parts manual 4!%(i3f’a - twinslantwinslan.net/~n0nas/manuals/onan/965-0262 onan 4.0kw bfa (spec...

$: Parts Manual 4!%(I3F’A - TwinsLANtwinslan.net/~n0nas/manuals/onan/965-0262 Onan 4.0KW BFA (spec C-D... · Index \ Adapter, Air Duct 14 Adapter, Carburetor - LP 14 Armature. Generator$
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PartsManual4!%(I3F’AGenSet

T’.,. ,

/“---,,

965-0262 “1-88 (SPEC C,D)Replaces

I12-84 (SPEC C)Prfntd in U.S.A. IRedistribution or publication of this document

by any means, is strictly prohibited.

General Ih’formation,

f~

For parts or service, contact the dealer from whom you purchased this equipment or refer to “your Nearest ,,Authorized Onan Parts and Service Center.

To avoid errors or delay in filling your parts order, always give the MODEL, SPEC NO. and SERIAL NO. from theOnan nameplate.

o c)

L 4

MODEL AND SPEC NO.

SERIAL NO.

For handy reference, insert “YOUR”nameplate kformation in the spaces above.

M-1149

.

/-41

\ )_.

Std. #36DRedistribution or publication of this documentby any means, is strictly prohibited.

Important Safety Precautions

Read and observe these safety precautionswhen usingor working on electric generators, engines and relatedequipment. AISO read and foilow the literature providedwith the equipment.

proper operation and maintenance are criticalto perfor-mance and safety. Electricity,fuel, exhaust, movingpartsand batteries present h=ards that can cause severepersonal injuryor death.

FUEL, ENGINE OIL, AND FUMES AREFLAMMABLE AND TOXIC

Fire, explosion, and personal injury can result from im-proper practices.

●

●

�

●

●

●

●

●

●

Used engine oil, and benzene and lead, found insome gasoline, have been identifiedby governmentagencies as causing cancer or reproductivetoxicity.When checking, drainingor addingfuel or oil,do notingest, breathe the fumes, or contact gasoline orused oil.

Do not fill tanks with engine running.Do not smokearound the area. Wipe up oil or fuel spills. Do notleave rags in engine compartment oron equipment.Keep this and surroundingarea clean.

Inspect fuel system before each operation and per-iodicallywhile running.

Equip fuel supply with a positive fuel shutoff.

Do notstore ortranspotiequipment withfuel intark

Keep an ABC-rated fire extinguisheravailable nearequipment and adjacent areas foruse onall typesoffires except alcohol.

Unless provided with equipment ornoted otherwisein installation manual, fuel lines must be copper orsteel, secured, free of leaks and separated orshielded from electrical wiring.

Use amoved, non-conductiveflexiblefuel hoseforfuel c%ections. Do notusecoppertubing as afiex-ible connection. It will work-harden and break.

EXHAUST GAS IS DEADLY

Engine. exhaust mntains carbon monoxide (CO),an odorless, invisible, poisonous gas. Learn thesymptoms of CO poisoning.

Never sleep in a vessel, vehicfe, or roomwitha gen-set or engine running unless the area is equippedwith an operating CO detector with an audiblealarm.

Each time the engine or genset isstarted, or at leastevery day, thoroughly inspect the exhaust system.Shut down the unit and repair leaks immediately.

.

. Warning: Engine exhaust is known to the State ofCaliforniato cause cancer, birth defects and otherreproductive harm.

Make sure exhaust is properly ventilated.

●

●

●

●

●

●

Vessel bilge must have an operating powerexhaust.

Vehicle exhaust system must extend beyond ve-hicle perimeter and not near windows, doors orvents.

Do not use engine or genset cooling air to heat anarea.

Do not operate engine/genset in enclosed areawithoutample fresh air ventilation.

Expel exhaust away “fromenclosed, sheltered, oroccupied areas.

Make sure exhaust system components are se-curelyfastened and not warped.

MOVING PARTS CAN CAUSE SEVEREPERSONAL INJURY OR DEATH

●

●

●

●

●

Do not remove any guards or covers withthe equip-ment running.

Keep hands, clothing, hair, and jewelry away frommovingparts.

Before performing any maintenance, disconnectbattery (negative [-] cable first) to prevent acciden-tal starting.

Make sure fasteners and joints are secure. lightensupportsand damps, keep guards in positionoverfans, drive belts, etc.

If adjustments must be made while equipment isrunning,use extreme caution around hot manifoldsand movingparts, etc. Wear safety glasses and pro-tective clothing.

BAITERY GAS IS EXPLOSIVE

. Wear safety glasses and do not smoke whilesewic-ing batteries.

. Ahvays d=onnect battery negative (-) lead firstand reconnect it last. Make sure you connectbatterycorrectly.A directshort across batteryterminalscancause an explosion. Do not smoke while servicingbatteries.Hydrogen gas given off duringchargingisexplosive.

. Do not disconnect or connect battery cables if fuelvapors are present. Ventilate the area thoroughly.

GSP-1lof2

Redistribution or publication of this documentby any means, is strictly prohibited.

DO NOT OPERATE IN FLAMMABLE ANDEXPLOSIVE ENVIRONMENTS

Flammable vapor can be ignited by equipment operationor cause a diesel engine to overspeed and become diffi-cult to stop, resulting in possible fire, explosion, severepersonalinjuryand death. Do not operate diesel equip-ment where a flammable vapor environment can becreated by fuel spill, leak, etc., unless equipped withan automatic safety device to block the air intake andstop the engine.

HOT COOLANT CAN CAUSE SEVEREPERSONAL INJURY

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

ELECTRICAL SHOCK CAN CAUSE SEVEREPERSONAL INJURY OR DEATH

●

●

●

●

●

●

Do notse~-ce controlpanel or engine with unit run-ning. High voltages are present. Work that must bedone while unit is running should be done only byqualified service personnel.

Do not connect the generator set to the publicutilityor to any other electrical power system. Electrocu-tion can occur at a remote site where line or equip-ment repairs are being made. An approved transferswitchmust be used if more than one power sourceis connected.

