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ELECTRIC GENERATING PLANTS

LK
SERIES

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 G E N E R A L INFORMATION
This instruction book contains information for the proper installation^
operation, and maintenance of your equipment. We suggest that this
book be kept handy so that it can be referred to when necessary.

This equipment is the result of proven engineering design, highest

quality materials^ and expert workmanship. Thorough inspection and
testing assures you that this equipment will perform as expected.

If you wish to contact your dealer or the factory regarding this equip-
ment, be sure to supply the complete MODEL and SPEC. NO., and the
full serial number of the equipment as shown on the nameplate. This
information is necessary to identify the equipment among the many
basic and special optional types manufactured.

MANUFACTURER'S WARRANTY
The Manufacturer warrants, to the original user, that each product of
its manufacture is free from defects in material and factory workmanship
if properly installed, serviced and operated under normal conditions
according to the Manufacturer's instructions.
Manufacturer's obligation under this warranty is limited to correcting
without charge at its factory any part or parts thereof which shall be
returned to its factory or one of its Authorized Service Stations, trans-
portation charges prepaid, within one year after being put into service
by the original user, and which upon examination shall disclose to the
Manufacturer's satisfaction tp have been originally defective. Correction
of such defects by repair to, or supplying of replacements for defective
Sip
parts, shall constitute fulfillment of all obligations to original user.

This warranty shall not apply to any of the Manufacturer's products

which must be replaced because of normal wear, which have been subject
to misuse, negligence or accident or which shall have been repaired or
altered outside of the Manufacturer's factory unless authorized by the
Manufacturer.
Manufacturer shall not be liable for loss, damage or expense directly or
indirectly from the use of its product or from any other cause.
The above warranty supersedes and is in lieu of all other warranties,
expressed or implied, and of all other liabilities or obligations on part of
Manufacturer. No person, agent or dealer is authorized to give any
warranties on behalf of the Manufacturer nor to assume for the Manu-
facturer any other liability in connection with any of its products unless
made in writing and signed by an officer of the Manufacturer.

DATED A u g u s t 1, 1963

IMPORTANT

RETURN WARRANTY CARD ATTACHED TO UNIT

 LIST OF I L L U S T R A T I O N S

FIGURE ~ ipAGE NO.

1 Typical Installation 6
2 Dimensional Outline 7 .
3 Mounting Cushions 8
4 Mounting Base 9
5 Exhaust Installation 9
6 Carrying Frame .* 10
7 Dolly 11
8 Oil Drain Extension 12
9 Battery Connection - AC Remote Plant 12
10 Taping Wire Connections 13
11 - Plant Grounding , 14.
12 Remote Start-Stop Stations . . . . 15
13 AC Load Wire Connection 16
14 Receptacle Plate Connections - Manual Start Plants. 18
15 Fuel Reservoir "Day" Tank 19
16 Regulator, Assembling Gas — . . 20
17 ' Gas Fuel Installation . •. ? 21
18 Vacu-Flo Cooling 22
19 Governor Linkage Lubrication - 24
20 Crankcase Oil Level 24
21 Air Cleaner Service • 24
22 Fuel Shut-Off Valve 25
23 Carburetor Choking 26
24 Servicing the Breaker Points 35
25 Breather Valve 36
26 Governor Adjustment 39
27 Anti-Flicker 40
28 Carburetor Adjustments 41
29 Electric Choke Adjustment 43.
30 Magneto Stator Installation 46
31 Coil Installation for Magneto Ignition 46
32 Coil Installation for Battery Ignition 47
33 Ignition Timing 47.
34 Valve Service 49
35 Installing The Gear Cover 50 "»
36 Governor Cup 51
37 Timing Gears 52 ^
38 Fitting Piston Rings to the Cylinder 53
39 Reducing Connecting Rod Clearance 54
40 Bearing Installation 55
41 Oil Seal Installation 56
42 Crankshaft End Play 56
43 Brushes and Springs 58
44 Commutator Repair 59
45 Continuity Test Lamp 60
46 Armature Growler 60
47 Generator Assembly 62
48 Readi-Pull Starter (Model D) 65
49 Installing "Model D" Readi-Pull Starter 65
n
 TABLE OF C O N T E N T S

SUBJECT PAGE NO.

Description 1
Installation
Location, Manual Type Plant, Mounting 8
Exhaust 9
Separate Fuel Tank 10
Carrying Frame, Dolly 11
Oil Drain Extension, Battery •. 12
Wiring, Grounding • 13
Wiring Table, Remote Control Switch 14
Connecting the Load Wires 15
M
Fuel Reservoir Day" Tank, Readi-Pull Starter. 19
Assembling the Gas Regulator •• 20
Vacu-Flo Cooling 22
Preparation
Lubrication 23
Fuel, Before Initial Start 25
Operation
Starting the Plant ,• 26
Applying the Load ••• 27
Battery Charge Rate, Stopping the Plant 28
Function of the Controls 29
Abnormal Operating Conditions
Low Temperatures, High Temperatures 30
Dust and Dirt 31
High Altitude Operation 32
Periodic Service
Service Chart : 33
Daily Service, Weekly Service 34
Monthly Service 35
Adjustments
Governor 38
Anti-Flicker Mechanism 39
*" Carburetor - Gasoline 40
Carburetor - Gas Fuel 41
^ Electric Choke 42
Maintenance and Repair
General, Table of Clearances 44
Assembly Torques 45
Engine • • 45
Generator 58
6 3
Controls
Readi-Pull Starter 64
Special Purpose Section (2LK-IRV 1330/^)
Rated Output, Installation 67
Charge Rate, Governor Adjustment 69
Service Diagnosis • 70
Wiring Diagrams 78
III
 PLANT RUNNING HOURS
COMPARED TO AUTOMOBILE RUNNING MILES
The engine of your generating plant makes as many revolutions in one hour, as the
average automobile engine does when the car travels a distance of 41 miles.
100 running hours time on a generating plant engine is equivalent in total RPM's
to approximately 4100 running miles on an automobile.
However, do not conclude that the wear on the generating plant engine and the wear
on the automobile engine would be the same. The generating plant engine is built
much more rUggedly, (having larger main bearings, bigger oil capacity and has a
heavier crankshaft proportionately per horsepower) than most automobile engines.
Given the proper care and periodic servicing the generating plant engine will
continue to give many more hours of efficient service than an automobile engine
will after having been run the equivalent number of running miles.

Compare the running time of your generating plant engine with the number of miles
traveled by an automobile. The oil irt an auto is checked every one or two hundred
miles (3 to 5 hrs. running time) and changed every 1000 to 1500 miles (28 to 42 hrs.)
whereas in a generating plant or stationary power engine, the oil should be checked
every 6 to 8 running hours (250 to 350 miles) and changed every 50 to 100 operating
hours (2000 to 4000 miles) depending on operating conditions.
About every 5, 000 to 10, 000 miles (120 to 250 hours), services have to be performed
on an auto, such as checking ignition points, replacing spark plugs, condensers, etc.
Similarly on your generating plant engine, these same services have to be performed
periodically except the change period is reckoned in hours. 10,000 miles on an auto
is equivalent to about 250 running hours on your plant engine.
To arrive at an approximate figure of comparative generating plant running hours as
against automobile engine running miles, multiply the total number of running hours
by 41 to find the equivalent of running miles on an automobile.
Your generating plant engine can "take i t " and will give many hours of efficient
performance provided it is serviced regularly.
Below is a chart showing the comparison between a generating plant engine running
hours and an automobile running miles.
GENERATING PLANT AUTOMOBILE GENERATING PLANT AUTOMOBILE
RUNNING HOURS RUNNING MILES RUNNING HOURS RUNNING MILES

1 Hr. 41 Miles I 30 Hrs. 1,230 Miles

DAILY 4 Hrs. 164 " MONTHLY 120 " 4,920 "
AVERAGE 6 " 246 " . AVERAGE 180 " 7,380 "
1 8 " 328 " I 240 " 9,840 "

f 7 " 287 " 365 " 14,965 "

WEEKLY 28 " 1,148 " YEARLY 1,460 " 59,860 "
AVERAGE 42 " 1,722 " AVERAGE 2,190 " 89,790 "
( 56 " 2,296 " I 2,920 " 119,720 "

NOTE: Electric generating plants do not operate economically when used to

power electric refrigerators and will add from 4 to 8 operating hours per
day in addition to the regular lighting load.

IV
 DESCRIPTION

ORIENTATION

INTRODUCTION. - This instruction manual is supplied to assist in the

proper installation, operation, and servicing of the
LK series electric generating plants. Unless otherwise stated, these
instructions apply to all standard plants of the LK series.

NOTE
The plant model and specification, serial numbers, and electrical
characteristics appear on the nameplate. The manufacturer produces
many types of generating plants, and the MODEL & SPEC. NO. dri the
nameplate should always be mentioned in any reference to the plant if
contacting a dealer or the factory.

Some details of these instructions may not apply to special models hav-
ing modifications specified by the purchaser. Due to the wide variety
of uses for which these plants are suitable, these instructions must be
of a general nature. The use of auxiliary or special equipment, special
ff,
installation requirements, or unusual operating conditions may require
the operator of this generating plant to modify these instructions. How-
ever, by using the instructions and recommendations given in this man-
ual as a general guide, it will be possible to make a good installation,
and to properly operate and maintain the plant.

The engine end is designated as the "Front End" of the plant and the car-
buretor side is designated as the "Right Side" of the plant.

GENERAL DESCRIPTION

Each LK generating plant is a complete electric power plant, consisting

of an internal combustion engine, and a self excited electric generator,
directly connected to the engine. Controls and accessories suitable for
a normal installation and according to the particular model are supplied.

Each generating plant is given an actual running test at the factory and
is carefully checked under various electrical load conditions before
shipment, to assure that it is free of any defect and that it meets all per-
formance requirements. Inspect the plant carefully for any damage
which may have occurred in shipment. Any part so damaged must be
repaired or replaced before putting the plant into operation.
 DESCRIPTION
ALTERNATING CURRENT PLANTS. - the alternating current (ac)
plant generates current similar
to that supplied by most commercial power lines. This type plant must
be operated whenever electric power is desired.

Most electrical appliances can be used on either 50-or 60-cycle frequency

but it is advisable to check appliances before purchasing to assure that
they are adaptable to the current frequency and voltage. 50-cycle plants
operate at approximately 1500 rpm. 60-cycle plants operate at approxi-
mately 1800 rpm. Due to the speed difference, the output rating is low-
er for the 50-cycle plant.
The manual types of plants are designed for applications where portabi-
lity is important. A pull rope serves for hand cranking, and the plant
can not be connected to batteries for electric cranking. A mounted fuel
tank is provided. Electrical load wires must be attached to the genera-
tor output leads within the junction box on the plant. Load receptacles
can be conveniently added. '
The remote control type of plant is designed for applications where the
installation will be more or less permanent. When properly connected
to a 12-volt battery (or two 6-volt batteries in series), the plant may be
cranked electrically at the plant, from one or more remote control
switch locations, or through automatic controls. In the event of failure
of the starting battery current, the plant may be started manually. The
remote control type plant has a built-in charging circuit for keeping the
starting battery in a well charged condition. A separate 5-gallon (U.S.
Measure) fuel tank is used. Terminals inside the control box provide,
for connecting the electrical load wires.

A L L PLANTS. - The net weight of the plant is approximately 230-to 240-

pound s.

Standard models use gasoline fuel. Certain special models are equipped
for burning gas fuel.

ENGINE DETAILS

A vertical single cylinder, four stroke cycle, air cooled,. L-head,

internal combustion engine is used. The cylinder bore is 3-1/4 inches,
the stroke 3-inches, piston displacement 25-cubic inches, compression
ratio 5.5 to 1, and the rated horsepower at 1800-rpm is 5 h.p. The
cast iron cylinder and crankcase is a single casting.

The engine speed is controlled by a flyball type governor built into the
camshaft gear. The governor is adjusted at the factory. Ignition cur-
rent is supplied by a high tension, flywheel type magneto on manual-type
 DESCRIPTION

plants and by the starting battery on remote type plants. The engine is
cooled by air forced around the cylinder walls and head. Plants which
are "pressure cooled" have blower fins on the flywheel which draw air in
through the opening at the front of the blower housing. Remote-type
special models may be Vacu-Flo (suction) cooled, and have blower fins
which expel heated air out through the duct at the top of the blower hous-
ing, as desirable for small enclosure installations.

The engine has an aluminum alloy three ring piston, aluminum alloy con-
necting rod, and full floating type piston pin. The counterbalanced crank-
shaft turns in two unusually large sleeve type main bearings.
The cylinder head and oil base are removable for servicing the engine.

Positive splash type lubrication is standard. Oil capacity is 2 quarts U.

S. Measure.
The exhaust valve is stellite faced, seats on a stellite replaceable seat,
and uses a positive rotator providing long trouble-free performance.
Tappets are adjustable and self-locking.
GENERATOR DETAILS

All generators of this series generating plants are revolving armature,

four pole, self excited type. The machined steel ring frame mounts the
pole shoes and field coils. The armature is directly connected to the
engine crankshaft through a taper fit and held in place by a stud which
passes through the hollow center of the shaft.

AC GENERATORS. - The alternating current generator field is shunt

wound. Remote control models have an additional
series winding which permits use of the generator as a motor for crank-
ing the plant. The armature contains both ac and dc windings. The
direct current is used for energizing the field. The remote control
plant uses also direct current to charge the starting battery.

CONTROLS
AC MANUAL TYPE PLANTS. - These plants are started by manually
cranking with a pull rope. The carburetor
is manually choked. Electrical load is connected to the plant by con-
necting to the receptacles in the junction box mounted on the plant. The
plant is stopped by pushing a stop button on the ignition breaker box.
This type plant can not be connected to batteries for electric starting.
AC REMOTE CONTROL PLANT. - The remote control type plant is de-
signed for electrical starting, either
at the plant or by means of remote control stop-start switches. Auto-
matic or line failure transfer equipment may be connected to the plant.
 DESCRIPTION

The carburetor is automatically choked for starting. The control box is

mounted over the generator and contains a reverse current relay, a
start solenoid, a stop-start toggle switch, a two-step voltage regulator,
a stop relay, output terminals, manual or electric start switch, a
charge rate ammeter, and neceasary resistors. Terminals for battery
connections are provided. Output leads connect to terminals in the con-
t r o l box, for connecting to the load wires.

STANDARD ACCESSORIES
(Subject to Change)

MANUAL PLANT. -Manual plants are supplied with a Readi-Pull starter

(begin Spec.C), muffler, and instruction manual. The
Readi-Pull starter does not apply to Vacu-Flo cooled plants.
AC REMOTE CONTROL PLANT.-The ac remote control plant is supplied
with a muffler, separate 5-gallon fuel
tank with connecting fuel line, a flexible exhaust tube, and battery cables.

OPTIONAL ACCESSORIES

CARRYING FRAME KIT. - The plant can be mounted in a lightweight

tubular-steel carrying frame which provides
easier handling when moving the plant between successive locations. The
frame is intended for use with the manual starting plant having a mount-
ed fuel tank and no starting battery.
TWO-WHEEL DOLLY. - A 2-wheel dolly, onto' which the plant may be
permanently mounted, provides easy one-man
transportation of the plant. The dolly does not carry the starting bat-
tery nor the separate fuel tank used with various plants.
FOUR WHEEL DOLLY. - A 4-wheel dolly is available for installation
on housed models. The dolly is available in
kit form.
FUEL PUMP. - A fuel pump and related lines and fittings can be instal-
led on models not originally so equipped.
GAS CARBURETOR. - Some models are equipped with a special carburetor
and high compression cylinder head for gaseous
fuel operation. A gas conversion kit is available for field installation.
 DESCRIPTION

AUTOMATIC CONTROLS (AC Remote Start Plants Only). - A separate

control is
available for either 50 or 60 cycle ac units that will automatically start
and stop the plant as the load requires.
LOAD TRANSFER CONTROLS (AC Remote Start Plants Only). - Load
transfer
controls are available for use with either 50 or 60-cycle units in standby
service. When regular high line power fails, the load transfer control
automatically starts the standby plant and takes over the load. The plant
stops automatically when regular service is restored.
UNDERGROUND F U E L TANKS AND LINES. - 55 gallon and 110 gallon
fuel tanks and 1/4 inch
and 5/16 inch copper fuel lines in either 25 or 50 foot length are avail-
able for installing the fuel tank underground.
REMOTE START-STOP SWITCHES. - Additional remote start-stop
switches are available from your
dealer.
y.
3-CONDUCTOR CABLE. - This cable is designed for remote start-stop
station installation and is available from your
dealer.
RECEPTACLE PLATES FOR AC MANUAL PLANTS (Standard begin
Spec. C ) . - Two duplex, 3-prong grounding
type receptacles, which are mounted on a plate, and are connected
electrically, can be mounted on the plant junction box. These recep-
tacles permit easy "plug-in" of the load to the generator plant, as
desired for non-permanent type installations, and also provide a load
equipment ground. Matching 3-prong plugs for the load lines are
required. These receptacles plates differ between generator voltage
ratings. The receptacle for 120-volt circuits takes a plug with two
parallel blades and one grounding prong (an ordinary 2-prong plug
will fit). The receptacle for 240-volt circuits takes a plug with tan--
g.- dem blades (two blades in line) and one grounding prong.

RECEPTACLE PLUGS OR CAPS. - These 3-prong grounding type plugs,

to fit the receptacles mentioned
above, are available from your dealer.

