFLECTION

CRANKSHAFT

PULLEY

FIGURE 35. DRIVE BELT ADJUSTMENT

TABLE

6. TUN

ADJUSTMENTS

Spark Plug Gap, All Models

Spark Plug Gap, Gas Only Models
Ignition Points — Gap Setting
Dwell Angle

Valve Clearance Setting

TUNE

UP

ONAN suggests that the following specifications for
tune up be used in preference to those given in the

Ford manual. This is due to a difference in

idle speed) and removal of automatic vacuum ad-

vance.

E-UP

SPECIFICATIONS

EK SERIES

.028"
.025"

.024"

- .026"

35° - 39°

Zero Lash

EM SERIES

- - .028" •,.
.025"

.024"

- .026"

35° - 39°

Zero Lash

r/min

(no

33

CONNECTIONS

(Fuel,

Exhaust,

etc.)

Operator should periodically make a complete visual

inspection of the unit while running at rated

load.

Some of the things to check for are as follows:

1.

Check fuel and oil lines for possible leakage.

2.

Inspect exhaust lines and mufflers for possible

leakage and cracks.

3. Periodically or daily drain moisture from conden­sation traps.

4.

Inspect water lines and connections for leaks and

security.

5. Inspect electrical wires for security.

AC

GENERATOR

There are no brushes, brush springs or collector rings

on these generators, therefore they require very little
servicing.

Periodic inspections, to coincide with

engine oil changes, will ensure good performance.
Inspection: Inspect generator and control box for

loose or broken wires and parts. Check diodes and
printed circuit boards for excessive dust, grease or
moisture. Blow these assemblies out periodically with

filtered,

failure.

low pressure, compressed air.

CAUTION

Excessive foreign matter on diodes and heat
sinks will cause overheating and possible

Generator Bearing

Inspect the bearing for evidence of outer case
rotation every 1000 hours while the unit is running.

MAINTENANCE

Refer to Table 5 for Operator Maintenance Schedule.

Governor oil level should be even with bottom of the
oil level plug. When adding oil to the governor, the oil
should just start to flow out of the oil level plug hole.
Do not overfill.

KEEP GOVERNOR

LINKAGE LUBRICATED

Vmrrmrr/rm/r/fl'.a

SHIFT SLEEVE

ft TO LIFT JOINT

FROM BALL STUD

GOVERNOR

CONTROL LINKAGE

BALL JOINT

If unit is used for "prime power," replace the bearing
every 10,000 hours ortwo years. If the unit is used for
"standby," replace the bearing every five years.

Deterioration of the bearing grease due to oxidation
makes this replacement necessary.

If generator requires major repair or
ed Onan dealer or distributor.

OIL
FILL

MAINTAIN

OIL LEVEL

servicing,

contact an authoriz-

GOVERNOR

DISTRIBUTOR

WITH CAP AND ROTOR

REMOVED

DISTRIBUTOR

OILER.

FIGURE 36. MAINTENANCE

APPLY LIGHT FILM

OF NON-FIBRE GREASE

TO CAM

34

PARTS

CATALOG

NOTICE!

ITEMS REFERENCED AS OPTIONAL INDICATE PART IS FACTORY INSTALLED AND MAY NOT BE
APPLICABLE TO ALL MODELS. FOR FIELD CONVERSIONS ADDITIONAL PARTS ARE USUALLY
REQUIRED.

INSTRUCTIONS

REPAIR

All parts in this list are Onan parts. For Onan parts or
service, contact the dealer from whom you purchased
this equipment or your nearest authorized service
station.
please refer to the Onan nameplate and give the
complete MODEL, SPECIFICATION and SERIAL
NUMBER.

To avoid errors or delay in filling your order,

ONAN

FOR

ORDERING

PARTS

PARTS

FORD

PARTS

All Ford parts must be ordered from the Ford.Motor
Company of Dearborn, Michigan, or your nearest

authorized distributor. When ordering parts, referto
the Ford nameplate and give the complete SERIAL,
TYPE and OPTIONS NUMBER.

35

This catalog applies to the standard EK and EM generator sets as listed below. These sets are powered by a Ford
engine (see Ford manual). Engine parts modified oradded by Onan will bein this list and have Onan part numbers.
These supersede similar parts listed in the Ford manual. Onan parts are arranged in groups of related items and are

identified by a reference. All parts illustrations are typical. Using the Model and Spec No. from the set nameplate,
select the Parts Key No.
that differ between models. Unless otherwise mentioned, parts are interchangeable. Right and left sides are

determined by facing the front end of the engine.

(1,

2, etc., in the last column) that applies to your set. This Parts Key No. represents parts

ELECTRIC

MODEL

Pennsylvania Approved Sets

* - The Specification Letter advances (A to B, B to C, etc.) with manufacturing changes.

£ - These sets are reconnectible; refer to Specifications (Generator Details).

AND

SPEC

25.0EK-515R/

30.0EK-3R/

30.0EK-15R/

30.0EK-9XR/

37.5EM-515R/

45.0EM-3R/

45.0EM-15R/

45.0EM-9XR/ 45,000

NO.*

GENERATING

ELECTRICAL

WATTS

25,000 50

30,000
30,000
30,000

37,500
45,000

45,000 60

HERTZ

60 1
60
60

50

60

60

See special parts list following the main parts list.

SET DATA

DATA

PHASE

£

£
3

£ 12

1

£ 12 2

3

TABLE

WIRE

12

3

12

4

3
4 2

PARTS

KEY

NO.

1
1

1
1

2
2

100-0904

REPLACEMENT

EK & EM (Ford Motor Company Model C5PG-6005-A, Spec SO-30B)

General Description:

Includes — Complete Cylinder Block, Oil Pan, Water Pump, Oil Filter,
Fuel Pump and Filter, Starter Motor, Spark Plugs, Front Support,
Flywheel Housing Plate, Thermostat, and Alternator Mounting
Brackets.

Excludes — Carburetor, Air Cleaner, Charge Generator, Oil Pressure,
Water Temperature Gauge Senders, Oil Pressure Switch, High Water
Temperature Cut Off Switch, Anti-Dieseling Control, Radiator, Fan

Blades & Belts, Muffler and Exhaust Tube.

Engine listed is for Standard Spec 1 (Radiator Cooled) generator sets,
for all other models refer to factory. For EK generator sets Spec A
through F also order 141-0627 Carburetor and 145-0467 Restrictor Plate.

ENGINE

36

COOLING,

OIL

DRAIN

AND

EXHAUST

GROUP

REF.

NO. NO.

4
5 130-0351
6

8 503-0490 1
9 503-0491 1

10

11 505-0007 2
12 505-0098 1 Nipple, Close (1/8 x 3/4") ­13 505-0101 1 Nipple, Pipe - Oil Drain

14 505-0039 1 Elbow, Oil Drain
15 504-0030 1
16 503-0484
17 503-0131 1 Clamp, Hose - Oil Drain
18 193-0104 1 Sender, Water Temperature

19
20
21
22 155-1107 1
23 155-0923
24

25 102-0652 1 Adapter, Oil Drain
26
27 520-0404 2
28
29 850-0055 2 Washer, Lock - Spring (7/16")
30 405-1054 1

31 821-0014 6 Screw, Cap - Lockinghead -

32 870-0113 6 Nut, Retainer (5/16-18)
33 815-0181 8 Screw, Tapping - Lockinghead -

34 800-0026 4 Screw, Cap - Hexhead ­35 850-0045 4 Washer, Lock - Spring (5/16")

PART

1 RADIATOR

130-0660 1 Key 1

130-0604 1
2 ' 130-0449 1
3

504-0028

130-0352

130-0355 1
7 BELT

511-0075 1 Fan
511-0074 1 Water Pump

CLAMP, HOSE
503-0311
503-0365 1 2-1/4 x 1/2"

309-0178
193-0108
309-0169

505-0059

505-0135
870-0203

QTY.

USED DESCRIPTION

Key 2
Cap,

1

Valve,

1

Guard,

1

Guard,
Blade,

Hose,
Hose,

Hose,
2-1/8 x 1/2"

3

Bushing,

(1/4 x 1/8")

Low Oil Pressure Switch

Valve,

1

Hose,

1

Switch,

1

Sender, Oil Pressure

1

Switch,

Tube,
1 Gasket, Exhaust Tube
1 Tee (1/8") - Low Oil

1

2

Pressure Switch

Nipple, Half - Oil Drain

Stud,

Nut, Hex (7/16-20)

Flange, Adapter - Air Duct -

Optional
(5/16-18 x 1/2")

(#18 x 3/4")
(#18 x 3/4")

PART

Radiator

Radiator Drain

Fan (Right Hand)
Fan (Left Hand)

Fan

Lower - Radiator
Upper - Radiator

Upper - Radiator

Reducer

Oil Drain

Oil Drain

Water Hi-Temperature
Low Oil Pressure

Exhaust

Exhaust Flange

37

ANTI-DIESELING

GROUP

11

,-(§f@-*-19

38

ANTI-DIESELING

REF.

PART

NO. NO.

BRACKET, ANTI-DIESELING CONTROL

1

145-0182

IA 145-0422 1 Use Began During Spec C 24

SOLENOID, ANTI-DIESELING

2

307-0259 1

2A 307-1093

2B 307-1356 1 Begin Spec F

3

145-0164

4 152-0155 1
5

516-0059 1
LINK, THROTTLE

6" 145-0166 1

6A 145-0421 1

7 145-0165
8 145-0163

9 145-0158 1

10 150-0096 1
11 150-0638 1 Joint, Ball

12 516-0086 1
13 309-0155

14 309-0133
15 309-0131
16 309-0132
17 803-0002
18

870-0053

19 115-0025 1 Nut, Hex - Ball Joint -

20 850-0045 1
21 812-0079 4 Screw, Cap (Roundhead) -

22 850-0025 4

QTY.

USED

1

1

1

1

1

1

1

1

2

2

PART

DESCRIPTION

Early Spec C Models

Early Spec C Models
Use Began During Spec C

through E

Extension,

Solenoid Arm

(Early Spec C Models)

Swivel,

Choke Lever

Pin,

Cotter (Early Spec C

Models)

Early Spec C Models
Use Began During Spec C

Stop,

Throttle

Arm,

Override

Spring,

Throttle

Stud,

Governor Adjusting

Pin,

Roll (Early Spec C

Models)

Switch,

Micro (Early Spec C

Models)

Actuator (Early Spec C

Models)

Bracket, Micro Switch

(Early Spec C Models)

Cam,

Micro Switch (Early

Spec C Models)

Screw, Set (Socket) -

Throttle Stop - (8-32 x

3/16")

Nut, Hex - Governor

Adjusting Stud (10-32)

(1/4-28)

Washer, Lock (Spring) -

Ball Joint - (1/4")
Solenoid Mounting -

(8-32 x 1/2")

Washer, Lock (Spring) -

Solenoid Mounting (#8)

GROUP

REF

NO.

23

25

26

27

27
28

28

29

29
30

30

31

31
32
33
34

35
36

37

37

38

PART

NO.

860-0008
815-0134

853-0005

526-0048

870-0055
856-0002

307-1327
307-1323

307-1330
516-0059
334-0028
526-0006

815-0104
800-0003

850-0040

862-0001

above Serial #173734205

QTY.

PART

USED

DESCRIPTION

4 Nut, Hex - Solenoid

Mounting (8-32)

Screw, Machine (Fillister) -

Override Arm Mounting

(8-36 x 3/4")

Washer, Lock (External

Shakeproof) - Override
Arm Mounting (#8)

Washer, Flat - Override

Arm Mounting

(.172"

ID x

3/8" OD x 1/32" THK) - Brass

Nut, Hex - Override Arm

Mounting (8-32)

Washer, Lock (External/

Internal Shakeproof) ­Override Arm Mounting (#8)

"Shield,

Anti-Dieseling

Solenoid (Begin Spec F)

"Bracket, Anti-Dieseling

Solenoid Mounting (Begin

Spec F)

"Bracket, Solenoid (Begin

Spec F)

"Pin,

Cotter - Swivel

Choke Lever (Begin Spec F)

"Lead,

Anti-Dieseling

Solenoid

"Washer, Flat - Arm Swivel

Mounting (15/64" ID x
1/2" OD x 3/64" THK)

"Screw, Machine (Fillister

Head) - .8-32 x 5/16"

"Screw, Cap (Hexhead) -

Solenoid to Bracket
Mounting (1/4-20 x 1/2")

"Washer, Lock (Spring) -

Solenoid to Bracket
Mounting (1/4")

"Nut, Hex - Solenoid to

Bracket Mounting (1/4-20)

39

GOVERNOR, ALTERNATOR,

AND IGNITION

COIL GROUP

26-<^)3f

31

26

29^28

35

40

GOVERNOR,

REF.

NO. NO.

10
11 191-0571 1 Spacer, Alternator Mounting

12 191-0578 1 Heat Shield, Alternator
13 151-0312 1 "Governor
14
15
16 511-0077 1 Belt, V (Governors on

16 511-0078 1 Belt, V (Governors on sets

17 520-0214 1
18 115-0025 3 Nut, Linkage Stud
19 150-0638 1 Joint, Ball
20 801-0050 3 Screw, Cap - Hexhead

21 191-0732 1 Regulator, Alternator

22

PART QTY.