Disconnectstartingbattery (negative [-] cable first)before removingprotectiveshieldsortouchingelec-tricalequipment. Use insulative mats placed on drywood platforms. Do not wear jewelry, damp clothingor allow skin surface to be damp when handlingelectrical equipment.

Use insulated tools. Do not tamper with interlocks.

Follow all applicable state ,and local electricalcodes. Have all electrical installationspen’ormedbya quaiiied licensed electrician. Tag open switchesto avoid accidental closure.

Wti transfer switches, keep cabhet closed andlocked. Only authorized personnel should havecabinet or operational keys. Due to serious shockhazard from highvoltages withh catinet, allserviceand adjustments must be performed by an electri-cian or authorized service representative.

If the cabinet must be opened for any reason:

1. Move genset operation switch or Stop/Auto/Handcrankswitch (whichever applies) to Stop.

2. Disconnectgenset batteries (negative [-] leadfirst).

3. Remove AC power to automatic transferswitch. if instructionsrequire otherwise, useextreme caution due to shock hazard.

MEDIUM VOLTAGE GENERATOR SETS(601~ TO 15kV)

●

●

Medium voltage acts differently than low voltage.Special equipmentand trainingare requiredto workon oraroundmediumvoltageequipment. Operationand maintenance must be done only by personstrained and qualified to work on such devices. im-proper use or procedures will result in severe per-sonal injuryor death.

Do notworkon energized equipment. Unauthorizedpersonnel must not be permitted near energizedequipment. Induced voltage remains even afterequipment is disconnectedfrom the power source.Plan maintenance with authorized personnel soequipment can be de-energized and safelygrounded.

GENERAL SAFETY PRECAUTIONS●

●

●

●

●

Do not work on equipment when mentallyor physi-cally fatigued or after consuming alcohol or drugs. ‘“””-”

Carefully follow all applicable 100al,state and feder-al codes.

Never step on equipment (as when enteringor leav-ing the engine mmpartment). It can stress andbreak unit components, possibly resulting in dan-gerous operatingcondiions from leakingfuel, leak-ing exhaust fumes, etc.

Keep equipment and area dean. Oil, grease, dim orstowed gear can cause fire or damage equipmentby restrkthg airflow.

Equipment owners and operators are solely re-sponsible for operating equipment safely. Contactyour authorized Onan/Cummins dealer or distribu-tor for more information.

KEEP THIS DOCUMENTEASY REFERENCE.

NEAR EQUIPMENT FOR

.-.

GSP-12of2

.Redistribution or publication of this documentby any means, is strictly prohibited.

Index

\Adapter, Air Duct 14Adapter, Carburetor - LP 14Armature. Generator 24,26

Base, Oil 12Bearing, Camshaft 4Bearing, Crankshaft 4Block, Brush - Generator 24.26Block, Cylinder 4Block, Terminal 2880X, Breaker 20,21Bracket, Exhaust 23Bracket, Governor 10Breaker, Circuit 288rush, Generator 24.26

Carburetor, Gasoline 14,16Carburetor, LP 14Carburetor Components (Gaso) 18,19Clamp, Muffler 22,23Coil, Ignition 20Control , Generator 2B,30Cover, Air Cleaner 14,16Cover, Breather 4Cover, Control 28Cover, Valve 4Crankshaft 7Cushion, Vibration 12

Ouct, Air Cleaner 14

Element, Air Cleaner 14,16

-. Filter, Breather Tube 14, 16Filter, Oil 11Flywheel 7Fuse, 5 Amp, 10 Amp 28

Gasket, Exhaust Manifold 22,23Gearcase 9Generator 24,26Governor 10Guard, Scroll 13Guide, Valve 4

Harness, Wiring 24,26,28Harness, Wiring - Remote 28Head, Cylinder 4Housing, Air 13Housing, Air Cleaner 17Housing, Choke 14,16

Kit, Carburetor Repair 1B,19Kit, Gasket 4Kit, Tune-Up 21

Line, Fuel - Gasoline 14,16

Manifold, Exhaust 22,23Manifold, Intake 14,16Muffler, Spark Arrestor 22,23

Paint 31Piston 8Plug, Spark 20Points, Ignition 21Pump, Fuel - Electric 14, 16Pump, Oil 11

Relay, Start Solenoid 28,30Resistor, Fixed 24,26Ring, Piston 8Rod, Connecting 8Rod, Governor 10

Seal, Oil - Crankshaft 4,9Seat, Valve 4Shield, Heat - Exhaust 23Solenoid, Start 28Spring, Governor 10Stator, Generator 24,26Strap, Ground 12Switch, Ignition 28Switch, Pressure - Oil 11Switch, Rocker - Control 28

Tappet, Valve 4Tube, Breather 14,16Tube, Exhaust 23

Valve, Exhaust 4Valve, Intake 4

,-.

1


Introduction

This Catagroups of

og applies to the BFA Utility Vehicles Generator Set. Parts are arranged inrelated items. Each illustrated part is identified by a reference number

corresponding to the same reference number in the parts list for that group. Partsillustrations are typical. Using the Model and Spec No. from the nameplate, selectParts that apply to your Model and Spec No. Unless otherwise mentioned in the descrip-tion, parts are interchangeable between models. Right and left sides are determined byfacing the e~ne end (front) of the set. !.

Engine Data Table

~1[-llw-bq’..

Model and PartsSpecification Number volts Key Number

4.0 BFA-3cR/lsoooc 120/240 1

4.0 BFA-lR/19486C 120 2

4.0 BFA-lR/19486D 120 3

4.0 BFA-3CR/20275C 120/240 4

4.0 8FA-5DR/22540C 120/240 5

4.0 BFA-5DR/22541: 120/240 6

4.0 BFA-3CR/25206C 120/240 ‘7

4.0 BFA-3CR/26651C 120/240 8

4.0 BFA-3CR/26805C 120/240 9

4.0 BFA-5DR/27696C 120/240 10

4.0 BFA-5DR/27919C 120/240 11; 24;$,,$

4.0 BFA-3cR/ 12

2Redistribution or publication of this documentby any means, is strictly prohibited.

..—

,.

).

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.-


9Cylinder Block

,,—

,.—,~. .