HOUSING. - The protective housing is designed for the Vacu-Flo

equipped plants. The housing provides space for a fuel
tank and the starting batteries.

COLD WEATHER SHUTTER. - Fits Vacu-Flo plants. Limits air flow.

 INSTALLATION

FIG. 1 - TYPICAL INSTALLATION

 I N.S..T A L LAT IQJtS
/1UFFUER
AIR C L E A N E R
PIPE- T H D .
CARB.
FUEL INLET
•CONTROL BOX

- 2 K W 120 V 2 WIRE
2 KW 2 - 4 0 V 2 WIRE
UNITS

2 KW. 129/240 V

OIL DRAIN
gPIPE PLUS
r 3 WIRE UNITS

REMOTE
-4. MTG. HOLES
FOR ^ BOLTS OIL FILL- START

RECOIL
STARTER MR C L E A N E R .
CARB
- 3 G A L . F U E L TANK

•OUTLET BOX

- 2 KW IZQ V. 2 WIRE OR
2 KW 2 4 0 V. 2 WIRE
UNITS

-2 KW. I 2 0 / 2 4 O V
3 WIRE UNITS

MANUAL
START

-17 15 31.
16

PORTABLE RECOIL STARTER CARRYING FRAME

FIG. 2 - DIMENSIONAL OUTLINE

8 INSTALLATION

CAUTION

EXHAUST GASES FROM INTERNAL COMBUSTION ENGINES

ARE DEADLY POISONOUS. EXCESSIVE INHALATION WILL
CAUSE SERIOUS ILLNESS OR DEATH. NEVER OPERATE
THE PLANT INSIDE A BUILDING OR OTHER CONFINED
SPACE WITHOUT PIPING A L L EXHAUST GASES OUTSIDE
THE ENCLOSURE.

The preferable ambient air temperature for best engine performance is

well above freezing, and the preferable ambient air temperature for most
o
efficient generator operation is well under 100 F. and should not exceed
o
110 F. if conditions permit controlling the temperature.

MANUAL T Y P E PLANT. - The manual type of plant is particularly ad-

aptable to a wide variety of portable applica-
tions. The plant may be mounted on a carrying frame, dolly, trailer,
or suitable platform if desired. Install the muffler directly to the en-
gine exhaust outlet. Be sure to provide for adequate circulation of air
for proper cooling. Serious damage from overheating can result if cool-
ing air is obstructed. The plant may be operated out of doors, but rea-
sonable care should be taken to protect the plant as much as practicable
from exposure to the elements. Be sure the plant sets level when in
operation. Use rubber mounting cushions to minimize vibration.

-NUT
LOCK WASHER
FLAT WASHER
-MOUNTING RUBBER
PLANT
-MOUNTING BASE
-SPACER
-MOUNTING RUBBER
FLAT WASHER
BOLT

- L A R G E FLAT
WASHER (OPTIONAL)

FIG. 3 - MOUNTING CUSHIONS

MOUNTING, PERMANENT INSTALLATION. - Refer to the illustration,
Typical Installation.
Select a site for the plant which will be clean, dry, well ventilated, and
which preferably can be heated in extremely cold weather. A damp or
dusty location will necessitate more frequent servicing. Install batteries
as close as practicable to the plant. Mount the plant on a substantial
level, concrete or timber base, preferably at least 12 inches high. L o -
cate the base so as to provide at least 24 inches space on all sides for
convenience in servicing. Use the rubber mounting cushions to mini-
 INSTALLATION

mize vibration. See the mounting details as illustrated.

Provide separate air inlet and outlet openings large enough to provide for
proper circulation of cooling air. The openings may be adjustable if de-
sired, so as to partially control the temperature of the enclosure. In
ordinary temperatures the inlet and outlet air openings should be at least
3 square feet in area. The outlet should be nearer the ceiling.

POSITION MOUNTING BOLTS IN

CLEATS PLACED ACROSS FORM

-BOLT

XfiL LARGE FLAT

^Ik WASHER
-^tonioNAi)

Dimension'A'" 10"
T - IO'
• O 2"
• -or- zi*
•E-12'

FIG. 4 - MOUNTING BASE

EXHAUST. - Pipe the exhaust gases outside the enclosure, using 1 inch
pipe or larger. Increase the exhaust line size, by one pipe
size, after each additional 10 foot length. Avoid sharp bends if possible
by using bent pipe or sweeping elbow where necessary. Connect the
flexible exhaust tube to the plant exhaust outlet, a sufficient length of
pipe to conduct the gases outside the enclosure, and the muffler tb the
pipe outside the enclosure. Protect combustible walls, partitions, etc.
through which exhaust pipes pass with a metal thimble having the dimen-
sions shown in the illustration below. Insulate pipes where the danger of
personal contact exists. If the exhaust line must be inclined upward from
the plant, install a condensate trap at the point where the upward pitch
begins. Periodically drain the trap.

INGLE THIMBLE DIAMETER 1 2 "

L A R G E R OR D O U B L E
VENTILATED THIMBLE
DIAMETER 6 " LARGER IF EXHAUST LINE MUST BE PITCHED UPWARD
T H A N EXHAUST LINE CONSTRUCT A TRAP OF PIPE FITTINGS AT
, PPINT OF RISE
OLES I N E A C H E N D
| A V O I D SHARP BENDS J
INNER SLEEVE
4 D R A I N CONDENSATION TRAP
PERIODICALLY
EXHAUST LINE PASSING THROUGH
II WALL OR PARTITION

FIG. 5 - EXHAUST INSTALLATION

10 INSTALLATION

If exhaust noise f r o m the standard muffler will be objectionable, an un-

derground muffler may be constructed. Do not use an underground
muffler if there is any danger of its filling with water at any time. Use
a heavy metal drum, welding suitable pipe fittings in place. Do not use
a drum which contained any inflammable liquid without f i r s t making sure
that a l l explosive vapors have been driven out. Remove the bottom of
the drum or d r i l l holes in the bottom to allow condensation f r o m exhaust
gases to drain away. The muffler exhaust pipe should extend at least
24 inches above ground, with a gooseneck fitting on the end to prevent
entry of rain or snow.
SEPARATE FUEL TANK. - The separate fuel tank has a capacity of 5
gallons (U.S. Measure).

If the plant has no fuel pump, install the tank on a substantial support so
that the bottom of the tank w i l l be one inch above the carburetor fuel i n -
let.
On gravity feed installations, fuel leakage when idle, or flooding con-
dition during operation, w i l l result if the fuel tank is elevated too high.
If the plant is in a vehicle and subject to transportation jars, it is advis-
able to close the shut-off valve when not in operation.
Be sure to open the air vent at the top of the tank. The shut-off valve
should be turned all the way outward until it backseats.

If the plant has a fuel pump, install the fuel tank so that the bottom of the
tank will b e less than 4 feet below the fuel pump. The top of the tank
must not be above the fuel pump. As with an underground fuel tank, if
the fuel lift is more than 4 feet, install an auxiliary electric fuel pump.

Note that only one end of the flexible fuel line has a fitting, and this end
of the line should be assembled to the fuel filter at the plant inlet.
Thread about 15 inches of line through the rain cap (lubricate the line
with soap). Assemble the rain cap to the fuel tank. Press the metal tank
cap over the top of the rain cap to keep water from entering the vent hole.

FIG. 6 - CARRYING FRAME

 INSTALLATION 11

CARRYING FRAME (OPTIONAL ACCESSORY). - The illustration shows

the position of hardware
used to mount the plant. Use the existing mounting cushions, bushings,
and washers supplied with the plant. The frame fits lengthwise under
the plant so that handles are on opposite ends.
DOLLY ASSEMBLY (OPTIONAL ACCESSORY). - The illustration shows
the position of hard-
ware used to assemble the dolly and mount the plant. The dolly tires
and feet cushions serve to absorb vibration so that mounting cushions at
the oil base are not required.
Mount the plant on the dolly with the generator end toward the handles.
Grease wheel bearings.
(1) On each end of the axle install a washer, a wheel, a washer, and a
cotter pin. Spread the pins well.
(2) Select the pair of holes in the axle channel which fit the plant to be
mounted. Attach each handle by installing its stud into the axle channel
holes; leave the front holes open to mount the plant base.
(3) With the plant in position on the dolly, install 2 bolts with washers
through the oil base holes, next through the dolly handles, then through
the axle channel.
GRIP

HANDLE
(RIGHT)

AXEL ASSEMBLY

FIG. 7 - DOLLY
12 INSTALLATION'

(4) Install 2 bolts with washers through the remaining oil base holes,
next through the dolly handles. Use a thick flatwasher under the handle
end mounting holes. Use a lockwasher under each nut and tighten all nuts
on the bolts and studs.
(5) Secure a foot cushion to each handle with a lockwasher and nut. In-
stall the handle grips (if shipped loose)using soap suds to aid installation.
OIL DRAIN EXTENSION. - An oil drain extension pipe and coupling will
provide cleanliness and convenience in drain-
ing oil from the oil base. Before filling the oil base with oil as directed
in the following section, remove the drain plug from the oil base and in-
stall a 3/8" pipe nipple and coupling in its place. Install the drain plug
in the coupling. When draining the oil, remove only the plug.
PIPE NIPPLE

OIL BASS'
-PIPE COUPLING

FIG. 8 - OIL DRAIN EXTENSION

BATTERY, AC REMOTE CONTROL PLANT. - A 12 volt battery is re-

quired. If two 6 volt
batteries are used, the batteries must be connected in series by con-
necting a short cable between the positive post of one battery and the ne-
gative post of the other battery.

FIG. 9 - BATTERY CONNECTION - AC REMOTE PLANT

Connect one of the long battery cables between the positive (+) battery
post and the BATTERY terminal on the start solenoid in the control box.
Connect the other battery cable between the negative (-) battery post and
the grounding terminal (screw, stud, or solderless) on the generator.
 INSTALLATION 13

Be sure battery connections are tight. Coat the battery clamps and posts
lightly with grease or vaseline to minimize corrosion. Batteries ship-
ped "dry" must be prepared for use as directed on the tag attached to
each battery. Batteries shipped ready for use were fully charged when
shipped. Such batteries slowly lose their charge when standing idle and
it may be necessary to give them a "freshening" charge before putting
them in use. Use a hydrometer to determine the charge condition.

WIRING. - If necessary to install wiring, follow specifications of local

and national electrical codes. If in doubt, consult a licensed
electrician. Use sufficiently large, insulated wire between the plant
and the load. Install a circuit breaker or a fused main switch in the load
line near the plant. R E F E R TO THE APPLICABLE PLANT WIRING
DIAGRAM.

Where connections are made by joining two wires, always be sure to

tape the connections thoroughly. Apply two layers of half-lapped elec-
trician's tape and two layers of half-lapped friction tape, extending both
well beyond the ends of the connection.
Join leads
together
with
connectors
and tape
connections

FIG. 10 - TAPING WIRE CONNECTIONS

The wire size Will depend largely bn the distance and permissible volt-
age drop between the plant and the load, and the amount and kind of load.
Consult a competent electrician. Check national and local codes before
installing.
GROUNDING, A L L PLANTS. - If grounding is called for in local codes,
or. if radio interference necessitates it,
provide a separate ground. Radio interference may result if the plant
is grounded to a water pipe or to a ground used by a radio. Drive a 1/2"
diameter pipe or rod into the ground as near to the plant as possible.
Make certain that the ground rod will always penetrate moist earth.
Fasten an approved ground clamp to the rod. Run a wire (number 8 or
larger) (not smaller than 2 sizes smaller than the largest wire used in
the system) from the clamp to the plant ground terminal. If no separate
grounding terminal is provided on the plant, connect to the BATTERY
NEGATIVE or to the grounded load line wire.
The installation must be mechanically secure, and must have low resis-
tance electrically. Comply with national and local electrical codes.
14 INSTALLATION

GROUNDING T E R M I N A L G R O U N D I N G ROD
ON P L A N T S H O U L D BE A S
CLOSE TO P L A N T
AS PRACTICAL

A T T A C H GROUNDING
WIRE TO ROD W I T H
A N APPROVED T Y P E
OF C L A M P — DRIVE ROD
INTO M O I S T
EARTH

FIG. 11 - PLANT GROUNDING

WIRING TABLE - 115-V.
Unity Power Factor. 2% Voltage Drop (2.3 Volts)
WIRE SIZE NO. 14 12 10 8 6 4 2
WATTS AMPS * Distances expressed in feet per wire size.
100 .87 510 810 1280 2040 3250 5300 8200
200 1.74 255 405 640 1020 1625 2650 4100
300 2.61 170 270 430 680 1080 1770 2730
400 3.48 125 200 320 510 810 1325 2050
500 4.35 100 160 255 410 650 1060 1640
750 6.52 65 100 170 275 430 710 1090
1000 8.69 50 80 125 205 325 530 820
1500 13.04 35 55 85 140 215 350 550
2000 17. 38 25 40 65 100 160 265 410
2500 21.73 20 35 50 80 130 210 350.
Above figures represent a point to point distance for a 2~wire run. If
a 4% voltage drop is permissible, double the distance listed. If only
1% voltage drop is allowable, divide the distances listed by 2.
Single Phase 115-Volt A . C . - Use 115-Volt table above.
Single Phase 115/230-Volt A. C. S^Vire - Use 115-Volt table above
for each 115-Volt Circuit.
Single Phase 230-Volt A. C. - Double the distances listed in the 115-
Volt table above. Use Amps Column.
REMOTE CONTROL SWITCH, AC PLANTS. - One or more remote con-
trol switches may be con-
nected to provide remote control of starting and stopping remote plants.
The wire length from the plant to the switch determines the wire size
necessary. For distances up to 250 feet use #18 wire. Use #16 wire up
to 400 feet, or use #14 wire up to 630 feet.
 INSTALLATION 15

The four place terminal block, located in the control box, is marked
"REMOTE CONTROL", B + , 1, 2, and 3 appears in the illustration.
Terminal number 1 is used as a common ground, terminal number 2 con-
nects to the stopping circuit of the plant and terminal number 3 connects
to the starting circuit, of the plant. The terminal marked B + , is to be
used only with an automatic control installation.
s

Use single-pole double-throw momentary-contact center-off type switches

as Remote Start-Stop Stations as illustrated. Connect a l l number "2"
or "OFF" switch terminals to the number "2" terminal on the plant ter-
minal block. Likewise, connect together all number "3" or "ON" ter-
minals and also, all number " 1 " or "SINGLE" (not marked) terminals.
If the switch is to be mounted vertically, start position should be upward
to conform with operation at the plant when a toggle switch is used.

REMOTE CONTROL
TERMINAL BLOCK'
3 AT P L A N T
MOMENTARY CONTACT
SWITCH

FRONT

FIG. 12 - REMOTE START-STOP STATIONS

CONNECTING THE LOAD WIRES, AC REMOTE PLANTS. - The a.c.

load ter-
minals are located inside the control box and are marked. The same -
markings appear on the wiring diagram. These terminals are of the
solderless type and connections are made by simply inserting the end of
the load wire into the connector and tightening the screw. Thoroughly
strip 3/8 of an' inch of insulation from the end of each wire before in-
serting it into a terminal. Load wires enter the control box through a
grommeted hole. Be sure connections are clean and tight.
Leave the load line switch open until the plant has been started and
checked. No damage to the generator or controls w i l l result f r o m run-
ning the plant with no load connected.
16 INSTALLATION
"SINGLE PHASE.TWO WIRE CONNECTIONS
<ty*v

CONNECT GROUNDED ( W H I T E ) SIDE

OF LOAD C I R C U I T H E R E ( M 2 )
REMOTE
PLANTS
- C O N N E C T U N G R O U N D E D C B L A C K ) SIDE
OF L O A D C I R C U I T HERE CM,)

GENERATOR CONNECT GROUNDED (WHITE)

LEADS SIDE OF LOAD C I R C U I T TO
GENERATOR LEAD MARKED

MANUAL
PLANTS
RECEPTACLES RE-
MOVED. D I R E C T CONNECT U N G R O U N D E D
C B L A C K ) S I D E OF L O A D C I R -
L O A D WIRE
C U I T TO G E N E R A T O R L E A D M,
CONNECTIONS
ON A 120V. P L A N T I 2 0 V - I PH. C U R -
R E N T MAY B E O B T A I N E D FROM -
ANY RECEPTACLE.
MANUAL
WITH
ON A 2 4 0 V. P L A N T 2 4 0 V . - I P H . C U R -
R E C E P T A C L E BOX R E N T MAY B E O B T A I N E D FROM
ANY RECEPTACLE

SINGLE PHASE.THREE WIRE CONNECTIONS

> 2 4 0 V.
REMOTE
PLANTS

MANUAL
PLANTS > 2 4 0 V.
RECEPTACLES RE-
MOVED. D I R E C T >• 120 V.
L O A D WIRE
CONNECTIONS

120 V.
MANUAL "I P H A S E
WITH
USE P L U G HAV-
R E C E P T A C L E BOX USE PLUG
ING PARALLEL BLADES
HAVING TAN-
:
DEM B L A D E S AND WITH ; AND W I T H GROUNDING
GROUNDING PRONG PRONG
AS73

FIG. 13 - AC LOAD WIRE CONNECTIONS

 INSTALLATION 17

1-Phase, 2-Wire

On single phase, two wire plants, connect the load wires to the plant by
connecting the ground (white) load wire to the control box terminal marked
"M2". Connect the "hot" ungrounded (black) load wire to the control box
terminal marked "Ml".