1 314-0006 1 Suppressor, Distributor

2

166-0286

3 517-0090 1
4 166-0278 1

5

160-1045
7 160-0558
8 312-0058 2 Condenser, (1)

9 167-1528 1

191-0665

191-0716 1 Spacer, Alternator

191-0623 1 Pulley, Alternator

CABLE,

167-1525 1 Cylinder #1

167-1526 1 Cylinder #2

167-1527

167-1529 1 Cylinder #4

167-1530

167-1531 1 Cylinder #6

USED

1

1

8

1

SPARK PLUG

1 Cylinder #3
1

AIR

HEATER

Screw, Coil Bracket
Plug,

Advance
Coil,
Bracket, Coil
Nipple, Ignition Cables

(1)
Cable, Coil to Distributor

'Alternator (Motorola

#70D44039B)

sets with air cooled

exhaust manifold)

with water cooled exhaust

manifold)

Stud,

(3/8-24 x 1")

Cylinder #5

ALTERNATOR,

PART

DESCRIPTION

Distributor Vacuum

Ignition

Alternator

Linkage

Coil,

GROUP

- OPTIONAL EQUIPMENT

AND

IGNITION

REF.

NO.

23
24
25

26
27
28

29
30
31

32
33
34

35
36
37

38 854-0007 1 Washer, Lock - Internal -

39

40.
41

PART QTY. PART

NO.

191-0725 1 Guard, Alternator Belt
151-0316 1 Bracket, Governor

304-0045 1 Resistor, Fixed - Early
304-0015 • 2 Washer, Centering - Resistor

332-1292 1 Bracket Assembly, Terminal

104-0719 1 Flywheel, Includes Ring
104-0723 1

512-0051 1 Pulley, Governor Drive
813-0118 1 Screw (10-32 x 4-1/2") -

850-0030 1 Washer, Lock - Spring (#10)
870-0053 1 Nut, Hex (10-32)
800-0026 1 Screw, Cap - Hexhead -

850-0045 1 Washer, Lock - Spring (5/16")
104-0745 6 Bolt, Flywheel Mounting
815-0190 1 Screw, Cap - Roundhead-

850-0040 1 Washer, Lock - Spring (1/4")
850-0050 3 Washer, Lock - Spring (3/8")
526-0030 3 Washer, Flat (13/32" ID x

For components contact your nearest Motorola dealer or

Motorola Automotive Products, Inc.,
Franklin Park, Illinois

Check Governor nameplate and order components from
your nearest Hoof Products Company dealer.

COIL

USED DESCRIPTION

GROUP

Spec C Models

Gear

Gear,

60131.

Ring

Resistor Mounting

(5/16-18 x 3/4")

(8-32 x 3/8")

(#8)

7/8" OD x 1/8" THK)

9401

W. Grand Ave.,

REF.

NO.

PART

NO.

133-0204

133-0201
133-0202

406-0105

133-0203

505-0217
812-0077

8

850-0025

9

10

140-0261

* - Included in 133-0204 Carburetor Air Heater Assembly.

QTY. PART

USED DESCRIPTION

1 Heater Assembly, Carburetor

1 "Duct, Carburetor Heater
1 "Ring, Carburetor Heater

3 "Fastener

1 "Hose, Flexible (Order

1 "Adapter, Carburetor Air
1 "Nipple (1/4 x 4-1/2")

6 Screw, Tapping (Roundhead)

6 Washer, Lock (Spring) - #8
1 "Stripping, Weather (Order

1 ' Cleaner, Air

Air (Includes Parts
Marked *)

12"

of Bulk Hose

#503-0151)
Heater

(#32 x 3/8")

24"

of Bulk Stripping

(895-0098)

41

RESERVOIR

(DAY) TANK

GROUP

^ OPTIONAL EQUIPMENT

42

REF.

NO. NO.

"3 TANK, RESERVOIR

10 159-0860 1
11 501-0010 1

12 800-0071
13 850-0055 2

14 502-0003 1
15

16 862-0001 2
17 850-0040 2

PART QTY. PART

1

BRACKET, TANK MOUNTING
159-0861 1
159-0876 1 Two Quart

2 CLAMP, TANK MOUNTING

159-0680
159-0875 1 Two Quart

159-0294 1

159-0746 1 Two Quart
4 505-0057 2
5 159-0705 1 Reducer, Restricted
6 502-0002 3 Elbow, Male
7

502-0082
8

307-0565
9

159-0859

800-0005 2

USED

1

1
1

1

2

DESCRIPTION

One Quart

One Quart

One Quart
Plug

Nipple, Solenoid Valve to

Tank

Valve,

Solenoid (12 Volt)

Line,

Fuel - Tank to

Carburetor

Line,

Fuel - Tank to Fuel

Pump

Line,

Flexible Fuel

Screw, Cap (Hexhead) -

(7/16-14 x 1")

Washer, Lock (Spring) - (7/16")

Connector, Inverted Male

Screw, Cap (Hexhead) -

(1/4-20 x 3/4")

Nut, Hex (1/4-20)

Washer, Lock (Spring) - (1/4")

GASOLINE

FUEL

SYSTEM

GROUP

REF.

NO.

10
11 501-0134
12 503-0373
13
14
15
16
17 123-0910
18
19
20
21 505-0011
22
23

24

25 145-0467 1
26

PART

NO.

•CARBURETOR (Zenith #28810)

1

141-0575
141-0627 1 Key 1 (Begin Spec G)

141-0627 1 Key 2
2 145-0120
3 502-0002
4 148-0593

154-0133

5

520-0311

6
7 140-1089

104-0091

8
9 149-1052 1

140-1083

502-0354
502-0002 1
141-0372
123-1044 1

505-0038 1
505-0071
505-0302 2 Nipple, Half (Breather)

503-0614

854-0020

309-0269 j 1 . • Switch, Low Engine

QTY.

USED DESCRIPTION

Key 1 (Spec C through F)

1

1 Gasket, Carburetor Mounting
1 Elbow, Fuel Pump Outlet
1 Adapter, Carburetor
2 Gasket, Carburetor Adapter

Stud,

2
1 Element, Air Cleaner
2

1

1
1 Clamp, Fuel Line
1 Adapter, Fuel Line

1
1
2 Nipple (Breather)
1

2 Clamp, Hose (Breather)

1
2 Washer, Lock (Internal

Carburetor Mounting

Nut, Carburetor Mounting

(3/8-24)

Line,

Fuel Pump to

Carburetor
Cleaner, Air (Includes Element)
Line,

Fuel to Pump

Elbow, Carburetor Inlet
Knob,

Choke Shaft
Adapter, Breather
Valve,

Breather

Elbow, 90° (Breather)

Elbow, Street (Breather)
Hose,

Breather (Order 24"-

of Bulk Hose 503-0110)
Shakeproof) - Carburetor

Mounting - (3/8")

Plate,

Carburetor Restrictor

(EK Begin Spec G)

Temperature

PART

For Components, contact your nearest Zenith
Carburetor dealer or Zenith Carburetor Division,

The Bendix Corporation, 696 Hart Avenue,

Detroit, Michigan 48214

43

LIQUID

PETROLEUM

FUEL

SYSTEM

GROUP

^\ IO 9

OPTIONAL

EQUIPMENT

IEF.
MO.

10 1 Hose (11" of Bulk Hose

11 503-0183 2 Clamp, Hose 503-0183
12 505-0119 3 Elbow, Street (3/8 x 45°)

13
14 505-0125 1 Nipple, Pipe (3/8 x 6")
15 148-0604 1 Brace, Converter Mounting

16 504-0028
17 505-0129 1
18 505-0017
19 505-0010
20

PART

NO.

1 148-0643
2

505-0132

3 505-0102

148-0637 1 Regulator, Gas - Primary -

4

148-0625 1 Converter, LPG

5
6 505-0099
7

505-0060
8 505-0100
9

505-0135

148-0603

503-0032 2 Clamp, Hose (7/8")

QTY.

USED DESCRIPTION

1

'Carburetor (Impco #125-19)

1 Elbow, Carburetor Inlet
1 Nipple, Carburetor Inlet

1 Nipple (3/8 x 1")
1 Tee (3/8")
1 Nipple (1/2 x
1 Nipple, Half (3/8")

1 Bracket, Converter Mounting

1
2

1

(3/4"
to Primary Regulator

(3/4"

on LPG Vapor

LPG Vapor Only

#503-0386)

(11/16 to

Bracket

Valve,

Drain
Bushing,
Bushing,
Nipple, Half (1/4 x 1")

PART

x 90°)

x 1") - 2 used

1-1/8")

1-1/16")

Reducer (1 x 3/4")
Reducer (3/8 x 1/4")

REF.

NO.

21
22 130-0678 1
23 502-0103
24 505-0102 1
25 505-0132
26 505-0324 1
27

28
29 504-0005 1

30 505-0021
31 307-0312

32
33

34
35 800-0069
36
37

PART

NO.

503-0189

800-0009
862-0001

850-0040

800-0071 1
850-0055
For components contact yournearest Impco Dealer

or Impco Division, 16916 Gridley Place, Cerritos, •
California, 90701

QTY.

USED

1
1
1
2
1

1
1

2
2

2
1

2

DESCRIPTION

Hose (12" of Bulk #503-0110)
Line
Connector
Nipple, Pipe (3/4 x
Elbow, Pipe (3/4 x 90°)
Nipple, Half (3/4 x 2")
Clamp, Hose (1-3/16 to

1-1/2")

Hose (29" of Bulk Hose

#503-0249) •

Valve,

Drain

Bushing,
Valve,

Screw, Cap (Hexhead) ­Nut, Hex (1/4-20")

Washer, Lock (Spring) -

Reducer

(3/4 x 1/2")

Solenoid

(1/4-20 x

1-1/2")

(IM")

Screw, Cap (Hexhead) -

(7/16-14 x 3/4")

Screw, Cap (Hexhead) -

(7/16-14 x 1")

Washer, Lock (Spring) - (7/16")

PART

1-3/8")

44

20

GAS

AND

GAS-GASOLINE

OPTIONAL

22

24

EQUIPMENT

FUEL

SYSTEM

GROUP

GAS

REF.

NO.

10
11 115-0025 1 Nut, Hex (1/4-28) .
12 850-0040
13 .

14 308-0005 1

PART

NO.

1 148-0691

148-0643

2

505-0132

3
4 505-0102

148-0597

5

505-0100 1

6
7 505-0021

503-0542 1

8
9 503-0465 2 Clamp, Adapter Hose -

150-0638 1 Joint, Ball - Gas Only Sets

504-0007 1

QTY.

USED

'Carburetor (Mixer) - Gas-

1

1
1
1 Nipple, Gas Regulator (5/16-18 x 5/8")
1
1

1 Washer, Lock (Spring) - 1/4"

Gasoline Sets - (Impco Gas-Gasoline Sets
#100M-4)

'Carburetor (Mixer), Gas Only - Gas-Gasoline Sets

Sets - (Impco #125-29)

Elbow, Gas Regulator -

(3/4"

(3/4 x
Regulator, Gas
Nipple (1/2 x
Bushing,

(3/4 x 1/")
Hose,

Adapter - Gas-Gasoline

Sets

Gas-Gasoline Sets

Valve,

Gas-Gasoline Sets

Switch,

PART

DESCRIPTION

x 90°)

1-3/8")

1-1/8")

Reducer -

Fuel Pump Inlet -

Toggle - Gas-Gasoline

REF.

NO.

15 308-0150
16

17 149-0638
18
19

20 149-0752

21 307-0836
22
23

23
24

24

PART

NO.

306-0155

800-0025
850-0045

503-0273 1
800-0026

800-0026
862-0015

862-0015
Forcomponentscontactyournearest Impco Dealeror

Impco Division, 16916 Gridley Place, Cerritos,

QTY.

USED

Plate,

1
1 Bracket, Switch Plate Mounting
1 Cover, Fuel Pump Hole ­2 Screw, Cap (Hexhead) ­4

1 Strainer, Fuel (1") ­1

2
2

Switch Mounting -

Gas Only Sets

Washer, Lock (Spring) - 5/16"

(2)

Fuel Pump Hole Cover

(2)

Switch Mounting Plate

Optional

Valve,

Optional

Line,

Fuel (Flexible -

1"

x 12") - Optional

Screw, Cap (Hexhead) -

#18x3/4" '

Nut, Hex - (5/16-18)

Nut, Hex - (5/16-18)

PART

DESCRIPTION

Solenoid (1" - 12-Volt) -

California 90701

45

GENERATOR

GROUP

^-Jj'<l>iil»-"'

23

72

40

J

39

73

4647

46

GENERATOR

GROUP

REF.

NO.

10 234-0368
11
12

13 232-2078 1 Disc, Generator Drive
14 234-0370 1
15 234-0361
16
17 526-0238
18

19 220-2353
20

21

22
23

24
25

26
27

28 800-0009 4
29

30 805-0018
31 212-0342

32
33
34

35

36

PART

NO.