4


Cylinder Block

REF PART,. NO. NO.

1 110-3148

2 800-0051

3 850-00504 509-00415 516-0072

,. 6 104-07767

101-0450101-0450-02101-0450-10101-0450-20101-0450-30

8 104-05759 101-0415

10 101-043911 517-004812 110-006813

110-1807110-3055

110-3159

14 101-040515

101-0432101-0432-02101-0432-10101-0432-20101-0432-30

16 120-073517

110-1824110-1824-02110-1824-05110-1824-10110-1824-25

18110-0197110-0197-02110-0197-05110-0197-10110-0197-25

19 516-014120 800-0010

21. 526-0063

QTY PARTUSED DESCRIPTION

1

5

514

AR

1111121112

22

2

2

111

;1

22222

2222222

2

810ck, Cylinder(Includes Parts Marked*)

*Screw, Cap - Hex Head(3/8-16xl-l/4”)

*Washer, Lock - Spring (3/8”)*Seal, Oil*Pin, Drive - Bearing Stop*Shim (.005”)

Bearing, Crankshaft - Rear(Includes Thrust Washer)

* Standard.002” Undersize.010” Undersize.020” Undersize.030” Undersize

washer, Thrust*Gasket, Bearing Plate*Plate, Bearing - Rear*Plug, Expansion - Welch*Gasket, Intake Valve Guide*Guide, Valve

ExhaustIntake - Sets With Valve

Stem Oil SealsIntake - Sets Without

Valve Stem Oil Seals*8earinq, Camshaft

Bearin~, Crankshaft - Front* Standard

.002” Undersize

.010” Undersize

.020” Undersize

.030” Undersize*Tube, Oil Crankcase

Insert, Valve Seat -* Standard

.002” Oversize

.005” Oversize

.010” Oversize

.025” OversizeInsert, Valve Seat -

* Standard.002” Oversize.005” Oversize.010” Oversize.025” Oversize

Exhaust

Intake

*Pin. Gearcase AlignmentScrew, Cap - Hex Head

(1/4 -20xl-3/4”)Washer, Flat - Copper

(1/4” Screw)

REF PARTNO. NO.

22 110-2274

23 123-117424 526-001825 123-117526 123-117327 110-1879

28 110-192129 526-012230

110-2562110-2561

31110-2287110-0892

32800-0540800-0541

33115-0006115-0006-02115-0006-05

34 110-063935

110-0904

110-0893

110-0904110-0893

36 110-053937

110-180811O-236B

38110-1955110-1809

39 517-0120

40 110-3236

41 517-006742

168-0144168-0143

43 509-0168

QTYUSED

1

11111

318

11

22

126

4448

4

4

22

4

22

221

2

1

112

* - parts Included In

PARTDESCRIPTION

Cover, Valve (WithBreather Port)

Spring, Breather ValveWasher, Flat (1/4” Screw)Reed, Breather ValveBaffle, Breather ValveCover, Valve (Without

Breather Port)Gasket, Valve CoverWasher, Flat (5/16” Screw)Head, Cylinder

Right SideLeft Side

Gasket, HeadAll Except Key 3Key 3

Screw, Cap - Hex Head5/16-lBxl-5/8’’(Grade 8)5/16-18x2’’(Grade 8)

Tappet, ValveStandard.002” Oversize.005” Oversize

Lock, Valve SpringRetainer, Valve Spring

Rotator - Keys 1,2,4,5,6,B,9,10,12

Washer (Used In Place OfRotators On Intake Valves)

Keys 7,11Rotator - Key 3Washer (Used In Place Of

Rotators On Intake Valves)Key 3

Spring, ValveValve, Intake

Keys 1,2,3,4,7,6,9,11,12Keys 5,6,10

Valve, ExhaustAll Except Key 3Key 3

Plug, Cylinder Block OpeningKeys 1,2,8,9,12

Seal, Valve - Intake(Optional)

‘Plug, WelchKits

Gasket (Carbon Removal)Gasket (Complete Engine)

Seal , Valve - Intake(Optional)

110-3148 Cylinder Block.

5


3 4\ I

REF PART QTY PARTNo. No. USED DESCRIPTION

1 150-0078 1 Ring, Retaining2 150-1519 1 Hub, Governor Cup3 150-1520 1 Cup, Governor4 510-0015 10 Ball. Governor5 105-0332 1 Gear, Camshaft

(Includes SpacerAnd Plate)

Camshaft

58“

6 I

1

&fDpQD—0

i— 9

C 1056

REF PART QTY PARTNO. NO. USED DESCRIPTION

6 105-0541 1 Washer, Thrust7 150-0075 1 Pin, Center8 515-0001 1 Key, Woodruff9 105-0637 1 Camshaft(Includes Center Pin)

.. —,,

.

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,---


Crankshaft And Flynheel

i2

7

56

8*i-o

REF PART QTYNO. NO. USED

1 104-0170 1

2 850-0055 13 526-00174 134-3871 :5 518-0014 1

PARTDESCRIPTION

Screw, Cap - Hex HeadHeat Treated (Special)

Washer, Lock - Spring (7/16”)Washer, Flat (7/16” Screw)FlywheelRing, Retaining

REF PART QTYNO. NO. USED

6 104-0043 17 104-0032 18 515-0227 19 515-0001 1

10 104-1331 1

PARTDESCRIPTION

Washer,GearGear, CrankshaftKit, Key - All Except Keys 1,2Key, Woodruff - All KeysCrankshaft (Includes Keys)

,—


Piston And Rod

REF PARTNO. NO.

112-0186112-0186-05112-0186-10112-0186-20112-0186-30112-0186-40

2 112-02293 518-03114

113-0189113-0189-05113-0189-10113-0189-20113-0189-30113-0189-40

QTYUSED

22222224

222222

,—..

PARTDESCRIPTION

Piston (Includes Pin AndRetaining Rings)

Standard.005” Oversize.010” Oversize.020” Oversize.030” Oversize.040” Oversize

Pin. PistonRing, RetainingRing Set, Piston

Standard.005” Oversize.010” Oversize.020” Oversize.030” Oversize.040” Oversize

REF PARTNO. NO.