1-Phase, 3-Wire

On single phase, three wire plants, connect the load wires to the plant
by connecting the ground (white) load wire to the control box terminal
marked "M2". Connect one of the "hot" ungrounded (black) load wires to
the control box terminal marked "Ml", and connect the remaining "hot"
ungrounded (black) load wire to the control box terminal marked "M3".

Two 120-volt circuits are available. One circuit across "Ml" and "M2"
and another circuit across "M2" and "M3". The load on each 120-volt
circuit should not be more than 1/2 the capacity of the plant.

One 240-volt circuit is available. This circuit is across "Ml" and "M3".
"M2" is not used with a 240-volt circuit. If only 240-volt current is used,
the full rated capacity of the plant may be used.

Both 120-volt current and 240-volt current may be used at the same time.
However, the total of either 120-volt load plus 1/2 the 240-volt load
should not exceed 1/2 the capacity of the plant. For example: a total of
1000-watts is available on each 120-volt circuit of a 2000-watt single
phase 3-wire plant. If 500-watts of current is used on each 120-volt
circuit, only 1000-watts of 240-volt current is used, only 500-watts of
120-volt current is available on each 120-volt circuit.

CONNECTING THE LOAD WIRES, AC MANUAL PLANTS. - Manual. .

plants have output leads which extend to a
receptacle box (junction box prior to Spec. C ) . Connections to the out-
put leads may vary between different installations. If the receptacles
are disconnected and not used and the load wires are connected to the
generator output leads install a circuit breaker or a fused switch in the
main load line to provide for automatic disconnecting of the load.

If the application is essentially stationary, the user may desire to con-

nect the load leads within the junction box on the plant, using bolts or
connectors and taping each lead. If the main load lines are to be run in
rigid conduit, install a short length of flexible conduit between the out-
let box and the rigid conduit. Flexible conduit may be used entirely if
so desired. If conduit is not used, install a load conductor securing
device, to hold the load wires where they enter the outlet box.
18 INSTALLATION
t
1-Phase, 2 -Wire

On single phase, two wire plants, connect the load wires to the plant by
connecting the ground (white) load wire to the generator lead marked
"M2". Connect the black (hot) load wire to the generator output lead
marked "Ml".
1-Phase, 3-Wire

On single phase, three wire plants, connect the load wires to the plant
by connecting the ground (white) load wire to the generator lead marked
"M2". Connect one of the "hot" ungrounded (black) load wires to the gen-
erator lead marked "Ml", and connect the remaining "hot" ungrounded .
(black) load wire to the generator lead marked "M3". • ;

If the application requires plant operation at various locations, the user

may desire to add receptacles of adequate rating to the output leads,and
use plugs on the load leads such as those offered as optional accessories
by the factory, and available through the dealer. These two duplex 3-
prong grounding type receptacles are mounted on a plate which fits the
existing junction box on the plant. The receptacles are wired and the
assembly contains short leads for bolting to the generator output leads.
On the assembly for the 120/240-volt plant, the jumper bar between the
two ungrounded 120-volt receptacle terminals is broken out,, as neces-
sary to prevent a dead short which would cause failure of plant output.
Likewise, a future replacement of the 120-volt receptacle only, on,the
120/240-volt plant must have the jumper bar removed between the "hot"
terminals. When installing the receptacles and plate assembly, refer .
to the illustrations herein and bolt receptacle lead or leads marked
"Ml" to generator output lead marked "Ml", then tape the connection.
Likewise, connect M2" to "M2" and so on according to the model in
question.

I PHASE I PHASE
2 WIRE 3 WIRE

\
CONNECT TO CONNECT TO
BLACK CM,) BLACK CM3)
CONNECT TO GENERATOR GENERATOR
LEAD • LEAD
CONNECT TO WHITE CONNECT TO BLACK WHITE CM2)
(Mz) GENERATOR LEAD (MP GENERATOR LEAD GENERATOR
LEAD .

FIG. 14 - RECEPTACLE PLATE CONNECTIONS-

MANUAL START PLANTS
 INSTALLATION 19

F U E L RESERVOIR (DAY) TANK. - In standby service, the generating

plant may stand unused for many days.
In this period of shut-down, sufficient gasoline may evapprate from the
carburetor to lower its fuel level considerably. Prolonged cranking may
then be necessary in order to pump enough gasoline into the carburetor
for the engine to start. On installations where automatic, unattended
starting after extended shut-down is necessary, an auxiliary, gravity
feed fuel tank should be installed. Fuel from this tank flows by gravity
to the carburetor, thus replacing any fuel lost through evaporation and
promotes quick starting after an idle period.
VSNT CAP
(INSTALL ATLEAST
3 FEET ABOVE THE
VESEPVO//? TANK)
VEA/T L /A/£ TO EXTEG/Of

7?ESEeVO/l? TANK-^
J
fMOUA/T W
CONVEN/ENT PLACE
ON PLANT)

3 " •LINE FPOM FUEL PUMP

LARG£ a
PETUPHL/NETO
UA/PEI?GI?OOND
FUEL TANK "

LINE TO CAQBU£ETO&

FIG. 15 - F U E L RESERVOIR "DAY" TANK

INSTALLING SECONDARY GAS REGULATOR. - The secondary regu-

lator is designed to operate on an incoming line pressure of from two
to eight ounces, a primary regulator must be installed and adjusted to
reduce the line pressure before it enters the secondary regulator.

A fuel filter should be installed in the line, before the secondary regula-
tor to prevent pipe scale and other impurities from entering the regula-
tor. An electric solenoid shut off valve is required in some localities.

NOTE !

For model 2LK-1RV1330/ "Mobile Communications" or

"Utility Type" plant, refer also to Special Purpose Section.
20 INSTALLATION

GAS F U E L . - Plants equipped to burn gas fuel (natural gas or LPG) are
supplied with an atmospheric type gas pressure regulator.
The regulator is designed to operate on a fuel line pressure of eight (8)
ounces. If the fuel line pressure exceeds eight ounces, a primary type
regulator must be installed ahead of the regulator supplied, to reduce
the line pressure. Consult the fuel supplier.

The installation must conform to local gas regulations. Some localities

require the installation of a fuel filter, and an electric solenoid shut-off
valve.
Mount the regulator in an upright position on the,gas supply pipe. Use a
flexible line between the regulator outlet and the carburetor inlet. Use
care to see that no pipe cuttings, scale, etc. are trapped in the pipe so
as to enter, the regulator. Test thoroughly (soap bubble) for leaks after
finishing the installation.

SECONDARY
REGULATOR

CARBURETOR

ELECTRIC
. FUEL
SOLENOID

FIG. 17 - GAS FUEL INSTALLATION

 INSTALLATION 21
GAS F U E L
- ASSEMBLING THE REGULATOR -
M M
1. Assemble the 3/4 (B) and 1/8 (C) pipe plugs to the regulator.
2. Assemble the reducer bushing (L) when supplied, to the regulator.
3. Assemble the pipe nipple (K), elbow (D), and half nipple (E).
4. Some installations require a fuel filter. Install the filter in the
incoming fuel line ahead of the regulator as shown.
5. Install the regulator to the 3/4" incoming fuel supply line. Turn
the regulator to an upright position and support the supply line so
as to serve as a mounting for the regulator.
"ADJUSTING THE REGULATOR
This regulator was factory ad-
90" ELBOW @ justed to lock-off at a pressure
[|—NIPPLE®
of 4 ounces (7"water column).
^^REOUCING BUSHING©
The regulator will operate sat-
isfactorily at incoming pres-
GAS REGULATOR ( A ) sures of from 2 to 4 ounces.
ADJUSTING SCREW (5) If your gas supply pressure
EARLIER MODELS
HAD A D D I T I O N A L
OUTLET HERE WITH
is within these limits, no reg-
V l " PIPE PLUG. .VENT © ulator adjustment is required.
CBALANCE)
i* PI RE PLUG If your gas supply pressure is
under 2 ounces, the regulator
will not operate. If your gas
f GAS SUPPLY LINE supply pressure is between 4
DRY FUEL
FIITFB
and 8 ounces, install an ap-
FIG. 17 - GAS F U E L INSTALLATION pliance regulator set for 2
ounces ahead of the regulator, or adjust the regulator as follows:
WARNINGI A soap bubble placed over the regulator outlet will not
accurately test for regulator closing. The soap bubble's resistance
when multiplied by the greater area of the regulator diaphragm, is
enough to shut off this very sensitive demand type regulator.
1. Connect a manometer, which reads up to 14 inches water column, to
regulator's plugged test hole near inlet. Turn gas on.
2. Turn regulator closing adjusting screw (G) inward just far enough
so that the manometer reading remains constant when you repeatedly
cover and uncover the regulator outlet with your hand. Failure to
close indicates too high incoming pressure or dirty regulator valve
and seat.
3. Close the gas supply line valve. Remove manometer. Bleed air
from gas supply line. Install test-hole plug in regulator. Open gas
supply line valve. See that vent fitting (F) is installed.
4. With a clamp on each end, secure the hose (H) between the reg-
ulator nipple and the carburetor inlet.
5. Operate the engine to assure quick starting results.

Refer to the ADJUSTMENTS section for carburetor adjusting information.

22 INSTALLATION
VACU-FLO COOLING (Optional Equipment). - Cooling air is drawn
past the engine and out
through the front of the blower housing on plants which are Vacu-Flo
cooled (also referred to as suction cooled). This type of cooling is de-
sirable where the plant must be installed in a small enclosure. Provide
AT LEAST 103 square inches of free (net) air inlet area. Install duct
work to exhaust heated air outside of the enclosure, using flexible ma-
terial next to the engine air ducting scroll. Vacu-Flo type cooling is
available only for remote type plants,, all of which have battery ignition.
The optional cold-weather-air-shutter (damper) is thermostatically con-
trolled to limit air flow and includes a safety shut-down switch.

00

FIG. 18 - VACU-FLO COOLING

 PREPARATION 23

CAUTION

DO NOT A T T E M P T TO START OR O P E R A T E T H E P L A N T
UNTIL I T HAS B E E N P R O P E R L Y P R E P A R E D FOR O P E R -
ATION WITH OIL AND F U E L AS D I R E C T E D IN THIS S E C -
TION.

CRANKCASE LUBRICATION. - The oil capacity of the plant is 2 quarts

(U. S. Measure). Use detergent oil
classified by the American Petroleum Institute as Service "DG" or, as
marketed by most manufacturers, "MS/DG". The use of Service "DS"
is not recommended.

Multiviscosity oils such as 5W-20 or 10W-30 are not recommended, as

the oil consumption increases greatly (in some cases consumption may
be more than doubled). At low temperatures where cold starting may
be difficult and high oil consumption is not a factor, the use of multi-
viscosity oil may be justified. Do not use a non-detergent oil.

TEMPERATURE S A E NUMBER
0
Above 90OF. ( 3 2 C . ) 50
o o 0 0
3 0 F . to 9 0 F . ( - 1 C . to 3 2 C . ) 30
o o 0 0
0 F . to 3 0 F . ( - 1 8 C . t o - l C . ) 10W
0
Below OOF. ( - 1 8 C . ) 5W

When using a detergent type oil, always use oil of the same brand when
adding oil between oil changes. When mixed together, detergent oils of
different manufacturers sometimes form chemical compounds that are
harmful to internal engine parts.

Place a drop or two of non-gumming oil at the point where the governor
linkage engages the carburetor throttle a r m . Units with plastic type
ball joint require cleaning of ball joint only.
24 PREPARATION

FIG. 19 - GOVERNOR LINKAGE LUBRICATION

KEEP CRANKCASE OIL

AT T H I S L E V E L .

, N E V E R OPERATE ENGINE
WITH O I L BELOW T H I S
LEVEL.

FIG. 20 - CRANKCASE OIL L E V E L

Renew oil before

; FILTE 3 ELEMENT—. f i l l with engine
dirt reaches shelf
oil: to this, l e v e l . in cup.

OIL BATH
0
J"^ AIR C L E A N E R
.v
FILTER ELEMENT DIP FILTER
E L E M E N T IN A P A N
. / J OF O I L . DRAIN A N D
REPLACE

FIG. 21 - AIR CLEANER SERVICE

 PREPARATION 25

Lubricate the governor arm ball joint with a dry type lubricant such as
powdered graphite to assure best performance and longest life of the ball
joint. If graphite is not available, use light non-gummy oil.

Remove the air cleaner mesh element (Fig. 21) and dip in oil of the same
SAE number as used in the crankcase. Allow the excess oil to drain off,
reassemble the air cleaner.

F U E L . - The manual type plant has a 3-gallon rectangular tank mounted

over the generator. The stationary type plant has a 5-gallon
separate tank. Measures are U . S . Standards. Fill the tank nearly full
with clean, fresh, automotive type "regular" grade of gasoline. Do not
use a highly leaded premium type gasoline, as its use will necessitate
more frequent carbon removal and spark plug and valve service. Do
not fill the tank entirely full of cold gasoline. Expansion of the fuel as
the plant warms up may cause the gasoline to overflow and result in a
fire hazard. Observe the usual precautions when handling gasoiine.
NEVER F I L L THE TANK WHEN THE PLANT IS RUNNING, BECAUSE
OF FIRE HAZARD.
Open the fuel shut-off valve all the way until it back seats. Inspect the
fuel system for leaks.

If the preceding instructions have been followed, the plant should be

ready for operation. Before starting the plant, however, carefully study
the sections OPERATION and ABNORMAL OPERATING CONDITIONS
immediately following.

OPEN VALVE ALL THE WAY

TO BACK SEAT
A 283

FIG. 22 - F U E L SHUT-OFF VALVE

BEFORE INITIAL START. - Clean the spark plug in gasoline before the
initial start to dispose of preservative oil
placed in the cylinder before factory shipment. Dry it thoroughly.
26 OPERATION

BEFORE ATTEMPTING TO START THE PLANT, MAKE

SURE THE PLANT HAS BEEN PROPERLY INSTALLED
AND PREPARED FOR OPERATION AS DIRECTED IN
THE PREVIOUS SECTIONS.

ALTERNATING CURRENT PLANTS

STARTING THE REMOTE CONTROL PLANT E L E C T R I C A L L Y . - Be-

fore
starting a new plant the first time, or one which has run out of fuel, it
will be necessary to pump gasoline into the carburetor. Work the fuel
pump primer lever or allow the plant to crank electrically by holding
the START-STOP s'witch at the START position. It usually takes ap-
proximately 30 revolutions of the crankshaft to properly fill the car-
sburetor with gasoline. If fuel does not reach the carburetor, inspect
carefully for an air leak between the fuel pump inlet and the fuel tank.
iBe .sure all valves are open and the pump primer lever is returned to
inward .position. The air vent on the separate tank must be partially
(Open.
SOLID LINES INDICATE CHOKING
POSITION OF CHOKE LEVER.
OPEN POSITION IS INDICATED BY
BROKEN LINE.
ELECTRIC
^\ CHOKE

T U R N WEIGHT-LEVER IN
T H I S .DIRECTION TO OPEN

- Electric Choke - - Manual Choke -

•FIG. 23 - CARBURETOR CHO KING

'.To start the plant, push the START-STOP toggle switch to the START
position. The plant should start after a few revolutions. The carbure-
ttor ;isjautomatically choked. If the plant does not start after a few
crank ings of .approximately 5 seconds each, carefully check the fuel and
igriition systems. Release the start switch as soon as the plant starts,
tmaking-sure:that the:switch.returns to the center position. If one pr
imore.remote control switches have been installed, check the installa-
itiontby 'trying the START tand STOP positions of each remote control
:switch. Gaseous.fue led models do not use choke.
 OPERATION 27

STARTING THE REMOTE CONTROL PLANT MANUALLY. - To start

the plant
manually, f i r s t be sure the carburetor is properly filled with gasoline
as described above under STARTING THE REMOTE CONTROL PLANT
ELECTRICALLY. Do not have a heavy electrical load connected to the
generator. On plants not equipped with a recoil starter accessory kit,
engage the knot of the starting rope in a notch of the flywheel rope
sheave and wind the rope in a clockwise direction to within a few inches
of the handle. Crank the engine with a strong, fast pull the f u l l length
of the rope. Do not jerk the rope. Repeat the cranking as necessary.
If the plant does not start readily, check the fuel and ignition systems,
correcting any trouble found. No choke used on gas fueled models.

STARTING MANUAL PLANTS. - The mounted tank supplies a continu-

ous supply of fuel to the carburetor
by gravity feed. Adjust the manual carburetor choke (as illustrated)
as necessary for the temperature conditions. If the plant has been
standing idle in cold weather, the carburetor choke may have to be com-
pletely closed for the first cranking. In hot weather, or if the plant is
still warm from recent operation, little or no choking should be re-
quired. Avoid overchoking. Before cranking, adjust the choke. On
plants not equipped with a recoil starter accessory kit, wind the start-
ing rope on the flywheel rope sheave in a clockwise direction to within
a few inches of the rope handle. Crank the engine once with a strong,
fast pull the f u l l length of the rope. If the plant fails to start at the
f i r s t cranking, change the choke setting and repeat the cranking. As
the plant starts, adjust the choke position to the point where the plant
runs smoothly. As the plant warms up, gradually open the choke to the
running position, as illustrated. No choke used on gas fueled models.