•

1

2

205-0089 1 Blower
510-0101

3
4

*

5

515-0145 1 Key, Exciter Rotor -

150-1456

6

7 805-0033

150-0717

8
9 211-0185

232-2106
201-1739

509-0125
800-0513

232-2102
STUD,

GENERATOR THROUGH
520-0721 4 1 Phase Generator
520-0718 4 3 Phase Generator
305-0481 1 Spacer, Voltage Regulator Chassis

CHASSIS ASSEMBLY, VOLTAGE REGULATOR

(See Separate Group For Components) -

SPECATHROUGHE

305-0489
305-0491 1
800-0091

850-0060
402-0030
850-0040

338-0521

212-1105

214-0046
204-0083

212-1225
526-0018

QTY.

USEO

1 Rotor Assembly, Wound (Includes

1
1 Stator Assembly, Wound

1 Bracket and Contact Assembly -

8 Bolt, Place (5/8-11 x 1")
1
1

1

2

1 Rotor Assembly, Wound - Exciter

1 Wrapper, Generator End Bell
1
1 Washer, Bearing Retainer
1

1 Stator Assembly, Wound - Exciter

1

1
4
4

2
4

1
8

1

4
4

1

4
4

Collector Ring on Early Brush
Type Generators)

Bearing

Brushless Generator
iBegin Spec F (Includes

Parts Marked t)

Switch Assembly, Overspeed
Bell,

End
Screen,
Bracket, Generator Mounting

(See Separate Group for

Components) - Brushless Genen

Grille,

Generator Air Inlet

Seal,

"O" Ring - Bearing

Screw, Cap - Hex Head

(3/4-10 x

- Brushless Generator

Spacer, Bearing - Brushless Generator

Mounting

Brush Type Generator
Brushles Generator
Screw, Cap - Hex Head

(1/2-13 x

Washer, Lock - Spring (1/2")

Mount, Vibration - Generator End
Washer, Lock - Spring (1/4")
Screw, Cap - Hex Head

(1/4-20 x

Harness Assembly, Voltage

Regulator
Bolt, Place (3/8-16 x 1")
Rig Assembly, Brush - Includes

Brushes and Springs Brush

Type Generators

Spring,

Type Generator

Brush Brush Type

Generator

Ring,

Collector Brush

Type Generator

Spacer, Brush Rig Mounting -

Early Brush Type Generators

Washer, Brush Rig Mounting -

Early Brush Type Generators

PART

DESCRIPTION

Generator

1-1/2")

1-1/4")

1-1/2")

Brush Brush

REF.

NO.

37
38
39
40
41

42

43
44 862-0001

45
46

47
48

49 150-0723 1
50

51
52
53
54

55 850-0050 4
56

57 526-0018

58
59

60
61
62 812-0189

63
64

65
66

67
68
69

70
71

72 850-0040
73

* - Order by description giving complete Model, Spec and

t - Included in 150-1456 Bracket and Contact Assembly.

PART

NO.

503-0611
231-0149
232-2210
232-2211
516-0152

508-0001
800-0008

850-0040
853-0013

800-0003
850-0040
870-0250 1

862-0001
853-0013 1
150-1356
862-0011 4

800-0009

850-0040

114-0023

850-0079
856-0010 1

850-0055
800-0072 9

812-0146
850-0040

800-0520
800-0071
850-0055

800-0051 8
850-0050
862-0001

Serial Number,

QTY.

USED

Hose,

4

1
2
2
2

1

2

2
2
4

2
2

2

1

2

4

4

4

1

1

9

4

4
2

4
4

8
2

2

Insulator
Adapter, Generator
Cover, Adapter Slot
Catch,

Adapter Slot.Cover . .

Pin,

Generator Adapter

Alignment

Grommet, Rubber - Generator

Adapter

Screw, Cap - Hex Head

(1/4-20 x

Nut, Hex (1/4-20)
Washer, Lock - Spring (1/4")
Washer, Lock - ET (1/4")

- Spec B through F

Screw, Cap - Hex Head

(1/4-20 x 1/2")

Washer, Lock - Spring (1/4")

fPoint, Overspeed Switch
fNut, Insulation - Overspeed

Switch
fNut, Hex (1/4-20)
tWasher, Lock - ET (1/4")
fBracket, Overspeed Switch

Nut, Hex - Machine (3/8-16)
Washer, Lock - Spring (3/8")
Screw, Cap - Hex Head

(1/4-20 x
Spec B through F

Washer, Flat (17/64" I.D. x

5/8" O.D. x 1/16" Thick)­Brush Type Generators

Washer, Lock - Spring (1/4")

- Brush Type Generator

Screw, Cap - Hex Head

(1/4-20 x

Brush Type Generator
Washer, Lock - Spring (3/4")
Washer, Lock EIT (3/8")
Screw, Machine - Round Head

(3/8-16 x 3/4")
Washer, Lock - Spring (7/16")
Screw, Cap - Hex Head

(7/16-14 x

Screw, Machine - Round Head

(1/4-20 x 3/8")
Washer, Lock - Spring (1/4")
Screw, Cap - Hex Head

(3/4-10 x 1")
Screw, Cap - Hex Head

(7/16-14 x 1")
Washer, Lock - Spring (7/16")
Screw, Cap - Hex Head

(3/8-16 x

Washer, Lock - Spring (3/8")
Washer, Lock - Spring (1/4")

Nut, Hex (1/4-20)

PART

DESCRIPTION

1-1/4")

1-1/2")

-

1-1/4")

-

1-1/4")

1-1/4")

47

22

VOLTAGE REGULATOR GROUP

14-15-16-17

- SPEC A THROUGH E

7-8

18-19-20 14-15-16-17

48

VOLTAGE

REGULATOR GROUP-SPEC A THROUGH

E

REF.

NO. NO.

10
11 871-0010 3 'tNut,
12 526-0009 3 'tWasher, Flat (7/32"

13 850-0030 3 'tWasher, Lock - Spring - Rectifier 32 862-0001 2
14 812-0079 2 'tScrew, Machine - Roundhead

15 526-0048 2
16 853-0005 2

PART

CHASSIS ASSEMBLY, VOLTAGE REGULATOR

(Complete) Heat Sink (#8-32)

305-0491 Brushless Generator (Includes 18 812-0079 1 "tScrew, Machine Roundhead
305-0489

1

305-0482
358-0029 1 "tRectifier, Silicon

2

RECTIFIER, SILICON CONTROLLED 20 871-0007 1 'tNut,

3

364-0014
364-0012 2

RECTIFIER,SILICON

4

358-0035

358-0031
5 363-0048
6 332-1265
7

812-0077
8 853-0005
9 812-0077 6 "tScrew, Machine Roundhead

853-0005 6 'tWasher, Lock

'

QTY.

USED

1 Brush Type Generator (Includes
1 'fChassis, Voltage Regulator

2 'Brushless Generator

2 'BrushlessGeneratorfCRI &CR2)
2 tBrush Type Generator (CRI &CR2)
3 'tHeat Sink, Rectifier
6 'tlnsulator, Stand
6

6

Parts Marked
Parts Marked

tBrush Type Generator

'tScrew, Roundhead - Heat Sink 25 853-0005 2 'tWasher, Lock

Mtg.

'tWasher, Lock

Sink
Stand

(#8-32 x-3/8") 315-0341 1

Stand

Hex -

(CRI,

x

1/16"

(CRI,
Mtg.
Rectifier Lead

(#8-32

'tWasher, Flat (Brass)

x

3/8" O.D. x 1/32"

'tWasher, Lock

Lead

Lead

PART

DESCRIPTION

')
t)

(CR3)

(Q4 & Q5)

(Q4 & Q5)

off

(8-32 x 3/8")

- ET -

Mtg. (#8)

off

Insulator

off

Insulator

Rectifier Mounting 29 853-0005 2

CR2 & CR3)

Thick) - Rectifier

CR2 &

(CRI,

x 1/2")

to

Heat Sink

to

Heat Sink

Heat 26 860-0008 2

-

Mtg.

- ET
Mtg. (#8)

(#10-32)

I D.

xl/2"

O.D.

CRS)

CR2 &

to

Heat Sink Contact Point

- ET -

Mtg.

CRS)

(#10)

(.172"

I.D.

Thick)

Rectifier

(#8)

(#8)

-

REF.

NO.

17 871-0007

19 853-0005 1 'tWasher, Lock

21 508-0002 2 'fGrommet, Rubber
22 332-1415 1 'tClamp, Cable
23 332-1266 1 'tBIock, Terminal
24 812-0081 2

27 REACTOR ASSEMBLY, COMMUTATOR

28 812-0077 2

30
31 150-0723 1

33 853-0013 1 'tWasher, Lock
34 870-0250 2
35 332-1043 2 'tJumper - Terminal Block

' - Parts included in 305-0491 Voltage Regulator.

t - Parts included

PART

NO.

''

-'j •

315-0343 1

860-0008 2

QTY.

USED DESCRIPTION

in

305-0489 Voltage Regulator.

2

'tNut,

Hex -

Rectifier Lead

Terminal-Block Lead

Heatsink (#8-32

Terminal Block
Sink

Hex -

to Heat Sink (#8-32)

"tScrew Machine - Roundhead

Terminal Block Mounting
(#8-32

Block Mounting

'tNut,

Hex -

Mounting (#8-32)

"Brushless Generator
tBrush Type Generator

"tScrew, Machine - Roundhead

Reactor Mtg. (#8-32

'tWasher, Lock

Reactor Mounting

'tNut,

Hex -

'tPoint, Contact - Overspeed

Switch

'tNut,

Hex -

(1/4-20)

'tNut, Insulator - Contact Point

(1/4)

- ET -

(#8)

Terminal Block Lead

x 5/8")

- ET -

Terminal Block"

- ET -

Reactor

Contact Point

- ET

PART

to

to

x 1/2")

to

Heat

Terminal

(#B) • .

x 3/8")

(#8)

Mtg.

(#8-32)

(1/4)

-

-

-

49

MOUNTING AND

HOUSING

GROUP

22

40

50

REF.

NO. NO.

3 405-1780 1
4 403-0895 .2
5 405-1808 4
6 406-0105 8

7 405-1809 1
8

9 406-0157 1

10 406-0089 1
11 405-1812 1
12 821-0014 As Req.

13 405-1811 1
14 405-1409 1

15 403-0903 1
16 403-0904 1
17 416-0612 1

18 520-0663 2
19 405-1814 2 Support, Housing Center

20 337-0090 1
21 508-0001 1

22 402-0338 1

23
24
25
26
27
28
29

30 801-0080
31 301-3155

32 PANEL, CONTROL BOX HOUSING

33 301-3154
34 CABLE, BATTERY

PART

1

403-0902

2 403-0894 1

405-1777

870-0068
402-0337
402-0010
402-0012
402-

0011

403-

0633

526-0141

1

301-3156
301-3156

301-3156

416-0049
416-061.3

1
1

QTY.

USED

1

1
1
1
1
1
1
1

1

1

PART

DESCRIPTION

1

Chassis, Front
Chassis, Rear - Housed Sets
Panel,

Rear Housing Access

Housed Sets

Cover, Conduit Opening

Housed Sets

Panel,

Side Door - Housed

Sets

Clamp, Door - Housed Sets

"Panel,

Top -

Panel,

Housed Sets

Handle, Door (Includes

Keys) - Housed Sets
Catch,
Panel,

Screw,

(5/16-18
Panel,

Cooled Sets

Extension,

Unhoused Radiator Cooled

Sets

Trim,

Unhoused Sets

Trim,

Unhoused Sets

Frame, Battery Hold-down

Stud,

Housed Sets
Strap,
Grommet, Rubber - Control

Box Housing

Housed Sets)
Mounting Assembly, Engine

End - (Includes Parts 57 800-0091 1

Marked

"Nut, Huglock (7/16-20)
"Spacer, Engine Mount
"Mount, Rubber (Front)
."Cup, Metal
"Mount, Rubber (Lower)
"Spacer, Mount
"Washer, Flat (15/32"

1-1/4"

"Screw,

(7/16-20 x 3-1/2"

Housing, Control

Unhoused Sets

Unhoused Sets
Housed Sets - (Also Unhoused

Sets With Circuit Breaker)

Housed Sets With Circuit

Breaker

Saddle, Control

Housing - Unhoused Sets

14-1/2"

. 10" long

Housed Sets

Rear Door

Door - Housed Sets 43 821-0010 As Req.

Rear - Housed Sets

Cap

Front - Radiator

Right Hand Chassis
Left Hand Chassis

Battery Hold-down

Ground

*)

OD x 1/8"

Cap

long

-

(Locking Head)

x 1/2")

Radiator Hood

(2

used

ID x

THK)

(Hexhead)

Ig)

Box-

Box

MOUNTING AND

-

-

-

on

HOUSING

REF.

NO

35 416-0667

-

-

-

-

-

36 301-3191 1

-

37

38 406-0002
39
40

41 301-3196 1
42 234-0369 1

44
45

46
47

48
49

50
51

52 526-0018
53
54

55
56

58 856-0013
59 800-0071

60 856-0012

61 813-0098 22
62 850-0030
63 870-0053 16 Nut,
64 815-0026
65 853-0018

66 526-0115' -

67 850-0045 .2 Washer, Lock (Spring) - 5/16"

68 865-0007 2

GROUP

PART

NO.