5

114-0300114-0300-10114-0300-20114-0300-30

6 114-0240

7 870-0302

QTYUSED

22224

4

PARTDESCRIPTION

Rod, Connecting (IncludesBolt And Nut)

Standard.010” Undersize.020” Undersize.030” Undersize

Bolt, Connecting Rod(Special)

Nut, Hex - Crown Lock(5/16-24)


REF PARTNO. NO.

1 103-0667

2 150-15423 509-00084 510-00135 510-00146 516-0130

7 150-1187

r.. Y7 -2 13

\


1 Gearcase (Kit)(Includes Parts Marked*)

1 *Arm And Shaft, Governor1 *Seal, Oil - Governor Shaft2 *Bearing. Needle1 *Ball. Bearing1 *Pin, Dowel - Governor Cup

stop1 *Yoke, Governor

REF PARTNo. NO.

8 815-0046

9 509-004010 103-040811 526-0065

.-12

800-0032800-0034

13 150-0678


2 *Screw, Machine - Pan Head(8-32x3/8”)

1 *Seal, Oil - Crankshaft1 Gasket, Gearcase Mounting5 Washer, Flat - Copper

(5/16” Screw)Screw, Cap, Hex Head

4 5/16-18xl-3/4°~ 5/16-18x2-l/4°1 *Clip, Sensitivity Adjustment

* - parts Included In 103-0667 Gearca!se.

..’,


REF PARTNO. NO.

1 870-0131

2 150-00963 150-16124 800-0004

5 526-00636 150-15777 518-0004


1 Nut, Hex - Self Locking(1/4-20”)

1 Stud, Speed Adjustment1 Spring, Governor2 Screw, Cap - Hex Head

( l/4-20x5/8° )2 Washer, Flat (1/4” Screw)1 Bracket, Governor1 Clip, Retaining

Governor

,.—

..\


8 870-0131 1 *Nut. Hex - Self Locking( 1/4-20)

9 150-0629 1 *Rod, Governor Arm ToCarburetor

10 870-0053 1 *Nut, Hex (#10-32)11 150-0639 1 *Joint, Ball12 149-0003 1 Gasket, Governor Bracket

150-0630 1 Linkage, Governor (IncludesParts Marked*)

* - Parts Included In 150-0630 Governor Linkage.

10 ,Redistribution or publication of this documentby any means, is strictly prohibited.

. .

Oil System

—

REF PARTNO. NO.

1 122-03202 122-0321

3 122-06454 122-03475 122-03606 502-00537 309-03198 800-0028

9 526-0065

10 815-0194

E—13

12

14

15

1918

16 ,/17

.%@Q

i.

QTYUSED

11

112

2

2

/21

1

PARTDESCXIPTIUi

Adapter, Oil FilterGasket, Oil Filter

Adapter MountingFilter, Oil - Spin-OnSeal, Air - Oil FilterDrain, Oil FilterElbow, Street - 45”Switch, Low Oil PressureScrew, Cap - Hex Head

(5/16-18xl”)Washer, Flat - Copper (5/16”

Screw)Screw, Tapping - Hex Head

(#10-32x3/8’ )

REF PARTHo. No.

11 336-3377

12 526-006613 801-0050

14 120-014015 120-0398

16 850-004017 800-0007

18 120-0491

19 120-016120 120-0413

I

QTYUSED

1

11

1122

1

11

PARTDESCRIPTItXd

Lead, Electrical - Low OilPressure Switch

Washer, Flat (3/8” Screw)Screw, Cap - Hex Head

(3/8-24xl”)Spring, Oil By-Pass ValveValve, Oil 8y-PassWasher, Lock - Spring (1/4”]Screw. Cap - Hex Head

(1/4 -20xl” )Pump, Oil (Cc+nponents Not

Sold Separately)Kit, Gasket - Oil ?umpCup, Oil Pump Intal:e

(Includes Scraw Piae And Cup)

-..

.,”.”


Oil Base AndMounting Hardware

REF PARTND. NO.

1 102-0957

234567

8

1:

11

12

102-1200526-0030123-1400123-0191504-0092

526-0195526-0195102-1275102-0889821-0018

800-0082800-0082800-0047

13 856-001014

402-0477402-0480

15 402-0283

16

402-0283402-0283

17402-0290402-0290402-0290

18402-0282402-0282402-0282

21862-0004062-0004862-0004

QTYUSED

1

14111

2211

20

221

1

122

11

211

211

211

7

PARTDESCRIPTION

Base, Oil (Includes PartsMarked*)

Gasket, Oil BaseWasher, Flat (3/8” Screw)Cap And Indicator, Oil FillGasket, Oil Fill CapValve, Oil DrainWasher, Flat (7/16” Screw)

Engine EndGenerator End

*Gasket, Oil Pan Mounting*Pan, Oil Base*Screw. Cap - Hex Washer

Head (1/4-20x5/8”)Screw, Hex Head - Cap

(7/16 -14x3 -3/4° )Engine EndGenerator End

Screw, Cap - Hex Head(3/8-16x5/8”)

Washer. Lock -EIT (3/8”)Package, Hardware Mounting

(Includes Parts Marked#)Engine EndGenerator End

~Cushion, VibrationEngine End

SCushion, Vibration -Generator End

Left SideRight Side

#Spacer, SleeveEngine EndGenerator End(Left Side)Generator End(Right Side)

#SnubberEngine EndGenerator End(Left Side)Generator End(Right Side)

#Nut, ,Hex.(7/16-14)Engine EndGenerator End(Left Side)

‘enerator‘nd(Right‘id=)12

3438

.—.

LS1003-1

REF PARTNo. ND.