IMPORTANT! !
This unit has been run and tested for about 3 to 4-hours at the factory.
Additional break-in time is required and will vary depending upon load
conditions, oil used,etc. Load during break-in should be between 1/2
load and rated load, preferably near rated load for best results. Above
procedure will result in faster break-in and lower o i l consumption.
APPLYING THE LOAD. - Best results are obtained if the plant is
allowed to thoroughly warm up before apply-
ing a heavy load. Load wires should be connected before operating,
according to the model in question, as instructed under INSTALLATION.

Apply the load to the remote control type plant by throwing the main line
switch to the ON position. If no main line switch was installed, throw
the switch for the individual load to the ON position. When possible
apply portions of the load in steps.
 28 ; OPERATION
Procedure for applying the load to the manual type plant will depend up-
on the installation and application. If no plug-in receptacles were added
at the plant, load application as given for remote control type plants
w i l l apply.

On the manual type plant, to which plug-in receptacles where added,

apply the load by inserting the load plug directly into the receptacle at
the side of the generator. The 240-volt output 3-prong grounding type
receptacle requires a tandem load plug having two blades in line and
one load equipment grounding prong. The 120-volt output 3-prong
grounding type receptacle is designed for a load plug having two blades
parallel and one load equipment grounding prong. An ordinary two
blade plug can be used in the 120-volt output 3-prong receptacle if
grounding of the load equipment is not desired.
CAUTION
Continuous overloading of the generator will cause
the generator temperature to rise to a dangerous
point and may lead to serious damage to the windings.
Keep the load within the rating of the plant as shown
on the nameplate.
BATTERY CHARGE RATE. - The starting battery is recharged by gen-
erator exciter current. The charging
rate is automatically switched by the 2 step voltage regulator to either
LOW rate or HIGH rate depending upon the charge condition of the bat-
tery. LOW rate can not be adjusted. HIGH rate is set at the factory
during the test run and can be further adjusted by moving the slide clip
on the adjustable resistor. Operating conditions, such as exceptionally
frequent starts may require increasing the HIGH charge rate. Check
the charge condition of the battery frequently with a hydrometer.

STOPPING THE PLANT. - To stop the manual type engine, press the
STOP button on the cover of the ignition
breaker box until the engine has come to a complete stop. The high
tension magneto provides a f i r i n g spark even when the engine is running
at very few rpm. Release of the STOP switch.too soon will allow the
plant to again pick up speed and continue to run.

To stop the remote'control type plant, hold the remote STOP switch or
hold.the control box switch at the STOP position.
i
In. an. emergency, if the STOP button fails to work, the plant may be
stopped-by closing the fuel shut-off valve.
_ _ _ _

For model 2LK-1RV1330/ "Mobile Communications" or

'Utility Type" plant, refer also to Special Purpose Section.
 OPERATION 29

CAUTION
Do not disconnect battery while plant is running as serious damage
to the control system will result.

FUNCTION OF THE CONTROLS. - Reference to the plant wiring dia-

gram, and a thorough understand-
ing of how the controis work, will aid in diagnosing trouble if failure
occurs.

This chart explains function of controls during remote plant starting:

Operate start switch

i
Energizes start solenoid

| Solenoid contacts close

Current fed to Current fed through volt- Current fed to elec-

generator series age dropping resistor tric choke operates
field, cranks energizes stop relay and carburetor choke.
engine. closes its contacts.

Battery current fed to ignition coil through ammeter and stop relay con-
tacts. NOTE: The resistor seemingly in this circuit serves only as a
tie point for LK series plants.
I
Engine starts
I
| Operate start switch until generator speed builds up.
I
Release start Generator DC current AC output current pro-
switch. produced. duced and fed to load.
i X
Takes over energiz- Recharges
a.
Start solenoid Takes over opera
de-energized. ing of stop relay. Battery. ting of choke.

The charge rate is high when the When the battery becomes fully
battery is not fully charged. DC charged, the voltage regulator
current passes through both the removes the adjustable resistor
adjustable resistor and the fixed from the curcuit and current
resistor which are paralleled by passes through the fixed
the closed contacts of the two- resistor only.
step voltage regulator.

Exciter voltage closes the reverse current relay, feeding current into
the battery through the ammeter.
30 ARNORMAT, O P E R A T I N G CONDITIONS

LOW TEMPERATURES
i

LUBRICATION. - Directions for the proper grade of oil to use in cold

weather are given in the PREPARATION section.
When changing o i l in cold weather, be sure to drain the oil only when
the oil is warm f r o m running.

If an unexpected drop in the temperature causes o i l in the crankcase to

become too thick to run freely from the oil drain, do not attempt to
start the plant. If the plant is started when the o i l is congealed, serious
damage may result f r o m improper lubrication. Remove the plant to a
warm location, or apply heat externally until the o i l is sufficiently warm.

FUEL. - Fresh winter grade, automotive type gasoline is an aid to

starting in cold weather. Premium highly-leaded gasoline
should not be used. Keep gasoline supplies free of moisture condensation.
Leave room in the fuel tank to compensate for expansion. Open the
o
carburetor main jet approximately 1 additional turn for below 0 F .
operation.

IGNITION. - Cold weather starting is aided by a properly serviced i g -

nition system. See that the ignition breaker points are
clean and properly adjusted. Clean and adjust the spark plug.

BATTERY. - If the plant uses starting batteries, keep the batteries in

a well charged condition. A discharged battery may freeze
o o
at 2 0 F . A fully charged battery will not freeze at -90 F.

COOLING. - The flow of air to the engine may be partially obstructed

to keep the engine at operating temperature, if desired.
However, use extreme care to avoid overheating.

HIGH TEMPERATURES
0
LUBRICATION. - In temperatures above 90° (32 C.) for continuous
operation use SAE number 50 oil. Keep the oil level
close to the f u l l level, and change the oil at least every 100 operating
hours.

COOLING. - The engine and generator of this plant depend upon a con-
stant supply of fresh air for proper cooling. See that no-
thing obstructs the circulation of air to and around the plant. Keep
cooling fins clean and unobstructed. Make sure that the blower housing
and cylinder air housings are properly in place and are undamaged.
Keep the ignition timing properly adjusted.

BATTERY PREPARATION FOR REMOTE START AC PLANT. - For a

usual
plant installation, follow the instructions for Batteries under INSTAL-
 3 1
ABNORMAL OPERATING CONDITIONS

LATION. However, if the installation will be made in a location where

temperatures are consistently high, battery life will be extended by
reducing the battery acid specific gravity.

Standard automotive type storage batteries will self discharge very quick-
o
ly when installed where ambient temperature is always above 9 0 F . ,
such as in a boiler room. To lengthen battery life, adjust the electro-
lyte from a normal 1. 275 reading at full charge, to a 1. 225 reading.

The cranking power of the battery is reduced somewhat when its elec-
trolyte is diluted to reduce acid activity and thus lengthen battery life.
o 0
However, if the temperature is consistently above 9 0 F . (32.2 C.)
adjust the electrolyte as fpllows:

1. Fully charge the battery. DO NOT BRING AN OPEN FLAME OR

BURNING CIGARETTE NEAR THE BATTERIES ON CHARGE B E -
CAUSE THE GAS RELEASED DURING CHARGING IS VERY FLAM-
MABLE.

2. While battery is on charge, use a hydrometer or filler bulb to si-

phon off all of the electrolyte above the plates in each cell. Do not
attempt to pour off! ! Dispose of the removed electrolyte. AVOID
SKIN OR CLOTHING CONTACT WITH E L E C T R O L Y T E .

3. Fill each cell with pure distilled water.

4. Recharge the batteries for one hour at a 4 to 6 ampere rate.

5. Use a reliable battery hydrometer, to test each cell. If the speci-

fic gravity is above 1.225, repeat steps number 2, 3, and 4 until the
highest specific gravity reading of the fully charged battery is not
over 1. 225. Most batteries require repeating steps 2, 3, and 4 two
times.

DUST AND DIRT

CLEANLINESS. - Keep the engine as clean as practicable. Service the

air cleaner as frequently as conditions require. Keep
oil and gasoline supplies in air tight containers. Do not allow cooling
fins of cylinders or cylinder heads to become dirty or obstructed. Keep
the generator commutator, brushes, and brush guides clean.

LUBRICATION. - Change the crankcase oil every 50 operating hours,

instead of every 100 operating hours, during severely
dusty operating conditions.
32 ABNORMAL OPERATING CONDITIONS

HIGH ALTITUDE OPERATION. - If the unit is to be operated at an

altitude of 2,500 feet or more above
sea level, the carburetor main jet adjustment should be "leaned" slight-
ly to obtain maximum possible power. The carburetor was factory ad^
justed for best performance at the factory altitude: approximately 860
feet above sea level.

Because the air becomes less dense as the altitude increases, less
fuel is required to maintain the proper air-to-fuel ratio. Consequently
any engine will develop less total power at higher altitudes. The usual
decrease in maximum power available at high altitudes is'approximately
•four percent for each 1, 000-feet above sea level.
 PERIODIC SERVICE 33
ONAN GASOLINE ENGINE SERVICE CHART

The following recommended Servicing Chart may be used as a guide to

estimating servicing requirements of Onan Electric Generating Plants
and Engines. It is based on the average of records kept by the factory.

The chart is based on the Units operating under favorable conditions,

such as: satisfactory installation, use of recommended f u e l and oils, etc.

SERVICE & PARTS

HOURS OF O P E R A T I O N

2000 1
o

3500

4000
2500

3000

4500
1000
REQUIRED

1500
o o o o o o o o o o
o o o o o o o o o o
T-4 <M CQ -=f t n CD t - OO cn in
Oil Change X X X X X X X X X X
Clean and Adjust Spark Plugs X X X X X X X X X X O
Service Air Cleaner X X X X X X X X X X »—i

Check Ignition Points X X X X X O

Clean Carbon X X X X X X X X X *
H
>
— <
Clean Carburetor X X X X
Check Tappets X X X X X X X g
Grind Valves X X x x O
Remove and Clean Oil Base . . X X X X o
Clean Crankcase Breather . . . X X X X X X X X X X
w
K
Inspect Commutator , X X X X X W
Inspect Brushes X X X X X "H
W
Lubricate Generator Bearings X X X X X -3
Clean Generator X X X X OH

Replace Spark Plugs o

A}31 E(bi TF Fi ) u
Replace Valves AS REQUIRE D
Replace Points AS REQUIRED
Replace Generator Brushes . . AS BfiOllIBED
Replace Piston Rings AS REQUIRED

If it is necessary to remove parts f o r inspection and gaskets are disturbed

they should be replaced with new ones. Keep spare cylinder head, c y l -
inder base, o i l base and other gaskets on hand.

When brushes are replaced be sure the commutator and slip rings are
in A - l condition. Seat brushes per instructions in service manual.

Periodic Inspection: For Loose or Poor Connections, Fittings, etc.

Recommended Fuel: Use a regular grade of automotive type gasoline.

If a high lead content fuel is used, i t w i l l be nec-
essary to remove the lead deposits more frequently.
 PERIODIC SERVICE

Follow a definite schedule of. inspection and servicing to assure the best
performance and long life of the plant. Service periods outlined below
are for average service and normal operating conditions. Under un-
usual service or abnormal operating conditions, service the plant more
frequently. Keep a record of the hours the plant is operated each day to
assure servicing at the proper time.

DAILY SERVICE

If the plant is operated more than 8 hours daily, perform

the following services each 8 hours of operation.

F U E L . - Check the fuel supply often enough to avoid running out of fuel.
NEVER F I L L THE F U E L TANK WHILE THE PLANT IS RUN-
NING. Use clean, fresh, regular automotive type gasoline of at least
68 octane rating. Use of a highly leaded premium grade of gasoline is
not recommended.

CRANKCASE OIL L E V E L . - Remove the oil fill cap and check the crank-
case oil level. Add oil as necessary to
keep the oil level at the full mark on the gage. Recommended grades of
oil are given under PREPARATION. Avoid overfilling which will allow
the connecting rod to cause oil foaming and interfere with efficient lub-
rication.

The oil fill cap gasket must always be in good condition and the cap must
always be securely tightened in place. Air leakage into the crankcase
at this point will cause oil leakage around the seals and excessive oil
consumption.

CLEANING. - A clean plant will give more satisfactory service. Wipe

off dirt and any spilled oil.

WEEKLY SERVICE

If the plant is operated more than 50 hours weekly, per-

form the following services each 50 hours of operation.

CRANKCASE. - If using diluted oil, or highly leaded gasoline, change

the crankcase oil each 50 hours of operation. Under
normal conditions and when using oil which is not diluted, change the
crankcase oil each 100 hours of operation. Do not drain the oil when the
plant has been standing idle. Run the plant until the oil is thoroughly
warmed up, then stop the plant and drain the oil.

AIR CLEANER, DRY T Y P E . - Remove and disassemble the air clean-

er. Remove the element and wash tho-
roughly in a solvent. Dry thoroughly and dip in oil of the same SAE
number as used in the crankcase. Allow to drain until dripping stops,
then reassemble. OIL BATH TYPE - Remove and clean filter element,
clean oil cup, refill with engine oil.
 PERIODIC SERVICE _35
GOVERNOR LINKAGE. - Put a drop or two of lubricating oil at the point
where the link engages the carburetor throttle
arm. Plastic type ball joint requires cleaning only.
Lubricate the governor arm ball joint with a dry type lubricant such as
powdered graphite to assure best performance and longest life of the
ball joint. If graphite is not available, use a light non-gummy o i l .

SPARK PLUG. - Clean the spark plug and reset the gap as given in the
Table of Clearances. Test the plug under compression
on a plug testing machine, if one is available. Replace a defective plug.
BATTERY. - If the plant uses a starting battery, keep the connections
tight and clean. Keep the electrolyte at the proper level
above the separators by adding clean water. Distilled water is recom-
mended for use in batteries. If distilled water is not obtainable, use
clean soft water such as filtered rain water. Do not use water which
contains alkali or minerals. Use a hydrometer to check the charge
condition before adding water. In freezing weather, add water only be-
fore running the plant, to assure mixing the water with the electrolyte.

MONTHLY SERVICE

If the plant is operated more than 200 hours monthly, per-

form the following services each 200 hours of operation.

FUEL SYSTEM. - On plants with a separate fuel tank, drain the fuel
tank and remove the shut-off valve and filter assem
bly. Carefully clean the filter screen. Tighten connections well when
reassembling. Empty carburetor bowl and fuel filter bowl of any sedi-
ment which may have accumulated.
A N T I - FLICKER BREAKER
OINTS

IGNITION BREAKER
POINTS
S E T G A P AT 0 . 0 2 0 "

ANTI-FLICKER CIRCUIT
USED PRIOR TO S P E C C

I G N I T I O N CONDENSER

FIG. 24 - SERVICING THE BREAKER POINTS

36 PERIODIC SERVICE

IGNITION AND ANTI-FLICKER BREAKER POINTS. - Remove the cover

and inspect the
breaker points. Contact points which are not badly burned or pitted may
be dressed smooth, using a fine abrasive stone or hone. If the points
are pitted or burned deeply, replace them with a new point set. Exces-
sive burning of the contact points is usually an indication of a defective
condenser, which should be replaced with a new one. Adjust the gap
between the points as given in the Table of Clearances. If retiming the
ignition is needed, refer to Maintenance and Repair herein. CLEAN
BREAKER POINTS ACCURATELY ADJUSTED AID STARTING.
Spec C units anti-flicker points are not connected into any cir-
cuit and may be used as ignition breaker points by changing the
ignition lead wires to the flicker point terminals and relocating
the ignition condenser closer to the flicker points.
EXHAUST SYSTEM. - Inspect all exhaust line connections carefully.
Make any necessary repairs or replacements.
CARBON REMOVAL. - Regular removal of carbon deposits from the
combustion chamber helps to keep engine ef-
ficiency high. The frequency with which it is advisable to remove car-
bon will vary considerably with the type of fuel used, the type of oil used,
and operating conditions. Use of highly leaded gasoline necessitates
frequent removal of carbon and lead deposits from the cylinder head,
top of piston and valves, and top surface of the cylinder block.

BREATHER VALVE. - The nylon ball, contained in the breather valve,

helps maintain a partial vacuum which is creat-
ed in the crankcase while running. Remove the hose which carries ex-
pelled air from the breather valve at the valve compartment cover, to
the air cleaner. Loosen the valve with pliers. Occasionally the valve
will lift out and remain inside the hose. Wash the valve in kerosene or
other suitable solvent. Then dry and replace. The valve must work
freely and must prevent expelled air from re-entering the crankcase.
The hose must not be restricted. Install parts removed. See the
illustration, Valve Service, under Maintenance and Repair section.
BREATHER TUBE
BREATHER VALVE
(Keep it clean.)

VALVE COMPARTMENT*
COVER

FIG. 25 - BREATHER VALVE

 PERIODIC SERVICE : 37
GENERATOR. - Check the condition of the commutator, ac collector
rings, and brushes. Clean the commutator (and ac
collector rings) with a dry, lint free cloth. If heavily coater or slightly
rough, sand smooth with #00 sandpaper. Do not use emery or carbor-
undum cloth or paper.

Install new commutator brushes and other rectangular brushes when the
old ones are worn to 5/8" or less in length.

See that all connections are tight. Remove carbon dust from the gener-
ator.
CONTROL BOX. - Keep the control box free of dust and dirt. See that
all connections are clean and tight. Replace with a
new one any part which does not function properly. Always disconnect
the battery ground before servicing controls to avoid accidental shorts.