416-0096

406-0335

301-3195

821-0016 4
809-0059 3
870-0106

800-0048 6
850-0050
870-0113

870-0020 6
800-0003 4

850-0040
862-0001

850-0060
862-0016

•

- Parts Included in 402-0338 Engine Mounting Assembly.

QTY.

USED

1

Tray, Battery
Junction Box, Output

4

•1
2
1

As Req.

3

6

As Req.

8
4
4

3
3

22

18 Screw, Machine (Trusshead)
18 Washer, Lock (External)

2 .

Housed Sets

Clamp, Battery Cable

Knob,

Door - Housed Sets

(Used

Catch,

Door - Housed Sets

(Used

Plate,

Junction

Bottom - Housed Sets

Bracket, Junction

Housed Sets

Cover,

End

Sets

Screw,

Cap

1/4-20

Screw,

Cap

5/16-18 x 3/4" - Housed Sets

Screw, Tapping (Pan Head)

#14

x 1/2" -

Nut, Speed - #14

Screw,

Cap

3/8-16 x 3/4" - Housed Sets

Washer, Lock (Spring)

3/8" - Housed Sets

Nut, Retainer - (5/16-18)
Nut, Weld - (5/16-18)
Screw,

Cap

1/4-20

Washer, Flat (17/64"

5/8"

OD x

Washer, Lock (Spring)

1/4"

Nut,

Hex
Washer, Lock (Spring)
Nut,

Hex ­Screw,

Cap

Ground Strap (1/2-13 x 1-1/4")

Washer, Lock (External/

Internal)

Screw,

Cap

Ground Strap (7/16-14

Washer, Lock (External/

Internal) - 7/16" Ground

Strap

Screw, Machine (Roundhead)

(10-32

Washer, Lock (Spring)

#10 - Housed Sets

Hex

Sets

(10-32

Washer, Flat (11/32"

11/16"

Nut, Wing - Battery Hold-

down (5/16-18)

PART

DESCRIPTION

-

on

Some Early Models)

on

Some Early Models)

Box

Box -

Bell - Housed

(Self Locking)

x 1/2"

(Self Locking)

Housed Sets

(Hexhead)

(Hexhead)

x 1/2"

1/16" THK)

(1/4-20)

(1/2-13)

(Hexhead)

- 1/2"
(Hexhead)

x 3/8")

(10-32) - Housed

x 3/8")

OD x 1/16"

-

-

-

ID x

-

- 1/2"

-

-

-

- #10

ID x

THK)

•'• '

-

-

-

x 1")

-

-

51

CONTROL

GROUP (ENGINE INSTRUMENTS PORTION)

52

REF.

NO.

10
11

12 307-1058
13 307-1031
14

15
16

17

PART

NO.

PANEL ONLY, ENGINE
301-3165
301-3267

2

301­3
4
5
6
7
8

9

3253
308-0138
308-0002
193-0107
193-0106

302-

0061
332-1239

332-1241
308-0003
332-1276

322-0073
322-0074
LAMP,

FAULT
322-0128
322-0107
322-0111
322-0108
322-0109

322-0110
CONTROL, CRANKER

300-0733 1
300-0714 1

CONTROL

QTY.

USED

CONTROL

Sets With One Fault Light
Sets With Five Fault Lights

- Optional

Bracket, Engine Control
Switch,
Switch,
Gauge, Oil Pressure
Gauge, Water Temperature
Ammeter, Charge (30-0-30)
Strip,

Ground Alarm)
Strip,
Plate,
Plug,

Five Fault Lights Use

Quantity of 1)

Relay (1) Start-Disconnect,

(1)
Relay, Start Solenoid

(Mounted in Chassis)
Holder, Lamp
Lamp,

Standard Sets
Overcrank (Optional)
Overspeed (Optional)
Low Oil Pressure (Optional)

High Engine Temperature

(Optional)

Low Engine Temperature

(Optional)
Standard Cranker

Cycle Cranker (Optional) -

See Separate Group for

Components

GROUP

PART

DESCRIPTION

Selector
Panel Light

Marker (B+, Remote,
Marker (21 through 36)

Switch (On-Off)

Keying (Sets With

Ignition

Panel

(ENGINE INSTRUMENT PORTION)

/

REF.

NO.

18

19

20
21
22

23

24

25

26

27
28
29
30

31 307-1061
32 332-0699
33 332-1240
34 312-0148
35 85.0-0040

36
37

PART QTY. PART

NO.
MONITOR, ENGINE CONTROL (See Separate
Group for Components)
300-0679 1 Sets With One Fault Light -

300-0681 1 Sets With Five Fault Lights
HARNESS ASSEMBLY, WIRING - CONTROL

(Includes Parts Marked *)
338-0527

338-0535
332-0537

332-0795
323-0765
332-1271

332-0051
338-0533

357-0004

323-0764
332-1269
332-1280
332-1043

862-0001
307-1157

USED DESCRIPTION

Standard

. • -Optional-•

Sets With One Fault Light

1

As Req. 'Terminal, PC Board
As Req. "Terminal, Crimp

1

2
3

- Standard

Sets With Five Fault Lights

- Optional
'Block, Terminal - 4 Place
'Block, Terminal - 16 Place

•Socket, Relay - 11 Place
"Housing,

Clip,
Harness Assembly, Wiring -

Rectifier, Diode (Part of

"Socket, Relay - 8 Place

"Jumper, Terminal - Sets

Relay, Starter Protection ­"Block, Terminal (6 Place) ­"Strip,

Screw, Cap (Roundhead) ­Washer, Lock (Spring) ­Nut, Hex - (1/4-20)

Spring,

Printed Circuit

Board Terminal

Tinnerman
Engine to Control •.' " v .
Standard Cranker Control)

With One Fault Light
Begin Spec D
Sets With Five Fault Lights

Marker (53 through 58)

Sets With Five Fault Lights
(1/4-20x1/2")
(1/4")

Relay Hold-down

* - Included in Wiring Harness Assembly.

53

CONTROL GROUP (AC OUTPUT PORTION)

46

54

CONTROL

REF.

NO. NO.

3 402-0078 4
4 337-0049 1

5

6 320-0307 1
7 STRIP, MARKER 302-0253 3 25.0EK-515R, 30.0EK-15R,

8 315-0342 1
9

10 303-0170 1
11 303-0032 1
12

13 303-0076 1
14 VOLTMETER 28

15 METER, RUNNING TIME

16 METER, FREQUENCY 34 322-0130 1 Light, Lower Scale -

17 AMMETER, AC (Sets With MeterPanel) 35 322-0131 1

PART

1 301-3158 1
2 PANEL ONLY, CONTROL 302-0209 2

301-3167 1

301-3168 1

301-3341 1 30.0EK-9XR & 45.0EM-9XR 19 302-0729 1

301-3169 1 25.0EK-53R, 30.0EK-3R,

301-3170 1

301-3342 1 30.0EK-9XR & 45.0EM-9XR 21

BREAKER, CIRCUIT

320-0002 1
320-0018 1
320-0431 1

332-1248 1
332-1242 1 Sets With Meter Panel

REACTOR, COMMUTATOR (Begin Spec F)
315-0384 1
315-0343 1 Without Leads and Terminals

SWITCH,
308-0012 1
308-0284 1 Sets With Meter Panel 26 854-0010 2

302-0421 1

302-0718 1

302-0779 1

302-0469
302-0466 1

302-0256 1 50 Hertz Sets
302-0221 1

302-0412 2 25.0EK-53R, 30.0EK-3R,

302-0719 1
302-0720 1 45.0EM-15R Sets 332-1264 1

302-0405 1 30.0EK-9XR Sets
302-0406 1

QTY.

USED DESCRIPTION

Box Only, Control

Sets Without Meter Panel

25.0EK-53R, 30.0EK-3R,

37.5EM-53R & 45.0EM-3R
Sets

25.0EK-515R, 30.0EK-15R,

37.5EM-515R & 45.0EM-15R
Sets

Sets 20

Sets With Meter Panel

37.5EM-53R & 45.0EM-3R
Sets

25.0EK-515R, 30.0EK-15R,

37.5EM-515R & 45.0EM-15R
Sets

Sets 302-0236 2

Rubber, Mounting - Control

Box

Strap,

Ground

Brush Type Generator

Key 1

Key 2
Brushless Generator
Lock, Circuit Breaker

Handle (Penn State)
Sets Without Meter Panel
Transformer, Voltage
With Leads and Terminals
Rheostat

Knob,

SELECTOR 25

1 50 Hertz Sets Sets

Rheostat
Sets Without Meter Panel
Knob,

Selector Switch 27

25.0EK-53R, 30.0EK-3R,

37.5EM-3R and 45.0EM-3R
Sets 30 508-0001 4

25.0EK-515R, 30.0EK-15R,

37.5EM-515R & 45.0EM-15R 25.0EK-515R, 30.0EK-15R,
Sets

30.0EK-9XR & 45.0EM-9XR Sets
Sets

Sets With Meter Panel

60 Hertz Sets

Sets With Meter Panel

60 Hertz Sets Sets

37.5EM-53R & 45.0EM-3R
Sets

25.0EK-515R, 30.0EK-15R
& 37.5EM-515R Sets

45.0EM-9XR Sets

GROUP

PART

(AC OUTPUT PORTION)

REF.

PART

NO.

NO.

18

TRANSFORMER, CURRENT

302-0079 3
302-0106 3

302-0117
302-0076 3

CLAMP, TRANSFORMER MOUNTING - UPPER

302-0235 2

302-0235 3

CLAMP, TRANSFORMER MOUNTING - LOWER

302-0236

22

SHIM,

TRANSFORMER MOUNTING

302-0253 2

23 •

813-0110

24

854-0010 6
815-0203 1 ••

871-0010 3
526-0049

29

856-0003

31 301-3244

32 307-1061 1

33 307-1157 1

36

BOARD ASSEMBLY, PRINTED CIRCUIT
(See Separate Group for Components)

332-1268 1

37

406-0332 "

QTY.

USED

3

3

6

2
1

1

,,"2

PART

DESCRIPTION

25.0EK-53R, 30.0EK-3R,

37.5EM-53R & 45.0EM-3R
Sets

25.0EK-515R, 30.0EK-15R- '•
& 37.5EM-515R Sets

45.0EM-15R Sets

30.0EK-9XR Sets

45.0EM-9XR Sets

Bracket, Transformer Mounting

25.0EK-53R, 30.0EK-3R,

37.5EM-53R & 45.0EM-3R
Sets

25.0EK-515R, 30.0EK-15R,

37.5EM-515R, 45.0EM-15R,

30.0EK-9XR & 45.0EM-9XR
Sets

25.0EK-53R, 30.0EK-3R,

37.5EM-53R & 45.0EM-3R
Sets

25.0EK-515R, 30.0EK-3R,

37.5EM-515R, 45.0EM-15R,

30.0EK-9XR & 45.0EM-9XR

Sets

25.0EK-53R, 30.0EK-3R,

37.5EM-53R & 45.0EM-3R
Sets

37.5EM-515R, 45.0EM-15R,

30.0EK-9XR & 45.0EK-9XR
Sets

Screw, Roundhead Machine -

Transformer Mounting
(10-32 x 2")

Washer, Internal Lock -

Transformer Mounting (#10)

Screw, Roundhead

(10-32 x 7/8")
Washer, Internal Lock (#10)
Nut, Hex (10-32)

Washer, Flat
Washer, External/Internal

Lock
Grommet, Rubber
Bracket, Relay Mounting -

37.5EM-515R & 45.0EM-15R

Relay, Voltage Selector -

25.0EK-515R, 30.0EK-15R,

37.5EM-515R &45.0EM-15R

Spring,

Relay Hold-down

25.0EK-515R, 30.0EK-15R,

37.5EM-515R & 45.0EM-15R

Light, Upper Scale -

25.0EK-515R, 30.0EK-15R,

37.5EM-515R & 45.0EM-15R
Sets

Brush Type Generator
Brushless Generator
Fastener

- •

•' • • >'

'•'

55

NOTE:

The 332-1264 Printed Circuit Board Assembly is
no longer available—order 332-1268 Printed Circuit
Board Assembly.

CONTROL

REF.

NO.

38
39
40
41

42
43

44
45

46 305-0524

GROUP

PART

NO.

406-0333
406-0334
332-0050

HARNESS, WIRING - AC CONTROL (Includes Parts

Marked *) SETS WITHOUT METER PANEL
338-0765
338-0764

338-0766
SETS WITH METER PANEL
338-0735
338-

0730

339-

0759

350-0556

323-0764
332-1280 As Req.

BLOCK, TERMINAL
332-0607

332-0795

(AC

2
2

2

1

1
1

1
1

OUTPUT PORTION)

QTY.