22850-0055850-0055850-0055

23526-0014526-0014526-0014

24526-0198526-0198526-0198

25526-0286526-0286

26526-0038526-0038

27 800-0064

28 850-005029

337-0418337-2055

30 816-0197

31 856-001632 403-1484

33 856-001234 862-000435

816-0206816-0206816-0206

36 332-014237 B56-000638 850-0055

QTY PARTUSEO DESCRIPTION

#Washer, Lock (7/16”)2 Engine End1 Generator End(Left Side)1 Generator End(Right Side)

#Washer, Flat (7/16” Screw)2 Engine End1 Generator End(Left Side)1 Generator End(Right Side)

#Washer, Flat (9/16” Screw)2 Engine End2 Generator End(Left Side)1 Generator End(Right Side)

#Washer, Flat (l” Screw)1 Generator End(Left Side)1 Generator End(Right Side)

#Washer, Flat (5/8” Screw)2 Engine End1 Generator End4 Screw. Cap - Hex Head

(3/8-16x4-l/2° )4 Washe’r, Lock - Spring (3/8”) /

Strap, Ground1 5“ Long - Key 6

6“ Long - All Except Key 6.1 Bolt, Carriage (7/16-14 x

1-1/4”) - All Except Key 61 Washer, Lock (EIT) (5/8”)1 Plate, Mounting - All Except

W%e~, Lock (EIT) (7/16”); Nut, Hex (7/16-14)

#Bolt, Carriage (7/16-”4x3-l/2”)2 Engine End1 Generator End(Left Side)1 Generator End(F?~gh”: Side)1 Terminal, Ground1 Washer, Lock - EI’i (1/4”)

Washer, Lock (7/16”),,—.

1

* - Parts Included In 102-0956# - Parts Included In Hardware

Oil Base.Mounting Package


Air Housing

11

CS 1065

REF PARTNO. NO.

1 821-0008

2134-4387

134-31493 821-0010

4134-3888

— 134-3688

134-39285 815-0261

QTY PART REF PARTUSED DESCRIPTION NO. NO.

4 Screw, Cap - Hex Head 6 134-3701( l/4-20x5/16° )

Scrol 1 7 134-37001 2 Position, With-Out Guard

- Key 9 81 Includes Guard - Keys l,2,3& 134-34182 Screw, Cap - Hex Washer Head &

( l/4-20xl/2° Long) 5+”&q 134-4;16Backplate, Scroll

1 3 O-Clock Position - Key 4 9 B15-04211 6 O-Clock Position - Keys 2,

3,5,6,7,10,11 10 850-00401 9 O-Clock Position - Keys 8,9 11 309-00775 Screw, Tapping - Hex Head

(1/4-20xl/2”)


1 Housing, Cylinder Air -Left Side

1 Housing, Cylinder Air -Right-Side

Guard, Scroll1 Screen

Keys 1, 2, 31 Guard - Wire Type

Except Key 34 Screw, Self-Tapping

Head (10-16xl/2”)4 Washer, Lock (1/4”)1 Switch, Temperature

- Close 220” F)

- All

- Hex

(Open 180”

,,—


Fuel System (LOW Pro file’ Air cleaner)Keys 1,2,3,4,5,7,8,9,10,11 ,12

\\32 33

I 64

??

-,—-

1. //

51.

/’a$3J’

1 i-d L~_y,o_.@‘9/

14 “_e. ‘--:--;’214-. c-:’ Z.-d

)7 }’*13 &# -’l ‘u9. ’16J623

40

/

66

62

. . ..

.49

,.—.

./’.’


Fuel System (Low Profile Air Cleaner)Keys 1,2,3,4,5,7,8,9,10,11 ,12

REF PARTNO. NO.

QTYUSED

1

1

11

1

11

111112

2

~

2

11

24

4111

111112

1

111

PARTDESCRIPTION

Filter, Breather Hose -Gasoline Fuel System

Clamp, Hose - Gasoline FuelSystem

BreatherTube (Gasoline Fuel System)Hose (LP Fuel System)

- Keys 7,11Clamp, Hose - Gasoline Fuel

SystemAdapter, Air Duct

Gasoline Fuel SystemLP Fuel System - Keys 7,11

Carburetor, Complete (IncludesMounting Gasket) (See SeparatePage For Components)

Gasoline Fuel System - NikkiLP Fuel System - Keys 7,11

Gasket, Carburetor To AdapterAdapter, CarburetorGasket, Adapter To ManifoldScrew, Cap - Hex Head

(5/16 -18xl”)Washer, Lock - Spring

(5/16”)Screw, Cap - Hex Head

(1/4 -20xl-3/8”)Washer, Lock - Spring (1/4”)Manifold, Intake

LP Fuel System - Keys 7,11Gasoline Fuel System - Keys

1,2,3,4,5,8,12Gasket, Intake ManifoldScrew, Cap - Hex Head

(5/16-18x2”)Washer, Lock - Spring (5/16”)Connector, Inverted MaleLine, Fuel - GasolineClamp, Loop - Insulated

Keys 1,2,3,4,5,8,9,10,12Nut, Hex (5/16-18)Elbow, Inverted MaleConnector Hose (90”)Pump, Fuel (Electric)Terminal, Fuel Pump LeadScrew, Hex - Lock

(1/4-20x5/16”)Housing, Choke (Includes

Screw)8i-Metal, ChokeElement And Cover, ChokeTerminal, Tab

REFNO.

PARTNO.

QTYUSEO

2

2

1

11

3

3

12

121121113

1

2

12

1

;11

1;

1

1

1

3

PARTDESCRIPTION

Screw, Machine - Round HeadW/ET (#8-32x5/16”)

Washer, Flat - 8rass(#10 Screw)

Screw, Machine - FillisterHead (#10-32x7/8”)

Washer, Lock - Sprir:g (S10)Connector, Fuel Pump LeadScrew,

Socket Head - Gasoline Fuel(#10-32xl/2° Long)

Round Head, Machine - LPFuel System (#10-32x2-l/4”)

Adapter, ChokeScrew, Self–Tapping - Hex

Head (#10-32x7/8° Long)Seal, O-Ring

Gasoline Fuel SystemLP Fuel System - Keys 7,11

Clamp, Air DuctSeal, Air Duct To AdapterScrew, Wing (1/4-20x3/4’i)Washer, Flat (1/4” Screw)Duct, Air Cleaner8racket, Air Duct SupportScrew, Cap - Hex Head