GENERAL INSPECTION. - Thoroughly inspect the entire plant for loose

connections, loose screws or nuts, oil leaks,
etc. Make any necessary repairs.
See that equipment which serves for radio noise suppression is in place
and with clean tight connections. Suppression equipment includes spark
plug shield, shielded ignition leads and by-pass capacitors in genera-
tor and control.
GENERATOR BALL BEARING. - A double sealed, prelubricated ball
bearing is used on the generator. No
periodic service is required.
38 ADJUSTMENTS

Generating plant satisfactory performance is dependent upon correct

adjustments. Adjustments can not fully compensate for troubles such
as low engine power due to engine condition. See also Special Purpose
Section.
GOVERNOR. - The governor controls the speed of the engine.
On ac generating plants, engine speed determines the output voltage and
current frequency of the generator. By increasing the engine speed,
generator voltage and frequency is increased, and by decreasing the
engine speed, generator voltage and frequency is decreased. An accurate
voltmeter is required in adjusting the governor of ac plants. A small
speed drop not noticeable without instruments will result in an object-
ionable voltage drop.

The governor arm is fastened to a shaft which extends from the gear
cover and is connected by a ball joint and link to the carburetor throttle
arm. If the carburetor has been removed, or the governor disassembled,
it may be necessary to readjust the governor.
A binding in the bearings of the shaft which extends from the gear cover,
in the ball joint, or in the carburetor throttle assembly will cause slow
governor action or poor regulation. Looseness or excessive wear in
the governor mechanism will cause erratic governor action or alternate
increase and decrease in speed (hunting). A lean carburetor adjustment
may also cause hunting. Springs of all kinds have a tendency to lose
their calibrated tension through fatigue after long usage. If all gover-
nor and carburetor adjustments are properly made, and the governor
action is still erratic, replacing the spring with a new one and reset-
ting the adjustments will usually correct the trouble.

When the plant is stopped, tension of the governor spring should hold
the carburetor throttle arm at the wide open position, pushed toward
the generator end of the plant. At wide open position, the lever on the
throttle shaft should just touch the carburetor body or clear it by no
more than 1/32 inch. This setting can be obtained by increasing or de-
creasing the length of the connecting linkage as necessary, by turning
the ball joint on the threads of the link. Be sure to retighten the ball
joint to the governor arm. This operation synchronizes governor action
with the carburetor throttle action.

ADJUSTING THE GOVERNOR - AC PLANT. - Refer to the illustration,

Governor Adjustment.
Connect the voltmeter across the output of the generator. With no elec-
trical load connected, start the plant and adjust the speed adjusting nut
to give a voltmeter reading of approximately 126 volts maximum for a
120-volt plant. Apply a full rated electrical load and again observe the
voltage reading, which should be approximately 108 volts minimum.
For 240-volt plants, these voltages will be approximately doubled. The
correct sensitivity adjustment gives the sharpest regulation without
 ADJUSTMENTS 39

causing a hunting condition. If the voltage spread between no load and

full load conditions is too great, turn the sensitivity screw out slightly.
If the voltage spread is satisfactory but there is a tendency toward
"hunting" at times, the sensitivity is too close and the sensitivity screw
must be turned inward slightly. Any change in the sensitivity adjustment
usually requires a compensating speed nut adjustment.

If a tachometer is used for adjusting the governor, engine speed for a

60-cycle plant should be approximately 1800-rpm, or for a 50-cycle
plant should be approximately 1500-rpm, with a drop of not more than
100-rpm from no load operation to full load operation.

"CARBURETOR
THROTTLE
PLATE

CAM GEAR

GOVERNOR
SHAFT
SPEED
ADJUSTING
NUT
DECREASE
GOVERNOR SPEED
SHAFT
YOKE
^-INCREASE
SPEED
GOVERNOR
CUP T A
DE?ER M .N ESC
^SENSITIVITY
DETERMINES ADJUSTING
SENSITIVITY
SCREW

FIG. 26 - GOVERNOR ADJUSTMENT

ANTI-FLICKER MECHANISM (Prior to Spec C Only). - The anti-flicker

mechanism, also called flicker resistance
mechanism, is provided to help eliminate flicker of lights in the load.
Breaker points and a field resistor are used to compensate for a surge
in the voltage during the power stroke of the engine. The breaker points
are located on the right side of the crankcase, protected by a sheet
metal cover. The breaker point set for the plant includes both the anti-
flicker points and the ignition points. Both moveable contacts are
40 ADJUSTMENTS

contained on one spring and are operated by one plunger off the engine
camshaft. The resistor is mounted on«the brush rig or support. See
that the breaker points are not burned or pitted. Burned or pitted points
are usually an indication of a defective condenser. The points gap at
full separation should be . 020". The plunger must work freely. If points
and condenser are in good condition and flicker of a small capacity
light bulb, while operating at average, plant load, is objectionable, check
to see if a new resistor is required. Beginning Spec C, anti-flicker
points remain but circuit and components not used.
If an adjustable resistor is used, loosen the sliding clip on the resistor
and, while watching a small light connected with an average plant load,
slide the clip along the resistor to the point where the least flicker is
noticeable. Tighten the clip at this position.

, L E A D TO RESISTO

ANTI-FLICKER
BREAKER
POINTS
SET GAP.AT
0.020"

BRUSH RIG
SUPPORT
IGNITION
BREAKER
POINTS

-^ANTI-FLICKER
CONDENSER

FIG. 27 - ANTI-FLICKER (Prior to Spec C Only)

CARBURETOR. - Refer to MAINTENANCE AND REPAIR-CARBURE-

TOR if it becomes necessary to remove the carbure-
tor for repairs. A small piece of-foreign matter lodging in a jet may
cause hard starting and poor"operation. Dirty gasoline may cause the
jets to wear larger, resulting in"excessive gasoline consumption. Be-
fore tampering with jet settings, mark the existing adjustment or count
the number of turns the needle was backed out from its seat.

The. carburetor is. a side (horizontal): draft type and has two adjusting
needles. The "idle" needle is located nearer the cylinder head. The
"main" needle is located on the top nearer the air cleaner. Turning
the/needle inward gives a leaner fuel mixture for either jet.

The?correct setting for the main jet needle-gives the best stability at
full rated: load operation. The correct setting for the idle needle gives
theibest. stability* at no load operation.

FulF.Ibad and no load: operating conditions* are necessary when making

carburetor adjustments.
 ADJUSTMENTS 41
To adjust the carburetor, turn the adjusting needles in gently (finger
tight) to their seats. Do not force them in, as they may be damaged by
seating too tightly. Back the main needle out about 2-1/2 full turns.
Back the idle needle out about 3/4 of a turn. Start the plant and allow
it to thoroughly warm up under a full load condition.

Slowly turn the main adjusting needle inward (clockwise) for leaner mix-
ture, until the plant begins to lose speed, or the voltage drops. Turn
the needle outward (counterclockwise) to the point where the plant will
carry the full load. Check the operation at various loads. If there is
a tendency to hunt (alternately increase and decrease speed) at any
load, turn the adjusting needle out for richer fuel mixture, until the hunt
is corrected, but do not turn the adjusting needle out more than 1/2
turn beyond the point where maximum generator output is obtained.
Adjust the idle needle with the plant warm, and with no ac electrical
load connected, slowly turn the idle adjusting needle inward (clockwise)
until the plant loses speed from lack of fuel. Then turn the needle slow-
ly outward until the plant runs smoothly. Refer also to Abnormal Oper-
ation Conditions.

A substantial change in a carburetor adjustment requires a compensat-

ing adjustment of the governor speed.

The throttle idle stop screw should be adjusted to clear the throttle shaft
stop by 1/32" when the plant is operating at desired speed and no load
condition. This setting helps prevent hunting during changes in load.

-THROTTLE
STOP
LEVER

(?—SET T H I S . , ,
SPACE AT
WHEN
/ / V a P L A N T IS
R U N N I N G AT
"NO LOAD"

FIG. 28 - CARBURETOR ADJUSTMENTS

CARBURETOR FOR GAS FUEL ONLY. - To adjust the gas fuel carbure-
tor, set the main adjusting
screw approximately 1-1/2 turns open, and set the idle adjusting screw
42 ADJUSTMENTS

approximately 1-1/4 turns open, to permit starting the engine. Further

adjust the screws as necessary for best operation while allowing the en-
gine to thoroughly warm up under an average load condition. Make the
final adjustment of the main adjusting screw while operating with a full
load connected. Turn the screw in until the plant voltage (or speed) be-
gins to drop, then turn the screw slowly outward until the voltage (or
speed) returns to normal, and operation is steady. If it is necessary
to turn the screw out more than 1/2 turn after normal voltage is attained,
in order to prevent surging, it may be necessary to adjust the governor
for slightly less sensitivity. Make the final adjustment of the "idle"
screw for best operation after the load is disconnected.

E L E C T R I C CHOKE. - The ac remote control type plant is equipped

with a thermal action electric choke. A ther-
mostatic coil (bi-metal) engages the choke shaft and is set at the fac-
tory to give the correct choking action for average temperature con-
ditions. When the plant starts, current from the generator is supplied
to a small heating element in the choke cover. This heating element
causes the thermal coil to wind tighter and turn the choke shaft, grad-
ually opening the choke as the plant warms up. When the plant is stop-
ped the thermal coil cools off, causing the choke shaft to return to the
correct position for the next start.
o
At a temperature of 7 0 F . , the choke should be approximately 1/8"
from the fully closed position. The thermal coil (bi-metal) is installed
in the choke body in a clockwise direction as viewed starting from the
inside turn. The thermal coil tends to coil tighter when heated rather
than unwind.

Extreme temperature may require a slight re-adjustment of the choke

setting. To adjust the choke, loosen the two screws which retain the
choke cover to the choke body. For less choking action, turn the cover
assembly slightly in a counterclockwise direction, looking at the ther-
mal unit end. For more choking action, turn the cover assembly slight-
ly in a clockwise direction.

If the choke does not operate properly, check to see that the heating
element heats properly. There must be no binding of the choke shaft or
thermal coil. Be sure to retighten the lock screw after any adjustment.
A manual operating lever and weight, fastened on the opposite end of
the choke shaft, may be used to operate the choke in the event the elec-
 ADJUSTMENTS 43

trie element burns out or the choke does not operate for any reason.
Turn the lever to horizontal position to open the choke. The choke would
remain at closed position if electric choke failure occured.

LOOSEN T H E S E
S C R E W S AND
ROTATE T H E
E N T I R E COVER
ASSEMBLY

A 32*

FIG. 29 - ELECTRIC CHOKE ADJUSTMENT

Note that the direction marking " C H O K E — a s appears cast on the body
of some carburetors is correct for manually choked plants, but is wrong
for electric choked plants due to the choke valve arrangement. Choking
position of the weight lever is vertical, on the shaft of electrically
choked plants. Choking position of the lever is horizontal on manually
choked plants.
 44 MAINTENANCE AND REPAIR

G E N E R A L . - Refer to the Service Diagnosis section for assistance in

locating and correcting troubles which may occur. If a
major repair or overhaul becomes necessary, the engine should be care-
fully checked and necessary repairs made by a competent mechanic. Ma-
jor generator repairs should be made by a competent electrician. Main-
tain factory limits and clearances as given in the Table of Clearances,
replacing worn parts when necessary. Avoid accidental shorts by dis-
connecting the battery when servicing control parts.
T A B L E OF CLEARANCES
All clearances given at room temperature of 7,0° F .
MINIMUM MAXIMUM
o
Intake Valve Tappet Clearance at 7 0 F . 0.015" 0.017"
o
Exhaust Valve Tappet Clearance at 7 0 F . 0.015" 0.017"
Intake Valve Stem Clearance in Guide 0.001" 0.0025"
Exhaust Valve Stem Clearance in Guide 0.0025" 0.004"
Valve Seat Width * 1/32" 3/64"
c
Valve F A C E Angle 44
Valve S E A T Angle • 45 o
Valve Interference Angle 1°
Crankshaft Main Bearing Clearance 0.002" 0. 003"
Crankshaft End Play 0.006" 0.012"
Camshaft Bearing Clearance 0.0015' 0.003"
Camshaft End Play 0.003"
Connecting Rod Bearing Clearance
(Alum. Rod) 0.002" 0.003"
Connecting Rod End Play 0.013" 0.038"
Timing Gear Backlash 0.002" 0.003"
Oil Pump Gear Backlash 0.002" 0.005"
Piston Clearance in Cylinder, Conformatic
Type (at bottom of skirt)
Interference 0.0005"
Clearance 0.0015"
o
Piston Pin Clearance in Piston at 7 0 F . Thumb Push Fit
Piston Pin Clearance in Rod at 70° F . 0.0002" 0.0007'
Piston ring gap in cylinder 0.010" 0.023"
Breaker Point Gap at Full Separation 0.020"
Spark Plug Gap - For Gaseous Fuel 0.018"
Spark Plug Gap - For Gasoline Fuel 0.025"
Crankshaft Main Bearing Journal-Std. Size 1.9995" 2.000"
Crankshaft Rod Bearing Journal-Std. Size 1.6255" 1.6260"
"Cylinder Bore - Standard Size 3.248" 3.249"
 M A I N T E N A N C E AND R E P A I R 45

ASSEMBLY TORQUES

Assembly torques as given here require the use of a torque wrench.

These assembly torques will assure proper tightness without danger of
stripping the threads. If a torque wrench is not available, you will have
to estimate the degree of tightness necessary for the stud, nut or screw
being installed and tighten accordingly. Be careful not to strip the
threads. Check all studs, nuts and screws often. Tighten as needed to
prevent them from working loose.

L B . F T . TORQUE

Cylinder Head Capscrews 29 to 31

Rear Bearing Plate Nuts 20 to 25
Connecting Rod Bolts 24 to 26
Flywheel Capscrew 40 to 45
Starter Armature thru Stud and Nut 45 to 50
Other 5/16 Inch Cylinder Block Studs and Nuts 10 to 12

ENGINE

CARBURETOR. - Carburetor maintenance should consist of regular

cleaning. Some types of gasoline have a tendency to-
ward formation of gum deposits inside the carburetor. This gum for-
mation can usually be removed by soaking in alcohol or acetone. A fine
soft wire may be used to clean jets.

See that the float is not damaged. If necessary to reset the float level,
use a small screw driver to bend the lip of the float. With the carbure-
tor casting inverted and the float resting lightly against the needle in its
seat, there should be 11/64 inch clearance between the outer edge of the
casting and the free end of the float (side opposite needle seat).

Carburetor adjustments appear in the ADJUSTMENT section herein. Be

sure the throttle assembly works freely. When reinstalling adjusting
needles, do not force them into their seats.

MAGNETO STATOR INSTALLATION. - The magneto stator assembly

is mounted on the gear cover
and the flywheel must be removed to expose it. The stator has 2 pairs
of mounting holes. The innermost holes give 19° spark advance as re-
quired for engines with speed range of 1500 to 2400 rpm. The outer-
most holes give 25° spark advance as required for engines with speed
range of 2500 rpm and above. Connect the smaller coil lead (ground)
to the stator mounting screw. Connect the larger coil lead to the igni-
tion coil (either terminal). Be sure the larger lead is held in place to
prevent rubbing on the flywheel.
46 M A I N T E N A N C E AND REPAIR
:
PRIOR TO SPEC. C

BEGIN SPEC. C.

USE OUTSIDE MOUNTING

HOLES FOR 2 5 ° SPARK
ADVANCE

USE INSIDE MOUNTING

HOLES FOR 19° SPARK
ADVANCE

FIG. 30 - MAGNETO STATOR INSTALLATION

IGNITION COIL INSTALLATION. - Coil connections differ between mag-
neto ignition plants and battery igni-
tion plants. Refer to the illustration which applies. The ignition coil is
grounded on magneto ignition plants but not grounded with battery ignition.
The spark occurs at the build-up of magneto current and at the collapse
of battery current (magneto ignition coil used prior to Spec C).

LEAD TO IGNITION
BREAKER POINT T E R M I N A L

IGNITION CO

G R O U N D TO
BRACKET
MOUNTING
SCREW

S P A R K PLUG-
GABLE

IF FLYWHEEL RUBS OR BINDS ON

MAG STATOR, LOOSEN MOUNTING
SCREWS AND TAP MAG AT POINT
OF BIND WITH A SOFT HAMMER!
RETIGHTEN SCREWS.
FIG. 31 - COIL INSTALLATION FOR MAGNETO IGNITION
 MAINTENANCE AND R E P A I R 47

IGNITION
LEAD TO IGNITION
COI L B R E A K E R POINTS
TERMINAL

LEAD TO
CONTROL
BOX

SPARK PLUG
CABLE

CONDENSER
A 341-2

FIG, 32 - COIL INSTALLATION FOR BATTERY IGNITION

TIMING THE IGNITION. - Ignition timing procedure is the same for
manual-start type plants with magneto igni-
tion as for remote-start type plants with 12-volt battery ignition.
The spark advance is 19° before top center for all models with engine
speeds ranging from 1500 to 2400 rpm. Models with engine speeds of
2500 rpm and up use the 25° spark advance.
ANTI-FLICKER CONDENSER AND C O N N E C T I O N S
USED PRIOR TO S P E C C
POINTS SPRING MUST NOT THESE SCREWS "
RUB WIRE .MUST BE LOOS-
ENED TO ADJUST
POSITION OF
, BREAKER BOX.