USEO

Stud, Fastener
Washer, Stud Fastener
Clip, Tinnerman

30.0EK-3R & 45.0EM-3R

25.0EK-515R, 30.0EK-15R,

30.0EK-9XR & 45.0EM-9XR

PART

DESCRIPTION

37.5EM-515R & 45.0EM-15R

30.0EK-3R & 45.0EM-3R

25.0EK-515R, 30.0EK-15R,

37.5EM-515R, 45.0EM-15R

30.0EK-9XR & 45.0EM-9XR
Resistor (47,000-Ohm,

1/2

Watt)

Socket, Relay

Terminal,

Sets Without Meter Panel
Sets With Meter Panel
Bridge, Rectifier (Begin

Crimp

(12 Place)
(16 Place)

Spec

F)

CRANKER

(Optional

REF.

NO.

Cl
C2 355-0010 1 Capacitor, Plastic Dielectric
CRI

CR2
CR3
CR4

HI 812-0061 2 Screw, Machine, Round

H2
H3
Ql
Q2
Q3 362-0017 1
Q4 362-0026 1
Q5

Rl
R2

R3 350-0548 1 Resistor, Composition
R4

R5
R6 350-0420 1
R7
R8 350-0520 1 Resistor, Composition
R9

R10 350-0500 1 Resistor, Composition

Rll 352-0152 1 Resistor, Wirewound

TBI

PART QTY.

NO.

300-0714
356-0039 1

359-0027 1
357-0004
357-0004 1 Diode, Rectifier (400
357-0004 ' • 1

853-0003 2 Washer, Lock - External Tooth
860-0006
362-0008 1
362-0008 1

362-0019
303-0171 1

350-0560 1

303-0171 1

350-0558

350-0546

350-0548

332-1275

USED

Control,
Capacitor, Electrolytic

Diode, Zener

Diode, Rectifier (400

1

Diode, Rectifier

2'

Nut,
Transistor
Transistor
Transistor

•

Transistor

1

Transistor
Potentiometer (100,000-Ohm,

Resistor, Composition

Potentiometer (100,000-Ohm,

1

Resistor, Composition

Resistor, Composition

1

Resistor, Composition

1

Resistor, Composition

Printed Wiring Board

1

DESCRIPTION

Cranker Cycle

12 Volt
(100 Mfd,
(.0022

Mfd,

Head (#6-32

Hex

(#6-32)

(0.1 Megohm,
(10,000-Ohm,

(68,000-Ohm,
(24,000-Ohm,
(6800-Ohm,
(47-Ohm,
(10,000-Ohm,
(1-Ohm,
(25-Ohm, 5 Watt,

1/2

CYCLE

Equipment)

PART

10

Volt)

100

VDC,

MA, 400
MA, 400

(400 MA, 400

x 3/8")

1/2

Watt,

1/2

Watt,

•

1/2

Watt,

1/2

Watt,

1/2

Watt,

1/2

Watt,

5%)

1/2

Watt,

Watt,

10%)

5%)

-

10%)

10%)

10%)

10%)
5%)

10%)

10%)

CONTROL

Volt)
Volt)

Volt)

(#6)

1/4

Watt)

1/4

Watt)

GROUP

- 12

VOLT

/

// s

lH

II

'

j \ riS tf3-^

I:,1!

W-v-ta

ii

i
11

56

EXCITER

ROTOR

GROUP

(BRUSHLESS

GENERATOR)

REF.

NO.

10
11
12 508-0156

PART

NO.

201-1739

1 363-0055

358-0015

2

363-0054

3
4 358-0016 3

850-0030

5

870-0053

6

7 508-0093

332-0050 2

8

813-0110

9

526-0009
508-0124

13 850-0030
14 870-0053

QTY.

USED

1

1

3

1

6
6

2
4
4
4
4

4
4

57

PART

DESCRIPTION

Rotor Assembly, Wound - Exciter

(Complete)
Heat Sink, Rectifier - Negative
Rectifier, Diode - Negative

(CR4,

CRS & CR6)
Heat Sink, Rectifier - Positive
Rectifier, Diode - Positive

(CRI,

CR2 & CR3)
Washer, Lock Spring (#10)

Diode Mounting
Nut, Hex - Diode Mounting (10-32)
Grommet, Rubber
Clip,

Wire

Screw, Roundhead - Heat Sink

Mounting (10-32 x 2")
Washer, Flat - Heat Sink

Mounting (#10)

Bushing,
Washer, Insulating - Heat Sink
Washer, Lock Spring - Heat Sink
Nut, Hex - Heat Sink Mtg. (10-32)

Insulating - Heat Sink

Mounting

Mounting
Mounting (#10)

PRINTED

CIRCUIT

BOARD

ASSEMBLY

GROUP

(AC)

332-1264

R22 R20 R22 R20

- Printed

Circuit

Board,

Complete

BRUSH

TYPE

GENERATOR

—• /

—^ ——J

C7 ^ ^^p-^

RS

—*

CIO

REF.

NO.

TBI 332-1252
Cl
C2,

C7 355-0005

C3,

C9
C4 355-0006
C5,

C8 355-0016

C6 355-0015
CIO
C13 356-0039
CR4 thru 11 357-0014
CR12 359-0035
CR13 359-0025
CR14 359-0026
CR15 359-0015
Kl 307-1063
Ql,

Q2

Q3

Rl,

R23 350-0355

R2,

R3 350-0351

R4
R5 353-0040

PART

NO.

355-0018
355-0017

355-0014

362-0017
361-0004

350-1075

rJ-i

CR7

QTY. PART

USED DESCRIPTION

1 Terminal Block

1 Capacitor (.47 Mfd., 100 Volt)
2 Capacitor (.22 Mfd., 200 Volt)
2 Capacitor (.47 Mfd., 400 Volt)

1 Capacitor (.47 Mfd., 200 Volt)

2 Capacitor (1 Mfd., 100 Volt)

1 Capacitor (.1 Mfd., 200 Volt)

1 Capacitor (.047 Mfd., 200 Volt)

1 Capacitor (100 Mfd., 10 Volt)

8 Rectifier, Silicon

1 Diode, Zener (6.8 Volt)

1 Diode, Zener (20 Volt)

1 Diode, Zener (18 Volt)

1 Diode, Zener (24 Volt)
1 Relay, Magnetic Reed

2 Transistor, Silicon (NPN)

1 Transistor, Unijunction
2 Resistor (47-Ohm, 1/2 Watt)
2 Resistor (33-Ohm, 1/2 Watt)

1 Resistor (4.7-Megohm, 2 Watt)

1 Resistor, Fixed (270-Ohm,

10 Watt)

REF.

NO.
R6 353-0039 1

R7

R8,

R16 350-0447 2

R9,

R10

R11
R12

R13
R14

R15

R17

R18
R20,

R22
R21
R24

PART

NO.

350-0398
350-0423 2

352-0151 1
350-1014

350-1007
350-0443 1
350-0435 1
351-0524

303-0168 1
351-0520 2

351-0522 1
351-0523

QTY.

USED

PART

DESCRIPTION

Resistor, Fixed (5,000-Ohm,

15 Watt)

1

Resistor (3,000-Ohm, 1/2 Watt)
Resistor (330,000-Ohm, 1/2 Watt)
Resistor (33,000-Ohm, 1/2 Watt)
Resistor, Fixed (15,000-Ohm,

5 Watt)

1

Resistor (13,000-Ohm, 2 Watt)

1

Resistor (6,800-Ohm, 2 Watt)
Resistor (220,000-Ohm, 2 Watt)
Resistor (100,000-Ohm, 1/2 Watt)

1

Resistor, Metal Film

(13,000-Ohm, 1/4 Watt)
Potentiometer
Resistor, Metal Film

(28,000-Ohm, 1/4 Watt)
Resistor, Metal Film

(5,110-Ohm, 1/4 Watt)

1

Resistor, Metal Film

(8,870-Ohm, 1/4 Watt)

58

PRINTED

332-1268 - Printed Circuit Board, Complete

CIRCUIT

BOARD

ASSEMBLY

/

\

XI

r

GROUP

-I

ru

mi

t

(AC,

r

\

\ \

Hi

——

V-X.

- — —•

V J

\

\

\ .

J

/

\

1

\

1

\

1

\ \ 1

t

i ^I—J '/tn on I—

T 7XTT ^.

\

\

-f—V

^ /

I

i.

REF.

NO.

TBI
Cl
C2,

C7

C3,

C9

C4,

C12

C5,

C8
C6
CIO
Cll
C13
CR4 thru 11
CR12
CR13

CR14 359-0026

CR15

Kl

Ql,

Q2
Q3 .
Rl,

R23

R2,

R3
R4 350-1075 1
R5

PART

NO.
332-1252
355-0018 1

355-0005 2
355-0017 2
355-0006 2
355-0016
355-0015 1
355-0014
355-0020
356-0039
357-0014 8
359-0016
359-0025 1

359-0015
307-1063
362-0017 . 2
361-0004
350-0355 2
350-0351

353-0040 1

QTY.

USEO

\ \\ \ \ \ >

V L ^

PART

DESCRIPTION

Terminal Block

1

Capacitor (.47 Mfd., 100 Volt)
Capacitor (.22 Mfd., 200 Volt)
Capacitor (.47 Mfd., 400 Volt)
Capacitor (.47 Mfd., 200 Volt)

Capacitor (1 Mfd., 100 Volt)

2

Capacitor (.1 Mfd., 200 Volt)
Capacitor (.047 Mfd., 200 Volt)

1

Capacitor (.1 Mfd., 400 Volt)

1

Capacitor (100 Mfd., 10 Volt)

1

Rectifier, Silicon
Diode, Zener (6.8 Volt)

1

Diode, Zener (20 Volt)
Diode, Zener (18 Volt)

1

Diode, Zener (24 Volt)

1

Relay, Magnetic Reed

1

Transistor, Silicon (NPN)
Transistor, Unijunction

1

Resistor (47-Ohm, 1/2 Watt)
Resistor (33-Ohm, 1/2 Watt)

2

Resistor (4.7 Megohm, 2 Watt)
Resistor, Fixed (270-Ohm,

10 Watt)

V

H

% \ / /

t

REF.

NO.
R6

R7
R8,

R16

R9,

R10

R11 R12
R13

R14 350-0443
R15,

R27

R17
R18

R20,

R22

R20,

R22
R21
R24
R25 350-1011

R26
R28

io

II

it

PART

NO.

353-0039 1
350-0398

350-0447 2
350-0423

352-0151
350-1007 1 Resistor (6,800-Ohm, 2 Watt)
350-0435

351-0521
303-0168

351-0520

351-0522 1

351-0523

303-0164

350-0459

517-0127

QTY

USED DESCRIPTION

Resistor, Fixed (5,000-Ohm,

15 Watt)

Resistor (3,000-Ohm, 1/2 Watt)

1

Resistor (330,000-Ohm, 1/2 Watt)
Resistor (33,000-Ohm, 1/2 Watt)

2

Resistor, Fixed (15,000-

2

Ohm,

5 Watt)

1 Resistor (220,000-Ohm, 2 Watt)

Resistor (100,000-Ohm, 1/2 Watt)

2

Resistor, Metal Film

1

(12,100 Ohm, 1/4 Watt)

1 Potentiometer

Resistor, Metal Film

2

(28,000-Ohm, 1/4 Watt)

Resistor, Metal Film

. (5,110-Ohm, 1/4 Watt)

Resistor, Metal Film

1

(8,870-Ohm, i/4 Watt)

Resistor (10,000-Ohm, 2 Watt)

1
1 Potentiometer

Resistor (1.0 Megohm, 1 Watt)

1

Cover, Potentiometer

2

(Not Illustrated)

PART

59

159-0967

MOUNTED

FUEL

TANK

ASSEMBLY

60

REF.

NO.

10 504-0007 1
11 501-0011
12 504-0004
13 505-0274
14 307-0565
15
16

17

PART

NO.

159-0490

1

159-0489

2

159-0512

3
4

159-0751

812-0150

5

850-0040 10

6
7 812-0158

505-0057

9

502-0020
502-0082
502-0002

QTY.

USED

1 Tank, Fuel (20 Gal.)

Strap Assembly, Fuel Tank

1
1 Cap & Indicator Assembly
1 Gasket, Fuel Tank Filler

8

2 Screw (1/4-20 x 2") -

1
1

1 Valve
1
1
1
1 Nipple, Hex
1 Elbow, Inverted

Neck

Screw (1/4-20 x 5/8") -

Roundhead Sheet Metal

Washer, Lock (1/4)

Roundhead Sheet Metal

Plug,

Pipe (1/8)
Valve,
Line,

Fuel (52") - Flexible

Plug,

Hex (1/8)
Valve,

Elbow, Inverted

PART

DESCRIPTION

Shut-off

Fuel Solenoid

179-0216

CITY

WATER

COOLING

^

ENG.

^

INLET

INSTALLATION — UNHOUSED (OPTIONAL)

WATER,

* V tf?)

REF.

NO. NO.

10 503-0189
11 1

12
13
14
15

PART

1 504-0003
2

110-0526

800-0007

3
4 850-0040
5

862-0001

6 307-0833 1
7 505-0100 3

505-0040 1

8
9 505-0185

505-0108
110-0576
503-0365

QTY.