1 123-1417 32 815-0285

2 503-0280 33 526-0062

3123-1277503-0103

815-011034

353637

B50-0030332-0556

4 503-0769804-0017

5140-1492140-1719

6

813-0111

3839

153-0499815-0359

146-0419146-0404154-0733154-1977145-0438800-002B

40509-0145509-0145140-1520140-1502518-0390526-0021140-1503140-1531821-0009

140-1521

789

10

41424344454647

11 850-0045

12 800-0023Locking (1/4-20x3/8”)

Seal, Air Duct To8reather Port

Nut, Hex - Locking(1/4-20)

Nut, Wing (1/4-20)Washer, Flat (1/4” Screw) “Nut, Hex - Locking (1/4-20)Bolt, Carriage (1/4-20x6-l/2”~Element, Air CleanerCover, Air CleanerSpacer, Air IntakeBracket, Air Intake

OuctBrace, Air Intake Duct

13.—-. 14

850-0040

154-2206154-2666

154-1446800-0033

850-0045502-0003149-1531518-0350

48

49 870-0212

865-0019526-0158870-0212816-0070140-0495140-1504140-1522140-1529

140-1528140-1533140-1672

123-1484

148-0840

502-0575

5051525354

E57

585960

1516

17181920

212223242627

28

293031

862-0015502-0002502-0313149-1828332-0529821-0008

153-0440

SealWrapper, Air Cleaner -

Keys 5,10,1161

62

63

Tube, Breather (Copper) -LP Fuel System - Keys 7,11

Adapter, Carburetor - LPFuel System - Keys 7,11

Elbow, Hose - 45” (1/2 NPT)LP Fuel System - Keys 7,11

Washer, Lock (#10)LP Fuel System

153-0017153-0114332-0527

64 850~0030

,—


Fuel System (High Profile Air Cleaner)Key 6

24

32

49*

314

,.—

XFS1462


REF PARTNO. NO.

1 154-22062 145-0438

3 146-0440

4 502-00035 140-12286 140-17117 140-14968 140-14949 153-0539

10 509-014511 146-024112 518-038713 850-004014 800-0023

15 154-197716 865-000617 800-0028

18 850-0045

19 154-0733

20 145-0521

21 815-0470

—. 22 526-023423 815-0285

QTYUSED

11

1

:1111

;122

:2

2

1

1

3

32

Fuel System (HighK:;o:ile Air Cleaner)

PARTDESCRIPTION

Manifold. IntakeGasket, Manifold To Carbure-

tor AdapterCarburetor, Gasoline (See

Separate Page For Components)Connector, Inverted MaleElement, Air CleanerHousing, Air CleanerWrapper, Filter ElementCover, Air CleanerBracket And Bushing, ChokeSeal, O-RingShaft, Electric ChokeRing, RetainerWasher, Lock - Spring (1/4”)Screw, Cap - Hex Head

(1/4-20xl-3/8”)Adapter, CarburetorNut, Wing (1/4-20)Screw, Cap - Hex Head

(5/16-18xl”)Washer, Lock - Spring

(5/16”)Gasket, Carburetor To

AdapterDeflector, Carburetor Air

SntakeScrew, Machine - Hex Head

(#10-32xl-l/2”)Washer, Flat (#10 Screw)Screw, Machine - Round Head

W/ET (#8-32x5/16”)

REF PARTNO. NO.

24 526-006225 153-011426 153-001727 153-005828 821-0004

29 153-054130 332-052731 123-141732 123-142933 140-173634 821-0009

35 815-0110

36 850-003037 800-0033

38 850-004539 154-144640 862-001541 518-035042 149-170543 149-182844 502-031345 502-000246 821-0008

47 332-052948 332-055649 503-028050 800-0034

QTYUSED

21112

111

;1

1

13

421111

i2

1111

PARTDESCRIPTION

Washer, Flat - Brass (Special)Element And Cover, ChokeBi-Metal, ChokeHousing, ChokeScrew, Cap - Hex Washer Head

(#10-32x5/16”)Link, ChokeTerminal, TabFilter, Breather TubeTube, 8reatherBracket, Air Cleaner SupportScrew, Cap - Hex Washer Head

(1/4-20x3/8° )Screw, Machine - Fill ister

Head (#10-32x7/8”)Washer, Lock - Spring (#10)Screw, Cap - Hex Head

(5/16-18x2”)Washer, Lock - Spring (5/16”)Gasket, Intake ManifoldNut, Hex (5/16-18)Clamp, Loop - InsulatedLine, FuelPump, Fuel - ElectricConnector. Hose (90”)Elbow, Inverted MaleScrew, Cap - Hex Lock

( l/4-20x5/16° )Terminal, Fuel Pump LeadConnector, Fuel Pump LeadClamp, Breather TubeScrew, Cap - Hex Head

(5/16-18x2-l/4”)

—..>/

17


Carbureto[p:ornponents

.

s-—-’

Q

i

1’‘1I

20

REF PARTNo. No.

146-0404

1 815-03892 146-04183 146-03224 146-03265 509-01456 146-03298 146-04209 146-0335

10 146-0331

11

QTYUSED

1

1111111i1

1

PARTDESCRIPTION

Carburetor, LPG (IncludesMounting Gasket)

Screw, Hex Washer HeadShaft, Throttle (Kit)

*Screw and Plug Kit*Gasket Kit

Seal, O-Ring*Valve and Seat Kit

Jet, Idle*Needle, Adjusting - Idle*Spring, Needle - Idle

AdjustingIntake, Air (Not Sold

Separately)

REFNo.

121314

15

16

171820

PARTNo.

154-0733146-0327 .

146-0343

146-0340

146-0341146-0342146-0356


Body (Not Sold Separately); *Gasket, Mounting - Carburetor1 Variable Jet Kit - Optional

(High Altitude Application)( Includes Parts Marked +)

1 +Jet, Power - Variable(Includes Gasket)

1 +Retainer, Needle - Power(Includes Gasket )

1 +Spring, Needle - i%.er1 +Needle,. Power - Complete1 Kit, Repair (includes Parts

Marked *)

* - parts Included in 146-0356 Repair Kit.+ - parts Included in 146-0327 Variable Jet Kit.


Carburetor Com ;~:~tsGasoline - E

.-

REF PARTNO. NO.