MOVE BOX
UP
TO RETARD
SPARK

MOVE BOX '

DOWN
TO ADVANCE
SPARK

LEADS GROUNDING PRY LEADS OFF

A G A I N S T COVER W I L L WITH SCREW-
CAUSE IGNITION FAILURE DRIVER TO R E -
MOVE T H E M .

FIG. 33 - IGNITION TIMING

48 M A I N T E N A N C E AND R E P A I R

Timing procedure follows:

•v
r

1. Remove the cover from the breaker box.

2. Crank the engine over slowly by hand in the direction of crankshaft

rotation until the witness mark on the flywheel and the "TC" mark
on the gear cover are exactly in line ON THE COMPRESSION STROKE.
See the illustration Ignition Timing.

3. Adjust the ignition breaker point gap width to .020 inch at full separ-
ation. .

4. Turn the flywheel to the left, against crankshaft rotation , until the
mark is about two inches past the 25° mark on the gear cover.

5. Turn the flywheel slowly to the right and note whether the ignition
points just separate when the mark on the flywheel aligns with the
19° mark on the gear cover. The engine must be on the compression
stroke. If the marks align as the points break, timing is correct. If
they do not, loosen the breaker box mounting screws and shift the whole
breaker box assembly slightly upward to retard the timing (points break-
ing too soon), or shift it slightly downward to advance the timing (points
not breaking soon enough). Tighten the breaker box mounting screws
securely after making an adjustment.

To accurately check the time at which the spark occurs, an automotive

type timing light may be used when the engine is running.
To accurately check the time at which the spark occurs, without run-
ning the engine, connect a continuity test lamp set across the ignition
breaker points. Touch one test prod to the breaker box terminal (to
which the lead to the coil is connected), and touch the other test prod
to a good ground on the engine. Turn the crankshaft against rotation
(backwards) until the points close. Then slowly turn the crankshaft with
rotation. The lamp should go out just as the points break.
'6. Install the breaker box cover.
F L Y W H E E L . - To remove the flywheel turn the flywheel mounting screw
outward :about 2 turns. Use a screw driver behind the
flywheel to take up the crankshaft end play. Then strike a sharp end-
wise blow on the head of the cap screw with a heavy soft faced hammer
to loosen. A suitable puller can easily be fashioned from a piece of bar
tsteel and the flywheel removed with the aid of the puller if so desired.
>
j'Do not drop the flywheel. A broken fin will destroy the balance. Use a
fsteeLkey for mounting the flywheel.
A magneto flywheel which has lost its magnetism can be remagetized.
The spark should jump a 3/16 inch gap with ease as tested by holding
 M A I N T E N A N C E AND REPAIR 49

the spark plug wire away from a clean metal part of the engine while
cranking. Never remove magnets from wheel.

VALVE SERVICE. - Properly seated valves are essential to good en-

gine performance. The aluminum cylinder head is
removable for valve servicing. Do not use a pry to loosen the cylinder
head, rap sharply on the edge with a soft faced hammer, taking care
not to break any cooling fins. A conventional type valve spring lifter
may be used when removing the valve spring locks, which are of the
split type. Clean all carbon deposits from the cylinder head, piston top,
valves, guides, etc. If a valve face is burned or warped, or the stem
worn, install a new valve.

INTAKE VALVE

|VALVE GUIDE

VALVE SPRING
CARBURETOR'
BREATHER VALVE' -VALVE SPRING -VALVE ROTATOR
(KEEP C L E A N ) EXHAUST VALVE ONLY
DETAINER WASHER
-VALVE SPRING
RETAINER LOCK
"VALVE ADJUSTING
SCREW

-TAPPET

"K-VALVE VALVE-

-SEAT -SEAT

- Valve
Grinding -
RIGHT WRONG

FIG. 34 - VALVE SERVICE

Worn valve stem guides may be replaced from inside the valve chamber,
Valve locks are the split, tapered type, the smaller diameter of which
must face toward the valve head. Tappets are also replaceable from
the valve chamber, after first removing the valve assemblies.

The valve FACE angle is 44°. The valve SEAT angle is 45°. This 1°
50 M A I N T E N A N C E AND R E P A I R

interference angle results in a sharp seating surface between the valve

and the top of the valve seat. The interference angle method of grinding
valves minimizes face deposits and lengthens valve life. .

The valves should not be hand lapped, if at all avoidable, since the sharp
contact may be destroyed. This is especially important where stellite
faced valves and seats are used. Valve faces should be finished in a
machine to 44°. Valve seats should be ground with a 45° stone, and the
width of the seat band should be 1/32 to 3/64 of an inch wide. Grind
only enough to assure proper seating.
Remove all grinding compound from engine parts and place each valve
in its proper locaticm. Check each valve for a tight seat, using an air
pressure type testing tool. If such a tool is not available, make pencil
marks at intervals across the valve face and observe if the marks rub
off uniformly when the valve is rotated part of a turn against the seat.

Lightly oil the valve stems and reassemble all parts removed. Adjust
the valve clearance.
T A P P E T ADJUSTMENT. - The tappet clearance may be easily checked
after first removing the valve compartment
cover and the blower housing. Crank the engine over by hand until the
intake valve (the one nearest the carburetor) opens and closes. Contin-
ue turning the flywheel slowly until the mark on the flywheel is in align-
ment with the TC mark on the gear cover. The correct tappet clearance
for both the intake and exhaust valves appear in the Table of Clearance.
Tappets are fitted with self locking adjusting screws. Use a 7/16"
wrench for the screw, and a 9/16" wrench for the tappet when making
any adjustment.

GOVERNOR
GOVERNOR COVER GOVERNOR
CUP- •> \ SHAFT

ROTATE
GOVERNOR CUP
SO T H A T ROLL
P I N FITS INTO
METAL LINED IF FEELER W I L L
A335 HOLE IN CUP
GOVERNOR YOKE- 1
ENTER HOLE
( SMOOTH SI DE TOWARD CUP ) BALL HAS
r F A L L E N OUT.

FIG. 35 - INSTALLING THE GEAR COVER

 M A I N T E N A N C E AND REPAIR 51

GEAR COVER. - After removing the mounting screws, tap the gear
cover gently with a soft faced hammer to loosen i t .

When installing the gear cover, make sure that the pin in the gear cover
engages the metal lined (smoothest) hole in the governor cup. Turn the
governor cup so that the metal lined hole is in downward position.
Adjust the roll (stop) pin to protrude to a point 3/4 inch from the cover's
mounting surface. Turn the governor arm and shaft clockwise as far as
possible and hold in this position until the gear cover is installed flush
against the crankcase. Have the yoke's smooth side toward the cup.
Be careful not to damage the gear cover oil seal.

GOVERNOR CUP. - With the gear cover removed, the governor cup
can be taken off after removing the snap ring from
the camshaft center pin. Catch the flyballs while sliding the cup off.

Replace with a new part, any f l y b a l l

which is grooved or has a flat spot, W H E N GOVERNOR IS
the ball spacer if its arms are worn PROPERLY ASSEMBLED
T H E DIMENSION SHOWN
or otherwise damaged, and the gov- ON D R A W I N G W I L L BE
AS INDICATED.
ernor cup if the race surface is
grooved or rough. The governor cup
must be a free spinning f i t on the CENTER P I N

camshaft center pin, but without any SNAP RING'

looseness or wobble. GOVERNOR CUP

GOVERNOR FLY B A L L
When installing the governor cup,
tilt the engine so the gear is up, put
the flyballs in place (equally spaced),
and install the cup and snap ring on
the camshaft center pin. FIG. 36 - GOVERNOR CUP

The camshaft center pin extends out 3/4" from the end of the camshaft.
This distance provides an in and out travel distance of 7/32" for the
governor cup, as illustrated. Hold the cup against the flyballs when
measuring. If the distance is less (the engine may race especially at
no load), remove the center pin and press a new pin in only the required
amount. Otherwise, grind off the hub of the cup as required. The cam-
shaft center pin can not be pulled outward nor removed without damage.
If the center pin extends out too far, the cup w i l l not hole the flyballs
properly.

TIMING GEARS. - If replacement of either the crankshaft gear or the

camshaft gear becomes necessary, install both gears
new, never one only. To remove the crankshaft gear, insert two long
#10-32 steel screws into the tapped gear holes and tighten the screws
alternately. As the screws are tightened, the screw ends w i l l seat a-
52 M A I N T E N A N C E AND REPAIR

gainst the crankshaft shoulder and force the gear off the end of the crank-
shaft.
S C R E W S PASS T H R O U G H
GEAR A N D BEAR ^CRANKSHAFT
GEAR
AGAINST CRANK-
S H A F T SHOULDER

( D * I Q - 3 2 SCREWS

T I G H T E N S C R E W S UP
A L T E R N A T E L Y T O PRESS
G E A R OFF E V E N L Y .

1
— T H E S E M A R K S MUST
C O I N C I D E WHEN I N -
STALLING TIMING
GEARS

r FIG. 37 - TIMING GEARS

The camshaft gear is pressed on and keyed to the camshaft. The cam-
shaft and gear must be removed as an assembly, after f i r s t removing
the crankshaft gear lock ring and washer. Before removing the cam-
shaft and gear assembly, remove the cylinder head and valve assem-
blies. Remove the operating plunger for the breaker points. Remove
the fuel pump (where used) and tappets. After removing the governor
cup assembly from-the gear, the camshaft may be pressed out of the
gear by use of a hollow tool or pipe which will f i t over the camshaft cen-
ter pin. Do not press on the center pin or damage it in any way. The
governor ball spacer is a press f i t to the camshaft gear.

If either the crankshaft gear or camshaft gear becomes damaged or

worn, replace both gears with new ones, never one only. When pres-
sing a camshaft gear onto the camshaft, be sure the gear is started
straight and that the key is properly in place. Install the governor cup
assembly before installing the camshaft and gear in the engine.

Note that each timing gear is stamped with "O" mark near the edge. The
gear teeth must mesh so that these marks exactly coincide when the
gears are installed, in the engine. Be sure, when installing the camshaft
gear and shaft assembly, that the thrust washer is properly in place be-
hind the camshaft gear. Replace the retaining washer and lock ring to
the crankshaft.

CYLINDER HEAD. - Models using gaseous fuel have a high compres-

sion cylinder head. This head has a 3/32" radius
boss visible on the thick edge near the spark plug to identify it from
standard compression.
 M A I N T E N A N C E AND R E P A I R 53

CYLINDER. - The cylinder wears very little in normal service. If

through improper lubrication or accident, the cylinder wall
should become scored or worn badly, the cylinder may be rebored and
honed to accomodate a new piston and rings of one of the available over-
sizes. Pistons are obtainable in .010", .020", .030", and .040" over-
sizes. Piston rings are available in .010", .020", .030", and .040"
oversizes. Use standard size rings on a .005" oversize piston. If the
cylinder is not being reconditioned, but new piston rings are being
installed, remove any ridge which may have become formed at the top
of piston ring travel in the cylinder bore. Engines might be fitted at the
factory with a .005" oversize piston and are so indicated by a letter " E "
following the engine serial number stamped on the side of the crankcase
near the oil fill, and on the plant nameplate.

PISTON AND RINGS. - The piston and connecting rod assembly are re-
moved through the top of the cylinder. The pis-
ton is fitted with two compression rings and one oil control ring. The
piston ring grooves should be cleaned of any carbon deposits, and the
oil return holes in the lower groove must be open. Before installing
new rings on the piston, check the ring gap by placing each ring squarely
in the cylinder at a position corresponding to the bottom of its travel.
The gap between the ends of the ring should be as given in the Table of
Clearances. Rings which are slightly oversize may be filed as neces-
sary to obtain the correct gap, but do not use rings which require too
much filing. Standard size rings may be used on a .005" oversize pis-
ton. . 010", . 020" and . 030" oversize rings are to be used on . 010",
.020", and . 030" oversize pistons, respectively. Rings of the tapered
type are usually marked "TOP" on one side, or identified in some other
manner, and the ring must be installed with this mark toward the closed
end of the piston. Space each ring gap one third of the way around the
piston from the preceding one, with no gap directly in line with the pis-
ton pin. The bottom piston ring groove should be fitted with an oil con-
trol ring and the two upper grooves fitted with compression rings. If
a chrome faced ring is used, it will be in the top groove.
!5=r

FEELER GAUGE

FIG. 38 - FITTING PISTON RINGS TO THE CYLINDER

54 M A I N T E N A N C E AND R E P A I R

The piston is fitted with a full floating type piston pin. The pin is kept
in place by two lock rings in the piston, one at each side. Be sure these
lock rings are properly in place before installing the piston and connect-
ing rod in the engine. Correct piston to cylinder clearance appears in
the Table of Clearance.
CONNECTING ROD. - Mark the connecting .rod before removing it to as-
sure reassembling with the same side facing the
camshaft. Note that the oil dipper splashes oil away from the camshaft.
The connecting rod.cap is installed on the side away from the camshaft.
i

The connecting rod bearing clearance to the crankshaft journal may be

reduced as necessary by carefully dressing the cap on a sheet of abra-
sive cloth (#320 grit or finer) placed flat on a surface plate or piece of
!
plate glass. f

The connecting rod and piston assembly must be properly aligned be-
fore reassembly to the engine. The aligning should be done on an ac-
curate aligning gauge by a competent operator. Misalignment may
cause rapid wear of piston, pin, cylinder and connecting rod.

Be sure the connecting rod oil dipper

is properly installed, as it is vital
to proper lubrication.

BEARINGS. - Removal of the cam-

shaft or crankshaft
bearings requires complete dis- CONNECTING
HOD CAP-
assembly of the engine. Use a
press or a suitable drive plug to
remove the bearings. Drive or
press the crankshaft bearings and -ABRASIVE MATERIAL ON
the camshaft bearings from the A FLAT SURFACE
outside toward the inside of the
cylinder block. Avoid damaging the FIG. 39 - REDUCING CON-
block during bearing removal. NECTING ROD CLEARANCE
The crankshaft main bearings must be installed from the inside of the
cylinder block with the oil hole in each bearing aligned with the oil hole
in the bearing boss and the notch in the bearing flange aligned with the
stop pin. The oil passage must beat least 1/2 open and near the top on
splash lubricated engines. New crankshaft main bearings are precision type
which DO NOT require line reaming or line boring after installation.
Crankshaft bearings are available in standard size or in 0.002 inch or
'0. 020 inch undersize. Using a press,or drive plug to install the bear-
ing in a cold cylinder block might result in damage to this type of bear-
ing. Warm the bearing plate and cylinder block to expand the bearing
o
bore size. Use hot water, a 200 F. oven, or in an emergency a low
flame from a torch. Only a little heat is required. The cold precision
 M A I N T E N A N C E AND R E P A I R 55
bearing should then require only light taps to position it. The flange of
the bearing must be against the inner end of the bearing boss. Use oil
on the outer surface of the bearing to reduce friction and coat the inner
surface before installing the crankshaft.
New camshaft bearings are precision type which DO NOT require line
reaming or line boring after installation. Coat the bearing with lubri-
cating oil to reduce friction. Place the bearing on the crankcase over
the bearing bore with the elongated hole in proper position and narrow
section facing out (except bores without oil holes install with bearing
groove at the top). Be sure to start the bearing straight. Press the
front bearing in flush with the outside end of the bearing bore. Press
the rear bearing in flush with the bottom of counterbore which receives
the expansion plug.

SHOULDER PIN
WILL FIJ-INTO NOTCH

ALIGN OIL HOLE

'N BEARING WITH
OIL HOLE IN P R E C I S I O N T Y P E - DO NOT
CRANKSHAFT •
BEARING BORE LINE REAM OR BORE.
EXCEPTION-EARLIER ENGINES \
DO NOT HAVE OIL HOLE IN BORE. \
PRECISION TYPE
DO NOT LINE BORE
OR REAM

CRANKSHAFT BEARING ALIGN HOLE IN BEARING \

•WITH HOLE IN BEARING BORE
CAMSHAFT B E A R I N G

FIG. 40 - BEARING INSTALLATION

OIL SEALS. - The gear cover must be removed to replace its oil seal.
Drive the old seal out from the inside of the gear cover.
The bearing plate must be removed to replace its oil seal. Drive the
oil seal out from the inside.

When installing the gear cover oil seal, tap the seal inward until it is
31/32 of an inch from the mounting face of the cover. When installing
the new style thin open-face seal, tap the seal inward until it is 1-7/64
of an inch from the mounting face of the cover.
When installing the bearing plate oil seal, tap the seal into the bearing
plate bore to bottom against the shoulder in the plate bore. After the
seal is in place, it is advisable to apply a thin coating of shellac or
Permatex around the outer surface of the seal at the point where it
56 M A I N T E N A N C E AND R E P A I R

comes in contact with the bearing plate boss. Use a seal expander, or
place a piece of shim stock around the end of the crankshaft, when re-
placing the bearing plate to avoid damaging the seal. Remove the shim
stock as soon as the plate is in place.
REAR B E A R I N G
MOUNTING PLATE
FACE OF
GEAR COVER
PTHIS SURFACE SHOULD
BE C L E A N E D OF A L L
OLD S E A L I N G C O M -
OIL POUND BEFORE I N -
SEAL STALLING SEAL.