USED

1

1
2
2
2

2

2

2

1

4

2

PART

DESCRIPTION

Valve,

Drain
Nipple & Bracket Assembly
Screw (1/4-20 x 1")
Washer, Lock (1/4")
Nut, Hex (1/4-20)
Valve,

Water •
Nipple, Close (1/2")
Elbow (1/2 x 90°)
Nipple, Half (1/2 x
Clamp, Hose
Hose,

Water (Order 11" of

Bulk Hose #503-0191)
Tee (1/2)
Adapter, Hose
Clamp, Hose
Hose,

Water (Order 3" of

Bulk Hose #503-0356)

1-1/2)

61

REF.

NO.

16 .505-0018
IT-

IS
19 503-0032

20
21 505-0166 1 Tee (3/4)

22
23
24 505-0132 1 Elbow (3/4 x 90°)
25
26
27 800-0069
28
29
30 130-0499

PART

NO.

505-0010

505-0020

110-1543
505-0102

505-0324 1 Nipple, Half (3/4 x 2")
850-0055 2 Washer, Lock (7/16)

130-0782
504-0019

QTY.

USED

Bushing,

2

2 Nipple, Half (1/4 x 1")
1

Hose,

2 Clamp, Hose
1

Bushing,

1 Adapter
2 Nipple, Close (3/4)

2 Screw (7/16-14 x 3/4)
1

Guard,
1 Valve
1 Bracket, Heat Exchanger

DESCRIPTION

Reducer

(1/2 x 1/4)

Water (Order 30" of

Bulk Hose #503-0110)

Reducer

(3/4 x 1/4)

Belt

PART

179-0218

WATER JACKET HEATER

NOTE:

REMOVE REAR

BLOCK AMD INSTALL HEATER ELEMENT

FREEZE

INSTALLATION (OPTIONAL)

PLUS

IN

ENGINE

REF.

PART QTY. PART

NO.

NO. USED DESCRIPTION

2 333-0118 1 Kit, Engine Heater
3 309-0106 1 Thermostat
4 333-0012 1 Box, Thermostat
5 520-0446 2 Stud (3/16 x 3/4")
6 850-0030 2 Washer, Lock (#10)
7 870-0053 2 Nut, Hex (10-32)
8 850-0025 2 Washer, Lock (#8)
9 812-0075 2 Screw, Roundhead Sheet

10 333-0013 1 Cover, Thermostat Box

Metal (8-32 x 1/4")

62

179-0225

STANDPIPE

COOLING INSTALLATION (OPTIONAL)

REF.

NO.

10
11
12
13
14
15

16
17
18
19 503-0491
20

21

1

504-0062

2

505-0130

3

505-0140

4

130-0659

5

307-0833

6

505-0359

7

850-0050

8

800-0048

9

505-0101
505-0028
504-0028
505-0258
505-0056

130-0636

505-0183

505-0385
503-0365
503-0490

505-0100
504-0019

PART

NO.

QTY.

PART

USED

DESCRIPTION

Valve,

Vacuum Relief
Plug (3/4)
Plug (1")
Standpipe
Valve,

Water (12 Volt)
Plug (1-1/4)

4 Washer, Lock (3/8)
4 Screw (3/8-16 x 3/4") -

2 • -Nipple, Close (1/2) • '

1 Valve, Globe

Hex Head Cap
Nipple, Close (3/8)
Coupling (3/8)

Valve,

Drain
Nipple (1-1/4 x 3")
Plug,

Steel (1/2)

Support, Standpipe

Elbow, Reducer

(1-1/2 x

Nipple, Half (1-1/2)

Clamp, Hose

Hose (1-3/4 x 15-1/2")
Hose (1-3/4" ID - Molded)

1-1/4)

63

179-0299

ENGINE

HEATER

INSTALLATION—OPTIONAL EQUIPMENT

mm

REF.

NO.

10 503-0311 2 Clamp, Hose
11 850-0025 2 Washer, Lock - (#8)
12 812-0075 2 Screw, Round Head -

:

13

14
15 850-0030 2 Washer, Lock - (#10)

16
17
18 309-0029

PART QTY. PART

NO.

1

505-0190 1
2 505-0106 1
3 503-0189 4 Clamp, Hose
4

5

505-0185 3
6 505-0021 2

7 333-0093 1 Heater, Engine
8 1

9 503-0517 1 Adapter, Hose

333-0013

520-0446

870-0053

333-0012

USED DESCRIPTION

Elbow (1/2x45°)
Nipple, Short - (1/2 x

Hose,

1

1

2

2

1
1

Water (Order 18" of

#503-0191 Hose)
Nipple, Half - (1/2")
Bushing,

Hose,

Cover, Thermostat Box
Stud - Thermostat Box

Nut (10-32)
Box, Thermostat
Thermostat

Reducer -

(1/2 x 3/4")

Water (Order 18" of

#503-0191 Hose)

(8-32 x 1/4")

Mounting (#10-32 x 3/4")

64

1-1/2")

{.:.

•v

179-0325

STANDPIPE

COOLING

INSTALLATION

WITH

(OPTIONAL)

MARSH

REGULATOR

REF.

NO.

10
11 505-0021

12
13 800-0027
14 850-0045 2 Washer, Lock (5/16)

15
16
17

PART QTY.

NO.

1 504-0062 1

2 503-0365

503-0491 1 '

3
4 505-0385

503-0490

5
6 505-0183

7

505-0101

8

505-0028
504-0028

9

505-0002

309-0241

862-0015

110-0526

505-0040

USED

• 2

Valve,

4 Clamp, Hose

Hose,
1 Nipple, Half (1-1/2")
1
1

1 Nipple, Close (3/8)
1 Coupling (3/8)
2
1 Nipple, Pipe (1/2 x 3")
2

1

2 Nut, Hex (5/16-18)

1

2 Elbow (1/2)

Water

Hose,

Water

Elbow, Reducer

(1-1/2 x

Valve,

Bushing,

(3/4 x 1/2)

Valve,

Control (Marsh)

Screw, Hex Head Cap -

(5/16-18 x 7/8")

Nipple Assembly, Waterline

PART

DESCRIPTION

Vacuum Relief

1-1/4)

Drain

Reducer

Water Temperature

65

REF.

NO.

18 505-0100
19
20 503-0437 1
21
22
23
24
25 130-0659 1 Standpipe
26 505-0056 1
27 505-0108
28 505-0019
29
30 505-0258
31 850-0050
32

33 130-0636 ' 1 Bracket, Standpipe Mounting
34 130-0782 1
35

36 850-0055

PART

NO.

307-0833

503-0189
505-0185
505-0129

505-0130

505-0359 1

800-0048

800-0069

QTY.

USED DESCRIPTION

2 Nipple, Close (1/2)

1

Valve,

Water (12 Volt)

Hose,
2 Clamp, Hose
2

1
1

1 Tee (1/2)
1

1 Nipple, Pipe (1-1/4 x 3")
4 Washer, Lock (3/8)
4 Screw, Hex Head Cap -

2
2

Water

Nipple, Half (1/2")
Bushing,
Plug,

Square Head (3/4)

Plug,

Steel (1/2)

Bushing,
Plug,

Square Head (1-1/4)

V ; (3/8-16.x 3/4") •

Guard,
Screw (7/16-14 x 3/4") -

Washer, Lock (7/16) -

PART

Reducer (1" x 3/4)

Reducer (1/2 x 3/8)

Belt

179-0329

HEAT

EXCHANGER

INSTALLATION

WITH

MARSH

(OPTIONAL)

REGULATOR

REF.

NO.

.6 850-0040

10 503-0269
11
12 505-0317

13 505-0426
14

15 800-0026
16 850-0045

PART

NO.

130-0796

1
2 505-0462

505-0220

3

130-0802

4

800-0004

5

7

862-0001
504-0005

8

503-0490

9

505-0444

504-0003 1

12 ^G 13 14

QTY.

USED

Exchanger, Heat

1
1 Elbow, Street (1/2 x 90°)

Nipple (1-1/2 x

1
1

Strap,

Heat Exchanger

. Mounting

Screw, Hex Head Cap -

2
2

2
1
1

1 Clamp, Hose
1 Nipple, Half (1-1/2 x 2-1/4")
1 Tee (1-1/2")
1

2
2 Washer, Lock (5/16")

(1/4-20 x 5/8")

Washer, Lock (1/4)

Nut, Hex (1/4-20)

Valve,

Drain (1/8 NPT)

Hose,

Radiator

(1-3/4"

Bushing,

(1-1/2 x 1/4)

Valve,

Screw, Hex Head Cap -

(5/16-18 x 3/4")

PART

DESCRIPTION

1-3/4")

ID x 15-1/2")

Reducer

Drain (1/4 NPT)

I5,I6,I7

NOTE:

1. Not Shown on Drawing.

REF.

NO.

17

18

19 505-0100 1 Nipple (1/2 x
20 307-0833
21
22 505-0021

23 503-0491 1

24

25 505-0129

26 130-0805

27

28

PART

NO.

862-0015

130-0803

505-0691

503-0311

505-0102
309-0241 1

850-0055
800-0069

130-0782 1

QTY.

USED

Nut, Hex (5/16-18)

2
1 Bracket, Heat Exchanger

1
1
1

3 Clamp, Hose

1
1
1 Nipple, Close (3/4)

2 Washer, Lock (7/16) ­2

Mounting

Valve,

Solenoid
Elbow, Street (3/4 x 45°)
Bushing,

(3/4 x 1/2)

Hose,

Radiator (1-3/4 ID -

Molded)

Bushing,
Bracket, Heat Exchanger

Valve,

Water Temperature

Control

(See Note 1)

Screw (7/16-14 x 3/4") -

(See Notel)

Guard,

Belt (See Note 1)

PART

DESCRIPTION

1-1/8")

Reducer

Reducer (1 x 3/4)

66

179-0355

EXHAUST

MUFFLER

INSTALLATION — TOP

MOUNTED

(OPTIONAL)

REF.

NO. NO.

8

9
10
11
12
13

1
2
3
4
5
6
7

PART

155-0988
140-0649
155-0978
155-0789
862-0015

850-0045
800-0026
505-0203

155-1112
505-0454
526-0172
800-0028
155-1383

QTY.

USED

1
2
1
2

10
10

6

1
1
1

8
4
1

DESCRIPTION

Muffler
Band
Shield,

Heat
Support
Nut (5/16-18)
Washer,

Screw

Coupling

Tube

Union

Spacer
Screw
Shield,

Lock

(5/16-18

(2")

Assembly,

(2")

(5/16-18

Rain

5,6,7

PART

(5/16)

x 3/4")

Exhaust

x 1")

67

179-0362

WATER

COOLED

MANIFOLD

INSTALLATION (OPTIONAL)

REF.

NO.

10
11
12
13 526-0030
14 505-0057 1 Plug (1/8")
15 505-0106 1 Nipple, Short (1/2 x

16 505-0108

17

18
19

20
21 800-0051

22
23

24

PART

NO.

1 505-0175
2 505-0172

154-1335

3
4 145-0120
5

6 520-0311
7 505-0271

154-1334

8
9 503-0189

503-0269

503-0517
505-0185 3 Nipple, Half (1/2 x

505-0018

511-0078
520-0515

526-0066
801-0027

520-0238

QTY.

USED

Elbow (2" x 90°)

1
1 Nipple, Close (2")
1 Flange, Exhaust Manifold
1 Gasket, Carburetor
1 Mount, Carburetor (Included

2 Stud (3/8 x
1 Nipple (1/4 x
1
4 Clamp, Hose
2 Clamp, Hose (2-1/4 x 1/2")

1

3 Washer, Flat (3/8")

1 Tee (1/2")
1
2

1
1 Linkage, Governor (See

4 Screw (3/8-16 x
4 Washer, Flat (3/8)

4 Screw (5/16-24 x 7/8")
2 Stud (3/8 x

With Item 8)

Manifold,

Adapter, Hose

(See Note 3)

Bushing,
Hose,

Water (Order 14" of

Bulk Hose #503-0191)

Belt, Governor (See Note 2)

Note 2)
Hex Head Cap

(See Note 4)

PART

DESCRIPTION

1-5/8")

3-1/2")

Water Cooled

Reducer (1/2 x 1/4)

1-13/16")

1-1/2")

1-1/2")

1-1/4")

-

68

CITY

WATER

COOLING

INSTALLATION

WITH

WATER

COOLED

MANIFOLD

— UNHOUSED (OPTIONAL) '

179-0365

55 43

REF.

NO. NO.

10 850-0050 7 Washer (3/8"), Lock
11 800-0052 4 Screw (3/8-16 x
12 50530057 1 Plug (1/8")
13 505-0040
14 505-0100
15 1

16 148-0274

17 504-0003 1
18 505-0018

19 505-0108 1 Tee (1/2")
20
21 503-0365 4 Clamp, Hose
22 1

23

24
25

26 526-0029

27 1

PART

1

505-0175

2

505-0172

3

154-1335

4 154-1334 1
5
6 520-0311

7 505-0271 1 Nipple (1/4 x
8

503-0189

9 505-0185 4 Nipple (1/2 x

110-0576 1

130-0782 1
850-0055
800-0069

QTY.