146-0419146-0440146-0417146-0418146-0322146-0326146-0325146-0329146-0343146-0420~A5-(3335~4!3-0331

QTY PARTUSED DESCRIPTIffl

111111111111

1

Carburetor, Complete(Includes Mounting Gasket)

Low Profile ModelsHigh Profile Models

Choke, Shaft Kit.Shaft; Throttle (Kit)

*Screw and Plug Kit*Gasket Kit

Float, Kit*Valve and Seet Kit

Jet, PowerJet, Idle

*Needle, Adjusting - Idle*spring, Needle - Idle

AdjustingIntake, Air (Not Sold

Separately)

REF PARTNo. No.

12 .13 154-073314 146-0327

15 146-0343

16 146-0340

17 146-034118 146-034219 145-043820 146-0356

QTYUSED

121

1

1

1111

PARTDESCRIPTION

Body (Not Sold separately)*Gasket, Mountink - Carburetor

Variable Jet Kit - Optional(High Altitude ,.ppli cation)(Includes Parts Yarkeci +)

+Jet, Power - Vari.:ble(Includes Gasketj

+Retainer, Needle - Power(Includes Gasket)

+Spring, Needle - Pow)er+Needle, Power - Complete*Gasket, Mounting - Carburetor

Kit, Repair (includes PartsMarked’*) ~

* - parts Included in 146-0356 Repair Kit.+ - parts Included in 146-0327 Variabl; Jet Kit.


Ignition

REF PARTNO. NO.

1 166-07722 166-05883 821-0009

4 167-16027 160-05588 160-1303

QTYUSED

114

221

.—../

H’

ES1116

-.

PARTDESCRIPTION

Coil, IgnitionClamp, CoilScrew, Cap - Hex Washer

Head (1/4-20x3/8”)Cable, Spark PlugNipple, Spark Plug CableBox, 8reaker (See Separate

Page For Components) (IncludesMounting Gasket)

REF PARTNO. NO.

9 160-115011 160-115112 167-029813 166-055414 850-200515 312-0051

jk- ]376

QTYUSED

112221

PARTDESCRIPTION

Gasket, 8reaker Box MountingPlunger, Breaker PointsPlug, SparkNut, Hex (Metric)Washer, Lock - Spring (Metric)Condenser, Ignition (.5 MFD)

.

/

.-.-

.<


Breaker Box

“TL#‘/I g )0

15

\14

REF PARTNO. NO.

160-1303

1 802-0022

2 509-00653 526-00084 160-12855 815-0358

‘1 312-0246


1 Breaker Box (Includes PartsMarked*)

1 *Screw, Cap - Hex Socket(#10-24 X 1-1/2”)

1 *Retainer (O-Ring)1 *Washer, Flat (#10 Screw)1 *Cover, Breaker 80X1 *Screw, Cap - Slotted

(#8-32 X 3/16”)1 *Condenser

REF PARTNO. NO.

8 802-0034

9 850-004010 160-11B311 160-121912 160-115014 336-237B15 160-1311

QTY PARTUSEO DESCRIPTION

2 *Screw, Cap - Socket HeadW:;V4;20 x 3/4”)

2 Lock (1/4”)1 *Point Set, Breaker

*Base, Breakeri *Gasket, 8reaker Box1 Lead, Breaker Box to Coil1 Tune Up Kit (Includes Points

and Condenser)

* - parts Included in 160-1303 8reaker BOX.

,,.—.


Exhaust System(Sets With High Profile Air Clean-r)

Key 6 ,s Qy+._s-\j

Exs 1083

REF PART QTY

NO. NO. uSEO

1 154-1762 12 800-0026 4

3 850-0045 4

4 154-1725 2

PART REF PART QTY

DESCRIPTION NO. NO. USED

Manifold, Exhaust - LH Down 5 154-2310 1

Screw, Cap - Hex Head 6 154-2311 1

(5/16-18 X 3/4”) 7 155-1256 2

Washer, Lock - Spring (5/16”) 8 155-1851 1

Gasket, Exhaust Manifold

PARTDESCRIPTION

Elbow, Exhaust (Right)Elbow, Exhaust (Left)Clamp, MufflerMuffler, Exhaust (Spark

Arrestor)

.

..—.,

22


Exhaust S stemY(Sets With Low Profi e Air Cleaner)

UL Listed And CSA CertifiedKeys 1 ,2,3,4,5,7,8,9,10,1 1,12

u

.-.

REF PART QTYNo. No. USED

1154-1947 1

154-2140 1‘154-2425 1

154-1762 12 800-0026 4

3 850-0045 44 154-1725 25 154-20616

154-15iZS’9’7 ;154-2143 1154-2554 1

7 800-0030 2

8 850-0045 29 862-0015 2

10 155-1239 1

PART REF PARTDESCRIPTION No. ND.

Manifold. Exhaust 11 155-12345.25” Tall - Prior To 6/83 12

Keys 1,2,3.9,10,11 155-12585.75” Tall - Keys 4,8 155-1520Includes Heat Shield - 8egin 155-18516/83

Left Hand Down - Key lfi~c~~{~ 155-1910Screw. Cap - Hex Head- -

(5/16-18x3/4”)13 154-2146

Washer, Lock -“Spring (5/16”) 14 821-0010Gasket, Exhaust ManifoldGasket, Exhaust Tube 15 154-i972Tube, Exhausti?’~ Long

12-1/2” Long 16 503-010790” Bend - With A ached

1)

1? 154-1883Clamp (18” Long) ~13.5°

Screw, Cap - Hex H d 18 154-1886(5/16-18xl-l/4”)

Washer. Lock - Spring (5/16”) 19 821-0010Nut, Hex (5/16-18)Clamp. Muffler 20 1S2-0184


1

1111

1

4

1

11

1

1

1

Bracket And Clamp, MufflerMuffler, Exhaust

End Inlet - Spark ArrestorCenter Inlet - Key 9Spark Arrestor - Key 7Center Inlet (Used With

90” 8end Exhaust Tube)Shield. Heat - Down Pipe

(14” Long) - Oelete Keys 7,8Screw, Cap - Hex Head

- Locking (1/4-?Oxl/2”)Shield, Heat - Exhaust

Manifold - Prior To 6/83- Delete Keys 7,&

Clamp, Shield To Exhaust Tube8racket, Heat Shield - Left

Side - Keys 9,128racket, Heat Shield - Right

Side - Keys 9,12Screw, Cap - Locking Head

(1/4-20xl/2° )Spacer, Heat Shield Mounting

- Key 9

–-..