31" •-DRIVE OR PRESS OIL

S E A L TO SHOULDER
3Z OF T H E PLATE BORE.
APPLY S H E L L A C
OR PERMATEX
AROUND S E A L A T T H I S SURFACE
THIS POINT SHOULD BE
CLEANED O F A L L PPLY SHELLAC OR
OLD S E A L I N G PERMATEX AROUND
•New style, thin COMPOUND B E - S E A L AT T H I S POINT.
FORE I N S T A L L -
open-face seal ING S E A L .
d i-m en s I on Is
1-7/64"
GEAR COVER OIL S E A L REAR BEARING PLATE OIL SEAL

FIG. 41 - OIL SEAL INSTALLATION

V A L V E COMPARTMENT OIL DRAIN. - A drain hole from the valve

compartment enters the crank-
case. This hole must be unobstructed to provide for proper drainage of
oil from the valve compartment.
CRANKSHAFT. - Inspect the bearing journals. If they are scored and
can not be smoothed out by dressing down, the bear-
ing journals should be refinished to use 0.002", 0.010", 0.020", or
0.030" undersize bearings or a new crankshaft should be installed.

R E A R BEARING
PLATE

M E A S U R E ENDPLAY
HERE
C R E F E R TO T A B L E O F
CLEARANCES)

FIG. 42 - CRANKSHAFT END-PLAY

If a worn main bearing journal can not be fitted with an available .pre-
cision type undersize bearing, then refinish it to the next undersize.
If a-worn connecting rod bearing journal can not be fitted by dressing
down the rod cap, then refinish it to take the undersize rod available.
 MAINTENANCE AND REPAIR 57

When installing the crankshaft, use gaskets as needed behind the bearing
plate to assure end play of 0. 006 to 0. 012 inch.

RUNNING TIME METER

Do not Guess- Know how many hours your plant runs, so that you can
change o i l and service the plant at proper intervals.

This meter w i l l be an investment rather than an expense. Simple to

connect. This meter runs only when the plant is operating.

PART NO USED WITH PLANT

302B212 60 Cycle, 120-Volt, AC

302-102 50 Cycle, 120-Volt, AC

304-99 Resistor - adding to either meter above makes

i t suitable for 240-volt use. '

Meters listed above are 3-1/2 inch diameter, and are f o r flush mount
ing on panel; f i t into 2-29/32 inch hole. For wall mounting, order
separately.

301-500 Instrument Box

0

R U N N I N G T I M E METER
©
I N S T R U M E N T BOX
58 M A I N T E N A N C E AND REPAIR

GENERATOR

The generator normally needs little care other than a periodic check of
the brushes, commutator and collector rings. If a major repair job on
the generator should become necessary, have the equipment checked by
a competent electrician who is thoroughly familiar with the operation of
electric generating equipment. Continuity tests may be performed with-
out disassembly of the generator.

GENERATOR DISASSEMBLY. - The procedure is mostly self-evident.

Remove the band and endcover. Re-
move constant-pressure-type springs and l i f t all brushes.
Remove generator through stud nuts. Hold both the end bell with its
brush r i g and the frame assembly, since they are separate parts, and
remove them as one assembly f r o m the adapter. Screw driver slots in
the adapter provide for prying the frame loose. Be careful not to let
the frame assembly rest or drag on the armature.

Turn the armature nut out to the end of the armature through stud. While
pulling outward with one hand under the armature, strike a sharp end-
wise blow on the nut to loosen the armature. Remove the armature and
blower as an assembly. The blower is a keyed and pressed f i t on the
armature shaft, and is a keyed and tapered fit to the engine crankshaft.

If the armature does not come loose, place a heavy brass rod on the
armature shaft near the ball bearing and strike a sharp downward blow
on the rod with a hammer. Rotate the armature 1/2 turn before re-
peating. Do not strike the commutator, collector rings, or bearing.

BRUSHES AND SPRINGS. - Inspect brushes periodically. Brushes worn

to 5/8 inch INSTALL BRUSHES
should be replaced. Replace springs W I T H B E V E L L E D TOP
S L A N T I N G DOWN
if damaged or if proper tension is TOWARD SPRING
questionable. Rapid brush wear may HOLDER

be caused from high mica between

commutator bars, rough commutator
or collector rings, or f r o m a devia- TO R E M O V E B R U S H
tion f r o m "neutral" position in the SPRING PRESS
S P R I N G HOLDER
adjustment of the brush r i g . NEVER DOWN AND OUT A S
bend the constant-pressure-type S H O W N IN B R O K E N
-•-BRUSH
spring over the edge of its support. LINES.
RING
FIG. 43 - BRUSHES AND SPRINGS
BRUSH RIG POSITION. - Check the witness mark on the brush r i g and
if necessary align it with the boss in the end
bell. If the brush r i g is adjusted so that there is arcing of the brushes,
brush wear will be rapid, voltage and current w i l l not hold steady, and
 M A I N T E N A N C E AND R E P A I R 59

the generator may overheat.

Whenever a new brush rig or armature is installed, the brush rig must
be adjusted to the point where the brushes do not arc regardless of where
the witness mark falls. This is commonly known as the "neutral" brush
position.

COLLECTOR RINGS (AC Units). - If the collector rings become groov-

ed or out of round, or the brush sur-
face becomes pitted or rough so that good brush seating cannot be main-
tained, remove the armature and refinish the collector rings in a lathe.
If the commutator appears to be rough or scored refinish it at the same
time. Remove or adequately shield the ball bearing during refinishing.

COMMUTATOR. - The commutator bars wear down with usage so that

the mica between them must be undercut. This
should be done as soon as the mica on any part of the commutator
touches the brushes. A suitable undercutting tool can be made from a
hack saw blade. Avoid injury to the surface of the copper bars. Leave
no burrs along the edges of the bars. The mica must also be undercut
whenever the commutator is refinished.
HACK SAW BLADE-
8L/)D£y

RIGHT
MICA WAY TO WAY TO
-TEETH PO/HT
TOWAfiD MA NOL E
GAIND BLADE TO
WIDTH OF MICA.
1 GRIND
TEETH
GRIND
TEETH

BRUSH

COMMUTATOR
MICA
BARS

•MICA PROPE/fL Y
UNDERCUT
HIGH MICA-

FIG. 44 - COMMUTATOR REPAIR

TESTING WINDINGS. - A test lamp set and an armature growler are
required for the various tests. Before making
any tests, lift all brushes into their holders and disconnect the load cir-
cuit wires from the plant. If the armature tests defective, the prac-
tical repair is to replace it. If a field coil tests defective, replace the
entire coil assembly unless the trouble is in one of the external leads.
Then it can be repaired as the nature of the trouble requires.
60 M A I N T E N A N C E AND R E P A I R

ARMATURE GROUND TEST. - To test the armature for a grounded

condition, lift or remove the brushes
so that none contact the commutator or collector rings. Use a contin-
1
uity type test lamp set. P'lace one test prod on the commutator, and
the other test prod on a bare, clean part of the armature shaft. The
test prods must make good electrical contact. The test lamp should
not glow. If the test lamp does glow, the dc winding or the commutator
is grounded. To test the ac winding, place one test prod on one of the
collector rings and the other test prod on the armature shaft. If the
test lamp glows, the ac winding or a collector ring is grounded. Re-
place a grounded armature with a new one.
' TEST LAMP ARMATURE
F O R T E S T I N G FOR OPEN
C I R C U I T S A N D GROUNDS.

\USE 3 Off 4 CANDLEPOWER

BULB.

WITH A I ^ V O L T BATTERY
USE A OJ^OLT BULB.

W I T H A a.VOLT BATTERY
U S E A BrVOLT B U L B .

Jm

-COMMUT/ITO/?

FIG. 45 - CONTINUITY FIG. 46 - ARMATURE

TEST LAMP GROWLER

ARMATURE OPEN CIRCUIT TEST. - The armature ac winding may

be tested for an open circuit
Without removal of the armature. Testing the dc winding requires
removal and the use of an armature growler.

To test the ac winding, be sure all brushes are lifted or removed.

Use a test lamp set. Place one test prod on each of the collector rings.
If the test lamp does not glow, the ac winding is open circuited.

To test the dc winding, place the armature in a growler. With the

growler current on, pass a smooth steel strip across the commutator
segments. Repeat all around the commutator. At some point around
the commutator, a spark should occur as the strip contacts two ad-
jacent segments. Rotate the armature slightly and repeat the test.
Continue until a spark is obtained between all adjacent segments. If
no spark is obtained at some point, an open circuit is indicated. NOTE-
A short circuit in the winding might prevent sparking. This condition
may be indicated by the short circuit test described in the next paragraph.
Replace an open circuited armature with a new one.
 M A I N T E N A N C E AND R E P A I R 61

ARMATURE SHORT CIRCUIT TEST. - To test for a short circuit, place

the armature in a growler.
With the growler current on, hold a steel strip about 1/2 inch above
the armature laminations. Pass the strip back and forth over the lam-
inations. Cover as much of the lamination area as possible. If the
strip is magnetically attracted to the armature at any point, a short
circuit is indicated. After testing in one position, rotate the armature
slightly in the growler and repeat the test. Continue until a complete
revolution of the armature in the growler has been made. Replace a
short circuited armature with a new one.

TESTING FIELD WINDINGS. - Use a test lamp set for all tests except
a short circuit. The field coils of all
ac plants are saturated shunt wound, the Remote Start plants having a
series field winding in addition for cranking and battery charging pur-
poses. When testing a field coil assembly, disconnect all of its exter-
nal leads from their terminals. Tag and mark each lead to assure pro-
per connections when reassembling.

TESTING FIELD WINDINGS FOR GROUNDS. - To test a coil assembly

for a ground, discon-
nect its external leads and touch one test prod to the terminal of one of
its leads and the other test prod to the generator frame. • If the lamp
lights, the coil assembly being tested is grounded. The ground may be
in a coil, coil connection, or coil lead. Repair or replace as needed.

TESTING FIELD WINDINGS FOR OPEN CIRCUIT. - To test a coil as-

sembly for an
open circuit, disconnect its external leads and touch one test prod to
the terminal of one coil lead windings and the other test prod to each of
the other leads of that coil winding in turn. If the lamp does not light,
the circuit being tested is open. If the fault lies in connection between
coils or in a coil lead, the trouble can be repaired. If it is inside the
coil proper, replace the entire coil assembly.

GENERATOR ASSEMBLY. - When assembling the generator, see

that there are not any nicks or dirt on the
armature tapered surface. These conditions may lead to an armature
that is not properly aligned. Tighten the armature stud nut securely.

BALL BEARING. - If replacement of the armature ball bearing becomes

necessary, pull the bearing from the shaft with a
suitable bearing puller. Be careful not to damage the armature shaft
because it must remain true to serve as a turning center when refinish-
ing the commutator or collector rings. Drive the bearing up to the
shoulder on the shaft. Use a double-sealed pre-lubricated ball bearing.
 1. ADAPTER
2. KEY
3. SCREW
4. BLOWER
5. PLATE
6. ARMATURE ASSEMBLY
7. BEARING
8. CLIP
9. STUD
10. SHOE
11. COIL ASSEMBLY
12. FRAME ASSEMBLY
13. CLIP
14. RIG ASSEMBLY
15. BELL
16. COVER
17. BAND
18. STUD
"T18
F I G . 47 - G E N E R A T O R A S S E M B L Y
 M A I N T E N A N C E AND R E P A I R 63
CONTROLS

If any of the control equipment fails to function properly, replace the

defective part with a new part of the same kind rather than try to repair
the old part. No attempt should be made to repair such parts as meters,
fuses, switches, relays, or receptacles. Check all electrical connec-
tions and contacts whenever servicing control equipment.

Always disconnect the battery whenever servicing controls to avoid

accidentally starting the plant. When disassembling controls, tag each
lead that has to be removed and mark the connection point of the lead
on the tag to assure correct connections when reassembling.
64 MAINTENANCE AND R E P A I R

READI-PULL STARTER

SERVICING THE READI-PULL STARTER. - Refer to the illustration

showing the Readi-Pull
manual starter disassembled.
CAUTION: The recoil spring may unwind and cause injury if let
fly wildly when starter is disassembled or reassembled.
The sheave hub bearing (16) has a recess which was packed full of
grease at the factory. Normally no additional lubrication is required.
However, if the starter is disassembled for some other reason, add
grease to the bearing and to the spring pawls (11) where they contact
the ratchet arm (13).
To install a new rope or internal parts remove the starter from its
mounting ring by removing the 4 clamping screws (19).

To install a new rope, rotate the sheave (10) with crankshaft rotation
direction to fully tighten the spring (8), back up only as necessary to
align the hole in the sheave with the slot in the cover (5), clamp the
rope to the sheave, then when released the rope will wind on the sheave.

To install a new recoil spring remove the sheave from the cover. Wind
the spring, with its rivet heads outward, forming a coil small enough
to be inserted in the recess of the starter cover. It may be necessary
to tie the spring with a piece of wire to prevent its unwinding during in-
stallation unless other help is available. Place the spring in the cover
recess in crankshaft rotation direction. Remove the tying wire if used.
While holding the spring to prevent its unwinding install the inside end
of the spring on the roll pin (7) in the cover. With the pull rope re-
moved, install the sheave assembly in the cover so that the tab on the
sheave enters the outside end loop of the recoil spring. Be sure the
thrust washer (9) is in place. Then install the pull rope.

Spring breakage is much less common than spring fatigue due to long
usage. In either case the spring should be replaced. Cleaning and lub-
ricating the pawls, and ratchet arms in the rope sheave will improve
a sluggish acting recoil. To temporarily extend the life of a fatigued
spring, try rewinding it "inside out" (rivets heads inward).

To install a ratchet arm (13) in the sheave, the pawl (11) must first be
removed. The ratchet arm will fit in only the correct position. The
spring pawl must be installed with its flat edge against the ratchet arm.

The anti-back lash cogwheel (6) is an easy press fit on the starter
cover.
 M A I N T E N A N C E AND R E P A I R 65
1- ROPE AND GRIP 7- ROLL PIN 13- RATCHET ARM 19- WASHER
2- ROPE ONLY 8- RECOIL SPRING 14- PIVOT ROLL PIN 20- MOUNTING RING
3- GRIP ONLY 9- THRUST WASHER 15- ROPE CLAMP 21- SPEED GRIP NUT
4- PLUG 10- ROPE SHEAVE 16- BEARING
5- STARTER COVER 11- PAWL 17- SCREW
6- COG WHEEL 12- PAWL SPRING 18- FLEXLOCK NUT
6A-SPRING WASHER 12A-SPIROL PIN

FIG. 48 - READI-PULL STARTER

'/////I

®
LOCK .
\J
Xl
WASHER ^ » \ \
Sv^Li^—SPECIAL NUT
SCREW

® ^\^t s / }V—BLOWER
HOUSING
FLAT WASHERS
DETAIL A ©

©
STARTER
ROPE
( 5 ) STARTER
^ ASSEMBLY

FIG. 49 - INSTALLING STARTER, SPEC "A" UNITS ONLY

66 M A I N T E N A N C E AND R E P A I R

INSTALLING THE STARTER, SPEC "A" UNITS ONLY. - Refer to

figure 49.
The blower housing on the engine must be as rigid as possible. Exam-
ine the blower housing carefully. If the mounting holes are worn or if
the blower housing is otherwise damaged, replace it with a new one.
Proceed as follows to install the complete starter kit.

1. Refer to the installation drawing. Do not change the flywheel mount-

ing screw. New screws (if furnished) are needed on other model
engines only.
2. Install the new ratchet-wheel (1) to the blower wheel, using the two
special head screws and lock washers provided. A 3/8 inch 12 point
socket or closed end wrench fits these screws. Tighten securely.

3. Four special nuts are supplied for mounting the starter to the blow-
er housing. If the blower housing is not already fitted with similar
mounting nuts, remove the blower housing and install the nuts in the
square holes (2) in the blower housing. See detail A. Reinstall the
blower housing, tightening securely in place.

4. Note that there are two small holes drilled through the starter cov-
er. See detail C. Pull slowly out on the starter rope while sight-
ing through one of these holes. When the starter is turned a partial
turn, the open-center roll pins in the starter rope sheave will align
with these two holes. While holding in the aligned position, insert a ten
penny common nail through each of the holes. Push the nails in up to
their heads.

5. Install the starter assembly (3) to the blower housing, making sure
that the nail ends enter the pilot holes in the ratchet wheel mounting
screws. It will probably be necessary to turn the flywheel a partial re-
volution to allow proper alignment. While holding in position, mount
the starter, using a hex head screw (4), lockwasher (5), and two flat
washers (6) at each mounting arm as shown in the detail drawing A.
Tighten the mounting screws securely. Remove the nails.

6. The direction of pull on the starter rope is adjustable to fit the re-
quirements of the individual installation. See detail B. To change
the direction of pull, loosen the four clamp screws (8) and turn the
starter in its mounting ring to the desired position. Tighten the four
clamp screws securely. Try the starter several times, making sure
that the pull rope will not rub against one of the clamp screws.