USED

1

Elbow (2 x 90°)

1 Nipple (2 x 2), Close 33 307-0833 1
1 Flange, Exhaust Manifold 34 800-0005 4

Manifold,

1 Mount, Carburetor (Included

2
4 Clamp, Hose

3

3

1
1

2
2
3

Cooled 36
with Item 4)

Stud (3/8 x

Half

Elbow (1/2")
Nipple (1/2")sClose
Hose,

Water (Order 63" of

Bulk Hose #503-0191)
Bracket, Hose
Valve,

Drain

Bushing,

(1/2 x 1/4)
Plug,

Hose Adapter

Hose,

Water (Order 3" of 54 130-0757

Bulk Hose #503-0356) 55 130-0522 1 '
Guard,
Washer (7/16"),
Screw (7/16-14 x 3/4") 520 0515 1
Washer
Hoso, Wntor (Order 2" of

iti til: H'

PART

DESCRIPTION

Exhaust - Water 35 850-0040 4

1-5/8")

3-1/2")
1-1/2")

1-1/2")

Reducer -

Belt 526-0030

H-ock

>;.: - ntif'M l i.'ifi'i!.

REF.

NO.

32

37
38
39 505-0324
40 309-0241

-

41
42 505-0032
43
44
45
46
47
48 812-0079

49
50
51
52 505-0021

53

PART

NO.

110-0526

862-0001
145-0120
505-0051 1

505-0289
505-0109 1

505-0102 1
505-0317
505-0385
332-0050

850-0025 1
860-0009
130-0499 1

821-0014 6

518-0178 1
511

-0078

• U- •-.Ytc.

li

•••ri.-.t

QTY.

USED

2

Bracket & Nipple Assembly
Valve,
Screw (1/4-20"x 3/4")
Washer (1/4"), Lock

4

Nut (1/4-20)

1

Gasket, Carburetor
Elbow (3/4 x 90°)
Nipple (3/4"), Half

1

Valve,

1

2
1

1
1
1
1

1
2

1

3

1

HI-

Water Temperature

Control
Bushing,
Coupling (1-1/2")
Nipple (1-1/2 x 2-1/2")
Nipple (3/3"), Close
Tee (1-1/2")
Nipple (1-1/2"), Half
Clip,

Wire

Screw (8-32 x

Round Head
Washer (#8), Lock
Nut (#8-32)
Bracket, Heat Exchanger
Bushing (3/4 x

Reducer
Screw, Lock -

(5/16-18 x 1/2")
Bracket, Tee.Support

' Clamp •' •"• ' '•'

"Washer - Governor Mounting

'Clip,

Cable - Solenoid Lead

'Stud - Governor Link

'Belt, Vee - Governor

PART

DESCRIPTION

Solenoid

Reducer

1/2"),

1/2"),

179-0370

5,6,7

HEAT

EXCHANGER

INSTALLATION (OPTIONAL)

II 12 26 13 14

REF.

NO.

10
11 505-0444 1 Nipple, Half

12 505-0317 1 Tee (1-1/2")
13 505-0426 1

14 504-0003 1
15 800-0026 2 Screw, Hex Head Cap -

PART

NO.

130-0796

1
2 505-0462

3

505-0642

4 130-0802
5 800-0004

850-0040

6
7

862-0001

8 504-0005

503-0490 1

9

503-0269 1 Clamp, Hose

QTY.

USED

1

Exchanger, Heat

1

Elbow, Street

1 Nipple (1-1/2 x 4") Mounting

4 Screw (1/4-20 x 5/8")
4 Washer, Lock (1/4) 22 505-0021 1

1

(1-1/2 x 90°)

Strap,

Heat Exchanger

Mounting

Nut, Hex (1/4-20) (3/4 xl/2)

Valve,

Drain (1/8 NPT)

Hose,

Radiator Molded)

(1-3/4 10x15-1/2")

(1-1/2"

Bushing,

(1-1/2 x 1/4)

Valve,

Drain (1/4 NPT)

(5/16-18 x 3/4")

PART

DESCRIPTION

x 2-1/4")
Reducer

15,16,17

REF.

NO. NO.

16 850-0045
17
18 130-0819

19 505-0100

20 307-0833

21 505-0691

23 503-0491
24

25
26
27
29

30 800-0069
31

31

PART QTY.

862-0015 2 Nut, Hex (5/16-18)

503-0311
505-0140

130-0805
504-0019
850-0055

130-0782

130-0782

USED

2

Washer, Lock (5/16)
1 Bracket, Heat Exchanger
2 Nipple (1/2 x

1

Valve,

1 Elbow, Street (3/4 x 45°)

Bushing,

1

Hose,

3 Clamp, Hose

1 Plug (1")

1

Bracket, Heat Exchanger

1

Valve,
2 Washer, Lock (7/16) ­2

Screw, Hex Head Cap -

(7/16-14 x 3/4") -

Guard,

1

PART

DESCRIPTION

1-1/8")

Solenoid

Reducer

Radiator (1-3/4 ID -

Globe

Belt

70

ENGINE

(STANDARD

CONTROL

SETS

MONITOR

WITH

GROUP

ONE

FAULT

- 12

O

VOLT

LIGHT)

-mo-

CRI

f

(03)

R4

CR7

-QTr>

rv.tQ

300-0679

-oo-

-00-

CR2

a

-nm-

-QED-

-CUD-

-mo- -QID-

Q8

^9

-CIE>

CR3

S)

o

IBl

REF.

NO.

Cl
C2

C3 356-0040
C4
C5 355-0005
CRI
CR2
CR3
CR4 357-0004 1 Diode, Rectifier
CRS 357-0004 1 Diode, Rectifier

CR6 364-0017 1 Diode, Rectifier
CR7 357-0004
Kl 307-1039 1 Relay, Armature

Ql 361-0003 1 Transistor
02

03
04
Q5
Q6
Q7 362-0008
Q8 362-0008

PART QTY.

NO.

300-0679

355-0005

356-0030

359-0027
357-0004 1 Diode, Rectifier
357-0004 1 Diode, Rectifier

362-0025
362-0025
361-

362-

362-0025

0003
0025

USED

Monitor, Engine Control

12 Volt
Not used
Capacitor, Plastic Dielectric

1

(.22 Mfd, 200 VDC,
Capacitor, Electrolytic

1

(10 Mfd,
Capacitor, Electrolytic

1

(1 Mfd,
Capacitor, Plastic Dielectric

1

(.22 Mfd, 200 VDC,

Diode, Zener

1

(1 Watt,

(400

(400

(400

(400

(8 Amp,

Diode, Rectifier

1

(400

Transistor

;

Transistor

Transistor

.

]

Transistor
i Transistor
i Transistor

1

Transistor

PART

DESCRIPTION

20

Volt)

35

Volt)

7.5

Volt,

MA, 400
MA, 400

MA, 400
MA, 400

30

Volt)

MA, 400

5%)

Volt)
Volt)

Volt)
Volt)

Volt)

(12

-

10%)

10%)

Volt)

REF.

NO. NO.

Rl 350-0536
R2
R3 350-0548
R4
R5 350-0572
R6
R7
R8

R8
R9

R9

R10
Rll 350-0584
R12

R12

R13
R14

R14

,

R15

R16
R17

R17
TB1

350-0526

303-0169

350-0552
350-0536
350-0505

350-0505
350-0517

350-0517
303-0169

303-0169
350-0584
350-0529

350-0529
350-0529
350-0529

350-0529

, . 350-0540

350-0540
350-1128

350-1128
332-1246

PART

QTY. PART

USED DESCRIPTION

Resistor, Composition

(1000-Ohm,

Resistor, Composition

(100-Ohm,

Resistor, Composition

(10,000-Ohm,

Potentiometer

(3.5 Meg Ohm,

Resistor, Composition

(1-Meg Ohm,

Resistor, Composition

(22,000-Ohm,

Resistor, Composition

(1000-Ohm,

Resistor, Composition

(2.7-Ohm,

Resistor, Composition

(27-Ohm,

Potentiometer

(3.5-Meg Ohm,

Resistor, Composition

(10-Meg Ohm,

Resistor, Composition

(270-Ohm,

Resistor, Composition

(270-Ohm,

Resistor, Composition

(270-Ohm,

Resistor,, Composition

(22b6-0'hm,

Resistor, Composition

(2200-Ohm,

Resistor, Composition

(220-Ohm, 2 Watt,

Printed Wiring Board

1/2

Watt,

1/2

Watt,

1/2

Watt,

'

r

1/4

1/2

Watt,

1/2

Watt,

1/2

Watt,

1/2

Watt,

1/2

Watt,

1/4

Watt, 30%)

1/2

Watt,

1/2

Watt,

1/2

Watt,

1/2

Watt,

1/2

Watt,

1/2

Watt,

10%)

10%)

10%)

10%)

Watt, 30%)

10%)

10%)

10%)

10%)

10%)

10%)
10%)
10%)
10%)

10%)
10%)

Tl

Cll

MS" .7

ENGINE

CONTROL

OPTIONAL

MONITOR

(5 Fault

Zl|

ffil

W| I8| n| lt| I5| M| a\ ll\ llj I0| 9| 8| 7| H 5| 4| 3| l\ il

Lights)

GROUP

- 12

VOLT

ll

Cl
C2
C3
C4

C5

C6
C7

C8

CRI
CR2
CR3
CR4
CRS

CR6

CR7
CRS
CR9

CR10
CR11

PART

NO.

300-0681
356-0040
355-0005
355-

0005

356-

0030
355-0005
355-0005
355-0005
355-0005
357-

0004
357-0004
357-0004
357-0004
357-0004
357-0004
357-0004
357-0004
359-0027

364-0017
357-0004

QTY.

USED

Monitor, Engine Control -

12 Volt - Optional

Capacitor, Electrolytic

(10 Mfd, 20 Volt)

Capacitor, Plastic Dielectric

(.22 Mfd, 200 VDC, 10%)

Capacitor, Plastic Dielectric

(.22 Mfd, 200 VDC, 10%)

Capacitor, Electrolytic

(1 Mfd, 35 Volt)

Capacitor, Plastic Dielectric

(.22 Mfd, 200 VDC, 10%)

Capacitor, Plastic Dielectric

(.22 Mfd, 200 VDC, 10%)

Capacitor, Plastic Dielectric

(.22 Mfd, 200 VDC, 10%)

Capacitor, Plastic Dielectric

(.22 Mfd, 200 VDC, 10%)

Diode, Rectifier

(400 MA, 400 Volt)

Diode, Rectifier

(400 MA, 400 Volt)

Diode, Rectifier

(400 MA, 400 Volt)

Diode, Rectifier

(400 MA, 400 Volt)

Diode, Rectifier

(400 MA, 400 Volt)

Diode, Rectifier

(400 MA, 400 Volt)

Diode, Rectifier

(400 MA, 400 Volt)

Diode, Rectifier

(400 MA, 400 Volt)
Diode, Zener (1 Watt, 7.5 Volt, 5%)
Diode, Rectifier (8 Amp, 30 Volt)
Diode, Rectifier

(400 MA, 400 Volt)

PART

DESCRIPTION

REF.

PART

NO. NO.

CR12 357-0004 1 Diode, Rectifier
CR13 357-0004 1 Diode, Rectifier
CRI4 357-0004 1 Diode, Rectifier
CRI5 357-0004 1 Diode, Rectifier
CR16 357-0004 1 Diode, Rectifier
CR17 364-0017 1 Diode, Rectifier (8 Amp, 30 Volt)

CR18 364-0017 1 Diode, Rectifier (8 Amp, 30 Volt)
CRI9 357-0004 1 Diode, Rectifier

CR20 364-0017 1 Diode, Rectifier (8 Amp, 30 Volt)
CR21 357-0004 1 Diode, Rectifier

Kl 307-1039 1 Relay, Armature (12 Voit)

K2 307-1039 1 Relay, Armature (12 Volt)
Ql 362-0025 1 Transistor
Q2 362-0025 1 Transistor
Q3 361-0003 1 Transistor
Q4 362-0008 1 Transistor
Q5 362-0008 1 Transistor
Q6 362-0008 1 Transistor
Q7 362-0031 1 Transistor
Q8 362-0031 1 Transistor
Q9 361-0003 1 Transistor
Q10 362-0008 1 Transistor
Q11 362-0008 1 Transistor
Q12 362-0008 1 Transistor
Q13 362-0008 1 Transistor
Q14 362-0008 1 Transistor
Rl 350-0526 1 Resistor, Composition

R2 303-0169 1 Potentiometer (3.5 Megohm.
R3 350-0572 1 Resistor, Composition

QTY.

USED DESCRIPTION

PART

(400 MA, 400 Volt)
(400 MA, 400 Volt)
(400 MA, 400 Volt)
(400 MA, 400 Volt)
(400 MA, 400 Volt)

(400 MA, 400 Volt)

(400 MA, 400 Volt)

(100-Ohm,

1/4 Watt, 30%)
(1 Megohm, 1/2 Watt, 10%)

1/2 Watt, 10%)

72

ENGINE CONTROL MONITOR

OPTIONAL (5 Fault Lights)

REF.

NO. NO.