7. Ocassionally check the operation of the starter, making sure the

starter is properly centered (step 5 above). See that the blower
housing mounting screws are tight. If the blower housing tends to shift,
its mounting holes may have become worn oversize, if the blower hous-
ing tends to weave or distort during starter operation, installation of a
new housing is recommended.
 M A I N T E N A N C E AND R E P A I R _6_7
INSTALLING STARTER, UNITS BEGINNING SPEC "B". - See that the
engine blower housing
is in good condition. If the mounting holes are worn or if the blower
housing is otherwise damaged, replace it with a new one. See Fig. 50.
1. Engage drive hole of rope sheave (11) with flywheel boss. Install flat-
washer (15) between rachet wheel (1) and rope sheave (11). Secure
with flywheel mounting screw (9) and lockwasher (10).
2. Four special nuts are supplied for mounting the starter to the blow-
er housing. If the blower housing is not already fitted with similar
nuts, remove the blower housing and install the nuts as shown in detail
A. Reinstall the blower housing, tightening securely in place.
3. Install centering pin (12) in starter center screw (14) allowing 3/8"
to protrude. For reinstallations readjust pin depth.
4. Center the starter assembly over the ratchet wheel with the center-
ing pin engaging the center hole of the flywheel mounting screw.
While holding in position, mount the starter, using a hex head screw,
lock washer, and two flat washers at each mounting arm as shown in
detail A. Tighten the mounting screws securely.
5. The direction of pull on the starter rope is adjustable to fit the re-
quirements of the individual installation. See detail B. To change
the direction of pull, loosen the four clamp screws (8) and turn the
starter in its mounting ring to the desired position. Tighten the four
clamp screws securely. Try the starter several times, making sure
that the pull rope will not rub against one of the clamping screws.

FIG. 50 - INSTALLING STARTER, UNITS BEGINNING WITH SPEC "B'

68 S P E C I A L PURPOSE SECTION
This section applies specifically to the "Mobile Communications" or
"Utility Type" models of the L K series generating plants. These sup-
plementary instructions are to be used, where they apply, instead of the
instructions for the standard generating plants.
The utility type of plant is designed to supply 12-volt dc output for radio,
etc., while the truck is stopped at a service job. At the same time, ac
power is available for flood lights, power tools, etc. Thus the gener-
ating plant eliminates the necessity of running the truck engine to prevent
battery run down at a service job.
When the plant is used to recharge a battery that is low (no load on the
battery) it will start charging at 30-amps or thereabouts, but very
quickly drop to a very low rate, so that it will take a very long time to
charge the battery. If the governor is adjusted to boost the speed, to
increase this low rate, the plant will no longer perform properly for
it original purpose. (Bear in mind that while an ordinary plant is
adjusted in our test room to provide best ac voltage regulation, the
Spec 1330 is adjusted for proper dc voltage for its purpose). A con-
ventional battery charging generator will taper ofi slowly, and charge
the battery much faster.
The utility type plant has a relay, which opens the charging circuit in the
generator set when the truck engine is running, to prevent the battery
from being charged from both sources at the same time. This is nec-
essary to prevent damage to the reverse current relays in both the truck
and generator set charging systems as a result of interaction between
them.
Vacu-Flo cooling and remote control of starting and stopping make the
plant suitable for installation in a small compartment.
- RATED OUTPUT -
(Alternating current and direct current are produced at the same time.)
Combined ac and dc rated output (SpecC) • • • 2500-Watts
(Prior to SpecC) 2000-Watts
Maximum dc amperes (automatically limited) 30-Amps
Available ac output
Spec. C (2500-Watts less watts of dc charging current)
Minimum (while full load dc connected-truck stopped)2110-Watts
Maximum (while truck running or battery charged and
no dc load connected) • • • 2500-Watts
Prior to Spec. C (2000-Watts less watts of dc charg-
ing current)
Minimum (while full load dc connected-truck stopped 1610-Watts
Maximum (while truck running or battery charged
and no dc load connected) 2000-Watts
Open circuit dc voltage (12-Volt battery charging) 15-Volts
Nominal ac voltage (power for tools, etc.) = • • • = • • • • 120-Voits
Requirements will differ between installations. Except for wiring, most
of the installation instructions are standard.
 SPECIAL PURPOSE SECTION 69
Consider the following factors when selecting the location for the plant:
(1) Near enough to truck's batteries or large enough cable td limit the
loss in cranking voltage. (2) Accessible for periodic servicing of fuel,
lubricating oil, air cleaner, etc. (3) Adequate air inlet and outlet for
combustion and cooling. (4) Protected from road splash, etc. (5) Shock
mounting.
F U E L . - The separate fuel tank must be securely mounted in an acces-
sible location. If the tank is to be carried for refilling, a
quick release clamp should be provided. Locate the tank so that the
fuel lift is not more than 4 feet. To prevent flooding, especially during
transit, the bottom of the tank should never be more than 1 inch above
the carburetor.
If the truck's fuel supply is used for the plant, provide an independent
supply line rather than connecting to the truck's supply line.
WIRING. - The installation involves wiring for cranking, charge-dis-
connect, ac output, and remote control of starting and stop-
ping. Refer to the Wiring Diagram for this model.
Install two sufficiently large battery cables between the truck's battery
and the battery terminals on the generator plant control. These cables
serve for cranking the plant and for charging the battery. In order to
crank the plant there must be at least 9 volts on the terminal at the plant
while cranking. Suggested battery cable sizes under adverse conditions
are: Up to 3 feet length use #2 size cable; 3 to 6 feet use #1/0; 6 to 9
feet use #3/0; 9 to 12 feet use #4/0. Battery condition, oil viscosity
and ambient temperature also affect the ability to crank.
Either polarity (negative ground or positive ground) of the battery can
be used with the plant. However, with reverse polarity, the ammeter
will read reversely and the operator should either reverse the wire con-
nections to the ammeter or mark the panel to clarify which direction of
the needle is "charge".
The ac output leads, Ml (hot) and M2 (grounded) extend out from the
generator. Receptacles can be located where convenient elsewhere on
the truck and permanently connected to the generator output leads.
Connect a wire from the armature (ARM) terminal on the truck's voltage
regulator to the terminal marked B in the plant control. The connection
will be to the coil energizing terminal of the plant relay which interrupts
generator lead A l . Use no. 18 or larger wire. This correction is not
used, when truck battery is charged with alternator. See the wiring
diagram.
One or more momentary contact switches may be connected to provide
remote control of starting and stopping. Make connections to the ter-
minal block in the plant control. Terminal number 1 is used as a com-
mon ground, terminal number 2 connects to the stopping circuit of the
plant and terminal number 3 connects to the starting circuit of the plant.
Connect the switch so that when held at O F F , number 2 is grounded and
when held at ON, number 3 is grounded.
 70 SPECIAL PURPOSE SECTION
OPERATION. - The purpose of this plant and its output rating is ex-
plained in the introductory paragraphs of this section.
CAUTIONS ! !
A voltage too high will overcharge and possibly damage the
battery. Adjust the governor only to correct the dc voltage
output of the generator at operating temperature. If a car-
buretor adjustment is made, then a recheck of the governor
adjustment must be made.
Do not become alarmed if the ammeter reads 45 amperes
when first starting the plant. After a few minutes the current
will come down to normal as the generator warms up and the
battery voltage comes up.
Consistently high charge rate (after warm up) could be due to
a poor battery in the truck or to running the plant too fast.
CHARGE R A T E . - Rated dc output is 30 amperes. A circuit breaker
opens the charging circuit to protect the generator
if dc output is too much. Equal time is consumed by the breaker to cut-
in and cut-out and it may go through this cycle several times, each suc-
ceeding cycle becoming more rapid, until it acts and sounds like a buzzer,
during an overload on the dc output. Generally, the battery will warm
up and the charge rate will drop so that the breaker will not reach the
buzzing stage.
As the battery reaches a charged condition, its terminal voltage ap-
proaches that of the generating plant, resulting in a desirable tapering
off charge rate. After the battery becomes fully charged, the charge
rate equals the dc load (radio, lights, etc.) connected.
The plants charge ammeter reads zero while the truck's engine is running.
AC OVERLOADING. - It is not expected that men on the job will deter-
mine available load each time before plugging in
tools etc. Overloading is apt to occur especially during night work when
both lights and tools are used. If the plant speed drops, ac lights will
dim, and part of the load must be disconnected. If more ac power is
required, simply run the truck's motor to take over the dc load for that
interval, and make the full rating available in ac output.
A short circuit across the ac terminals will collapse the field to protect
the generator.
GOVERNOR ADJUSTMENT. - To check or correct the engine speed, a
dc voltmeter is required, the plant must
be warm and all load disconnected. Proceed as follows:
1. Run plant with full ac load connected for at least 1/2 hour to reach
operating temperature.
2. With the load alternately removed and connected, adjust the gover-
nor sensitivity screw, if necessary, to attain a minimum drop in
speed from no load to full load operation with no hunting condition.
3. Remove the ac load and stop the plant, then disconnect the generator
lead A l at the relay in the plant control.
4. Connect the dc voltmeter across lead A l and ground.
5. Run the plant and adjust the speed to deliver 15 volts dc.
6. Remove the voltmeter, reconnect the A l lead to the relay and re-
place other parts removed.
 SERVICE DIAGNOSIS 71

POSSIBLE CAUSE REMEDY

ENGINE CRANKS TOO S T I F F L Y

Too heavy oil in crankcase. Drain. Refill with lighter oil.

Engine seized. Disassemble and repair.

ENGINE CRANKS TOO SLOWLY WHEN CRANKED E L E C T R I C A L L Y

Discharged or defective battery. Recharge or replace.

Loose connections. Tighten loose connections.

Corroded battery terminals. Clean corroded terminals. Re-

place cable if necessary.

Brushes worn excessively Replace brushes or clean commut-

or making poor contact. ator.

Short circuit in generator or Repair or replace parts necessary.

load circuit. Disconnect load.

Dirty or corroded points in Replace switch.

start solenoid switch.

ENGINE WILL NOT START WHEN CRANKED

Faulty ignition. Clean, adjust, or replace breaker

points, sparkplug , condenser, etc.,
or retime ignition.

Lack of fuel or faulty carbu- Refill the tank. Check the fuel sys-
retion. tem. Clean, adjust or replace parts
necessary.

Clogged fuel filter. Clean.

Cylinders flooded. Ground spark plug cable. Crank en-

gine with spark plug removed.

Poor fuel. Drain. Refill with good fuel.

Poor compression. Tighten cylinder head; and spark

plug . If still not corrected, grind
the valves. Replace the piston rings
if necessary.

Wrong ignition timing. Reset breaker points or retime ign-

ition.
72 SFPVTrF DTA G N O S I S

POSSIBLE CAUSE REMEDY

ENGINE RUNS B U T V O L T A G E DOES NOT BUILD UP

Poor brush contact. See that brushes seat well on commut-

ator and collector rings, are free in
holders, are not worn too short, and
have good spring tension.

Open circuit, short circuit, Refer to the GENERATOR section of

or ground in generator. Maintenance and Repair.

Residual magnetism lost. Magnetize the field.

V O L T A G E UNSTEADY BUT ENGINE NOT MISFIRING

Speed too low. Adjust governor to correct speed.

Poor commutation or brush Refinish commutator or undercut mica

contact. if necessary. See that brushes seat
well on commutator and collector rings,
are free in holders, are not worn too
short, and have good spring tension.

Loose connections. Tighten connections.

Fluctuating load. Correct any abnormal load condition

causing trouble.

GENERATOR OVERHEATING

Short in load circuit. Correct short circuit.

Generator overloaded. Reduce the load.

Improper brush rig position. Adjust.

ENGINE OVERHEATING

Improper lubrication. Change to proper oil.

Poor ventilation. Provide ample ventilation at all times.

Dirty or oily cooling surfaces. Keep the engine clean.

Retarded ignition timing. Retime ignition.

Generator overloaded. Reduce load.

 SERVICE DIAGNOSIS 73

POSSIBLE CAUSE REMEDY

VOLTAGE DROPS UNDER HEAVY LOAD
Engine lacks power. See remedies under "Engine Misfires
at Heavy Load".
Poor Compression. Tighten Cylinder head and spark plug
If still not corrected grind the valves.
Replace piston rings if necessary.
Faulty carburetion. Check the fuel system. Clean, adjust
or repair as needed. '
Dirty carburetor air cleaner Clean.

Choke partially closed. Choke plate must be wide open at

operating temperature.
Carbon in cylinders or in Remove carbon.
carburetor venturi.

Restricted exhaust line. Clean or increase the size.

ENGINE MISFIRES AT LIGHT LOAD

Carburetor idle jet clogged Clean.
or improperly adjusted.

Spark plug gap too narrow. Adjust to correct gap.

Intake air leak. Tighten. Replace gasket if necessary.
Faulty ignition. Clean, adjust, or replace breaker
points, spark plug, condenser, etc.,
or retime ignition.

ENGINE MISFIRES AT HEAVY LOAD

Defective spark plug. Replace.
Faulty ignition. Clean, adjust, or replace breaker
points, spark plug, condenser, etc.
or retime ignition.
Clogged carburetor. Clean carburetor.
Clogged fuel screen. Clean.
74 SERVICE DIAGNOSIS

POSSIBLE CAUSE REMEDY

ENGINE MISFIRES AT HEAVY LOAD(CONT. )

4
Defective spark plug cable. Replace .

ENGINE MISFIRES AT A L L LOADS

Fouled spark plug. Clean and adjust. .

Defective or wrong spark Replace.

plug.

Leaking valves. Grind valves.

Broken valve spring. Replace.

Defective or improperly Adjust or replace breaker points.

adjusted breaker points.

ENGINE BACKFIRES AT CARBURETOR

Lean fuel mixture. Clean carburetor. Adjust jets.

Clogged fuel filter. Clean.

Poor fuel. Refill with good, fresh fuel.

Reset breaker points or retime

Spark advanced too far. ignition.

Reseat or replace.
Intake valve leaking.
EXCESSIVE OIL CONSUMPTION, LIGHT BLUE EXHAUST

Poor compression. Usually Refinish cylinder . Install oversize

due to worn piston , rings, or piston and rings,
cylinder .

Oil leaks from oil base or Replace gaskets. Tighten screws and
connections. This does not connections. Check breather valve.
cause smoky exhaust.

Oil too light or diluted. Drain. Refill with proper oil.

Too large bearing clear- Replace bearings necessary.

ance.

Engine misfires. Refer to "Engine Misfires At All

Speeds"
 SERVICE DIAGNOSIS 75

POSSIBLE CAUSE REMEDY

E X C E S S I V E OIL CONSUMPTION, LIGHT B L U E EXHAUST (CONT.)

Faulty ignition. Clean, adjust, or replace breaker

points, spark plug, condenser, etc.,
or retime the ignition.

Too much oil. Drain excess oil. .

B L A C K , SMOKY EXHAUST, E X C E S S I V E F U E L CONSUMPTION

FOULING OF SPARK PLUG WITH B L A C K SOOT, POSSIBLE
LACK O F POWER UNDER HEAVY LOAD .

Fuel mixture too rich. See that choke opens properly. Adjust
jets properly. Adjust the float level.

Choke not fully open. See that choke opens properly.

Dirty air cleaner. Clean.

Excessive crankcase pres- Clean breather valve,
sure, causing excessive fuel
pump pressure.

LIGHT POUNDING KNOCK

Loose connecting rod. Adjust clearance or replace.

Low oil supply. Add oil. Change if necessary.

Oil badly diluted. Drain. Refill with proper oil.

ENGINE STOPS U N E X P E C T E D L Y

Empty fuel tank. Refill.

Defective ignition system. Check the ignition system. Repair or

replace as needed. See that the STOP
button lead is not grounded.

D U L L M E T A L L I C THUD. I F NOT BAD, MAY DISAPPEAR A F T E R

FEW MINUTES OPERATION. I F BAD, INCREASES WITH LOAD .

Loose crankshaft bearing. Replace unless one of the next two

remedies permanently corrects the
trouble.
76 S E R V I C E DIAGNOSIS ,

POSSIBLE CAUSE REMEDY

SHARP METALLIC THUD, ESPECIALLY WHEN COLD ENGINE

FIRST STARTED.
Low oil supply. Add oil.

Oil badly diluted. Change oil.

PINGING SOUND WHEN ENGINE IS SUDDENLY OR HEAVILY
LOADED
i

Carbon in cylinder. Remove the carbon.

Spark advanced too far. Reset breaker points or retime

ignition.
Wrong spark plug. Install correct spark plug.

Spark plug burned or Clean. Install new plug if necessary,

carboned.
Valves hot. Adjust tappet clearance.

Fuel stale or low octane. Use good, fresh fuel.

Lean fueL mixture. Clean fuel system. Adjust carburetor

jets properly.

Engine hot. Check air circulation.

TAPPING SOUND

Valve clearance too great. Adjust to proper clearance.

Broken valve spring. Install new spring.

HOLLOW CLICKING SOUND WITH COOL ENGINE UNDER LOAD

Loose piston. If noise is only slight and disappears
when engine warms up, no immediate
attention needed. Otherwise replace
parts, necessary.
VOLTAGE LOW AT FAR END OF LINE BUT NORMAL NEAR PLANT
Too small line wire used for Install larger or extra wires or re-
load and distance, duce load.
 : SERVICE DIAGNOSIS '. 11

POSSIBLE CAUSE REMEDY

MOTORS RUN TOO SLOWLY AND OVERHEAT AT FAR END OF

LINE BUT OK NEAR THE PLANT

Too small line wire used for Install larger or extra wires or
load and distance. reduce load.

NOISY BRUSHES

High mica between bars of Undercut mica,

commutator.

EXCESSIVE ARCING OF BRUSHES

Rough commutator or rings. Turn down.

Dirty commutator or rings. Clean.

Brushes not seating properly. Sand to a good seat or reduce load

until worn in.

Open circuit in armature. Install a new armature.

Brush rig out of position. Line up properly.

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