R4 350-0517 1
R5
R6
R7 350-0505 1
R8 350-0529 1 Resistor, Composition
R9 350-0540 1 Resistor, Composition
RIO 350-0380 1 Resistor, Composition
Rll 350-0529 1 Resistor, Composition
R12 350-0552 1 Resistor, Composition
R13 350-0505 1 Resistor, Composition
R14­R15
R16 350-0517 1 Resistor, Composition
R17

R18
R19
R20 350-0529 1

PART QTY. PART

USEO DESCRIPTION

350-0536 1
350-0548 1

350-0536 1 Resistor, Composition
303-0169 1 Potentiometer (3.5 Megohm,

350-0540 1 Resistor, Composition
350-0540 1
350-0517 1

Resistor, Composition

(27-Ohm,

Resistor, Composition

(1000-Ohm, 1/2 Watt, 10%)

Resistor, Composition

(10,000-Ohm, 1/2 Watt, 10%)

Resistor, Composition

(2.7-Ohm,
(270-Ohm,
(2200-Ohm, 1/2 Watt, 10%)
(510-Ohm,
(270-Ohm,
(22,000-Ohm, 1/2 Watt, 10%)
(2.7-Ohm,
(1000-Ohm, 1/2 Watt, 10%)
1/4 Watt, 30%)

(27-Ohm,
(2200-Ohm, 1/2 Watt, 10%)

Resistor, Composition

(2200-Ohm, 1/2 Watt, 10%)

Resistor, Composition

(27-Ohm,

Resistor, Composition

(270-Ohm,

1/2 Watt, 10%)

1/2 Watt, 10%)

1/2 Watt, 10%)

1/2 Watt, 5%)
1/2 Watt, 10%)

1/2 Watt, 10%)

1/2 Watt, 10%)

1/2 Watt, 10%)

1/2 Watt, 10%)

GROUP -12 VOLT

REF.

NO.

R21
R22 350-0505
R23
R24 350-0529
R25
R21
R27 350-0529
R28
R29
R30

R31
R32
R33
R34
R35
R36
SI
TBI

PART

NO.

350-0529

350-0529

350-0540
350-0380

350-0529
350-0540
350-0505
350-0529
350-0540

350-0529
350-0517
350-1128
350-0584 1 Resistor, Composition
308-0280
332-1231

QTY. PART

USED DESCRIPTION

1 Resistor, Composition

(270-Ohm,

1 Resistor, Composition

(2.7-Ohm,

1 Resistor, Composition

(270-Ohm,

1 Resistor, Composition

(270-Ohm,

1 Resistor, Composition

(2200-Ohm, 1/2 Watt, 10%)

1 Resistor, Composition

(510-Ohm,

1 Resistor, Composition

(270-Ohm,

1 Resistor, Composition

(270-Ohm,

1 Resistor, Composition

(2200-Ohm, 1/2 Watt, 10%)

1 Resistor, Composition

(2.7-Ohm,

1 Resistor, Composition

(270-Ohm,

1 Resistor, Composition

(2200-Ohm, 1/2 Watt, 10%)

. 1 Resistor, Composition

(270-Ohm,

1 Resistor, Composition

(27-Ohm,

1 Resistor, Composition

(220-Ohm,
(10 Megohm, 1/2 Watt, 10%)

1 Switch, Push - DPDT

(1A, 28VDC/.45A, 115 VAC)

1 Printed Wiring Board

1/2 Watt, 10%)

1/2 Watt, 10%)

1/2 Watt, 10%)
1/2 Watt, 10%)

1/2 Watt, 5%)
1/2 Watt, 10%)
1/2 Watt, 10%)

1/2 Watt, 10%)

1/2 Watt, 10%)

1/2 Watt, 10%)

1/2 Watt, 10%)

2 Watt, 10%)

FOR

EK AND EM

SERIES

SPECIAL

PENNSYLVANIA

PARTS

LIST

APPROVED

GENERATING

SETS

Refer first to this list for Pennsylvania Approved sets. Parts not in this list refer to the main parts list (Key 1 for EK
and Key 2 for EM). When referring to the main parts list, reference to Spec letter or voltage also applies to these
sets.

These sets are recognized by the numbers 30 (Gasoline Fuel), 31 (Gaseous Fuel), or

131

(Liquid Petroleum Fuel)
appearing in the model. These numbers may appear just before or after the diagonal line (/). The number
appearing after the diagonal line signifies a standard Pennsylvania Approved set (Example: 45.0EM15R31/1 E).

GAS AND GAS-GASOLINE FUEL SYSTEM GROUP

REF.

PART QTY. PART

NO.

NO. USED DESCRIPTION

20 149-0752 1 Strainer, Fuel (1")
21 307-0836 1 Valve, Solenoid

22 503-0273 1 Line, Fuel - Flexible

CONTROL GROUP (AC OUTPUT PORTION)

REF.

PART QTY. PART

NO.

NO. USED DESCRIPTION

320-0307 1 Lock, Circuit Breaker Handle

(1"

- 12 Volt)

(1"

x 12")

CONTROL GROUP (ENGINE INSTRUMENTS PORTION)

REF.

PART QTY.

NO.

NO. USED

3 SWITCH, SELECTOR

308-0138 1
308-0327 1

18 300-0730 1

Spec A through D

Begin Spec E
Monitor, Engine Control

(See Separate Group for

Components)

PART

DESCRIPTION

73

ENGINE
PENN

STATE

CONTROL

(1 Fault Light)

-QO-

MONITOR

CRl

-dO-

GROUP

- 12

o

VOLT

-QO-

(03) CR3

CR4

H

-GO-

CRS

a

5®

I* C3

-CUD- ®'

-CHO-

-QO-

-QED-

Z CUp-

cs +

300-0730

REF.

NO. NO.

Cl Not used Q4 362-0008

C2

C3
C4

C5 355-0005
CRI 357-0004
CR2
CRS 357-0004
CR4 357-0004

CRS 357-0004
CR6 357-0004
CR7 364-0017

Kl
K2
Ql

PART

300-0730 Monitor, Engine Control -

355-0005
356-0040

359-0027

307-1039 1 Relay, Armature (12 Volt)
307-1039 1 Relay, Armature (12 Volt) TBI 332-1246
361-0003

QTY.

USEO

12 Volt (Penn State)

1

Capacitor, Plastic Dielectric

(.22 Mfd, 200 VDC, 10%)

Capacitor, Electrolytic

1

(10 Mfd, 20 Volt)
Not used
Capacitor, Plastic Dielectric

1

(.22 Mfd, 200 VDC, 10%)

Diode, Rectifier

1

(400 MA, 400 Volt)

Diode, Zener

1

(1 Watt, 7.5 Volt, 5%)

Diode, Rectifier

1

(400 MA, 400 Volt)

Diode, Rectifier

1

(400 MA, 400 Volt)

Diode, Rectifier

1

(400 MA, 400 Volt)

Diode, Rectifier

1

(400 MA, 400 Volt)

Diode, Rectifier

1

(8 Amp, 30 Volt)

1 Transistor

PART

DESCRIPTION

REF.

NO. NO.

Q2
Q3

Rl 350-0536
R2 350-0526
R3 350-0552
R4
R5
R6
R7
RS 350-0529
R9
R10
Rll

O

T B 1

PART

362-0025
362-0025

303-0169
350-0572
350-0505
350-0517

350-0529
350-0540
350-0971

QTY.

PART

USED

DESCRIPTION

Transistor
Transistor
Transistor

Resistor, Composition

(1000-Ohm, 1/2 Watt, 10%)

Resistor, Composition

(100-Ohm,

Resistor, Composition

(22,000-Ohm, 1/2 Watt, 10%)

Potentiometer (3.5 Megohm,

1/4 Watt, 30%)

Resistor, Composition

(1 Megohm, 1/2 Watt, 10%)

Resistor, Composition

(2.7-Ohm,

Resistor, Composition

(27-Ohm,

Resistor, Composition

(270-Ohm,

Resistor, Composition

(270-Ohm,

Resistor, Composition

(2200-Ohm, 1/2 Watt, 10%)

Resistor, Composition

(220-Ohm,

Printed Wiring Board

1/2 Watt, 10%)

1/2 Watt, 10%)

1/2 Watt, 10%)

1/2 Watt, 10%)
1/2 Watt, 10%)

2 Watt, 5%)

74

nan

o

MANUFACTURER'S

LIMITED

WARRANTY

Onan extends to the original purchaser of goods for use, the following warranty covering goods manufactured or supplied by
Onan,

subject to the qualifications indicated.

(1)

Onan warrants to original purchaser for the periods set forth below that goods manufactured or supplied, by it will be free

(

' from defects in workmanship and material, provided such goodsare installed, operated, and mamtamedhn accord ance wrth

Onan's written instructions, arid further provided, that installation inspection and initial start-up on commercial-industrial
generator set or power system installations are conducted by an Onan Authorized Distributor or its designated service
representative.

PRODUCT APPLICATION
Goods used in personal, family and household

applications.

Goods used in commercial-industrial applications.
Commercial-industrial stationary generator sets.
Commercial-industrial, standby power systems

nominal operating speeds of 1800 rpms or less which
are installed in the U.S. or Canada (must include Onan
supplied generator sets, automatic transfer switch,

exerciser and running time meter).
Commercial-industrial, standby power systems with

nominal operating speeds of 1800 rpms or less which

are installed outside the U.S. or Canada (must include

Onan supplied generator

exerciser and running time meter).

Repair or replacement parts.

* Must be registered on Form Nr, 23C0.65 to be provided and completed by seller.

(2)

Onan's sole liability and Purchaser's sole remedy for a failure of goods to perform as warranted shall

or replacement of goods returned to Onan's factory at 1400 73rd Avenue N.E., Minneapolis, Minnesota 55432, or to an Onan
Authorized Distributor or its designated service representative, transportation prepaid.

Except as indicated below, this warranty does not include travel time and mileage labor for removal of Onan product from its
application and reinstallation.

set,

automatic transfer switch,

with,

PERIOD OF WARRANTY
One (1) year from date of purchase.

One (1) year from date of purchase.
One (1) year from date of initial start-up.

' Five (5) years or 1500 hours, whichever

occurs first from the date of initial start-up.

Labor allowance for the first two (2) years
or 1500 hours, whichever occurs first from
the date of initial start-up.

* Two (2) years or 1500 hours, whichever

occurs first from the date of initial start-up.

Ninety (90) days from date.of purchase,
excludes labor.

be.limitee1

tothei repair

a)

Removal and Reinstallation

'{

I

4

i. Garden Tractor Engines-Onan will pay up to a maximum of two (2) hours labor for warranty work requmng removal

and reinstallation of Onan industrial engines in garden tractor applications performed by an Onan Authorized

Distributor or its designated service representative.

ii.

iteh/c/es-Onan will pay one (1) hour labor for warranty work requiring, removal and

Onan Authorized Distributor or its designated service representative on vehicle applications utilizing a POWER
DRAWER® arid Onan supplied sliding tray generator set installations.

b)

Travel Time and Mileage

i Marine Generator Set Installations-Onan

hours and mileage costs up to one hundred fifty (150) miles related to warranty repairs, provided, such travel and

repairs are performed by an Onan Authorized Distributor.or its designated.s.ervi.ce representative.

ii Commercial-Industrial Standby Generator Set and System Installations-Prodded the generator set or system is

permanently w^ed in a stationary installation, Onan
fouT(4) hours and mileage costs up to one hundred fifty (150) miles for warranty repairs performed by an Onan
Authorized Distributor or its designated service representative.

will,

for six (6) months after date of purchase, pay travel time up to four (4)

will,

for six (6) months after initial start-up, pay travel time up to

re;"s

to"»«°"t.^

(3)

THERE IS NO OTHER EXPRESS WARRANTY.

IMPLIED WARRANTIES INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED

TO PERIODS OF WARRANTY SET FORTH ABOVE AND TO THE EXTENT PERMITTED BY LAW, ANY AND ALL IMPLIED

. WARRANTIES ARE EXCLUDED.

IN NO EVENT IS ONAN LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

(4)

All claims must be brought to the attention of Onan or an Onan Authorized Distributor or its designated service

representative within thirty (30) days after discovery that goods or parts fail to perform as warranted.

(5)

THIS WARRANTY SHALL NOT APPLY TO:

a)

Cost of maintenance, adjustments, installation and start-up.

b)

Failures due to normal wear, accident, misuse, abuse, negligence or improper installation.

c)

Products which are altered or modified in manner not authorized by manufacturer in writing.

d)

Failure of goods caused by defects in the system or application in which the goods are installed. ^

e)

Telephone, telegraph, teletype or other communication expenses.

f)

Living and travel expenses of persons performing sen/ice, except as specifically included in Section 2.

g)

Rental equipment used while warranty repairs are being performed.

h)

Overtime labor requested by purchaser.

i)

Starting batteries.

(6)

No person is authorized to give any other warranties or to assume any other liabilities on Onan's behalf, unless made or

assumed in writing by an officer of Onan, and no person is authorized to give any warranties or assume any other liability on
behalf of Seller unless made or assumed in writing by Seller.

LITHO IN

U.S.A.

7-4-75 - AB-355

h

(SL

ONAN

1400 73RD

AVENUE

N.E. • MINNEAPOLIS, MINNESOTA 55432

A DIVISION OF ONAN CORPORATION