23


.’

I%&im 5

rT34

T“

AGenerator b

Keys 1,5,8,9,12 @’

Q:

v I16 /

I/

/1

32

k

//

‘,/46 P ~’3 ,,’ 13

181917 \\.&\ 14‘

42

. .

43

2

,–-

...,”.

24


GeneratorKeys 1,5,8,9,12

,,-—--,REF PARTNo. ND.

1 862-00152 231-0164

3 850-00504 800-00S0

,.5 520-07326

201-2421

201-2504

201-2405

7 204-01108 203-01539 510-0047

10220-1818

220-182011 516-019612 860-001113 304-001514

353-0072

353-0084

,.-

15 850-003016 812-0118

17 800-0043

18 850-004519 526-011520 211-0364

QTYUSED

41

44

1

1

1

1

111

1

1412

1

1

:

4

441

PARTDESCRIPTION

Nut, Hex (5/16-18)Adapter, Generator To Engine

(Includes Alignment Pins)Washer, Lock - Spring (3/8”)Screw, Cap - Hex Head

(3/8-16xl-l/4”)Stud, Armature ThroughArmature (includes Parts

Marked*)120/240 Volt, 3 Phase -

Key 5120/240 Volt, 1 Phase -

Keys 9,12120/240 Volt, 1 Phase -

Keys 1,8*Ring, Collector*Commutator*8earing, 8all

Stator, Wound120/240 Volt, 1 Phase -

Keys 9,12120/240 Volt - Keys 1,5,8

Pin, AlignmentNut, Hex (#10-24)Washer, Centering - ResistorResistor, Fixed

5.7 Ohms At 25 Watts. 2,5Ohms At 50 Watts (4-1/2”Long ) - Key 3

5.7 Ohms At 25 Watts. 1.6Ohms At 50 Watts (4-1/2”Long) - Keys 7,12

Washer, Lock - Spring (#10)Screw, Machine - Round Head

(#10-24x5° )Screw, Cap - Hex Head

(5/16-18x5”)Washer, Lock - Spring (5/16”)Washer, Flat (5/16” Screw)8ell, End (Includes 4 Locating

Pins)

REFND.

PARTNo.


1 Clip, Bearing RetainerBlock, Generator 8rush

(Includes Parts Marked+)TopRight SideBottomLeft Side

+Screu, Cap - Hex Head8rass (#10-32xl”)

+Washer, Lock - ET (#10)+Nut, Hex - Brass (#10-32)+Washer, Lock - ET (#10)+Washer, Flat - 8rass (#10

Screw)+Nut, Hex - 8rass (#10-32)+Brush, Commutator (DC)+Brush, Collector Ring (AC)+Spring, Brush

Screw, Cap - Hex Head -Lock i ng - (#10 -32x7/8’i )

Support, Generator

2122

232-0596

212-0361212-0345212-0352212-0353815-0341

1111

23 4

24252627

853-0008871-0010853-0008526-0049

4848

282930

871-0010214-0095214-0096212-1232815-0359

84

1:17

3132

33363738394041

402-0475205-0090850-0055870-0203232-2107850-0040812-0156

234-0362

211

Fan; CoolingWasher. Lock - Swina [7/16”)

1124

Nut, Hix (7/16-20) - ‘Cover, GeneratorWasher, Lock - Spring (1/4”)Screw, Round Head - Machine

( l/4-20xl/2° )Wrapper, GeneratorHarness, Wiring

1 Phase - Keys 1,83 Phase (6 Wire) - Key 51 Phase (4 Wire) -

Keys 9,12+Block, Generator Brush

Top And Left SideBottom And Right Side

Bracket, Resistor Mounting

4243

1

338-0946338-1419338-1852

111

45212-0360212-0359304-0706

22246

* - Parts Included In The Armature.+ - parts Included In The Brush Block.

25


Generator- Extended ShaftKeys 2,3,4,6,7,10,11 QJ

5

1 @.- L 10 11

5

—

/

L-

7“‘Q1

T*/“

I —

. ..\

//

/

51

r39,54

20‘

43

52

/.—

26

-—-..

,


Generator- Extended ShaftKeys 2,3,4,6,?,10jll

REF PARTNO. NO.

1 862-00152 231-0164

3 850-00504 800-0050

5520-0733520-0781

6

201-2524

201-2531

201-2528

‘201-2573

7204-0110204-0125

8 203-01539 510-0047

10220-1820

220-1823

11

‘7516-0196516-0182

12 515-0015

14353-0072

3.53-0084

15 526-004416 232-258617 800-0043

18 850-004519 526-011520 211-0365

21 232-0596

QTYUSED

41

4A

;

1

1

1

1

:

11

1

1

441

1

1

214

441

1

PARTDESCRIPTION

Nut, Hex (5/16-18)Adapter, Generator To Engine

(Includes Alignment Pins)Washer, Lock - Spring (3/8”)Screw, Cap - Hex Head

(3/8 -16xl-l/4”)Stud, Armature Through

7/16 x 17-1/8” Long - Key 67/16 x 17-7/8” Long –

Keys 2,3,4,7,10,11Armature (Includes Parts

Marked*)120/240 Volt, 1 Phase

Keys 4,7120/240 Volt, 3 Phase -

Keys 10,11120/240 Volt, 3 Phase -

Key 6120 Volts, 1 Phase - 2 Step

Battery Charger - Keys 2,3‘Ring, Collector

4 Wire, 120/240 Volt2 Step Battery Charger -

120 Volt Single Phase*Conwnutator‘Bearing, Ball

Stator, Wound120/240 Volt - Keys 4.6,7,

10,112 Step Battery Charger -

120 volt - Keys 2,3Pin, Alignment

Keys 2,7,10Keys 3.4.6.11

Key, Extended Shaft(3/16xl-3/4”)

Resistor, Fixed5.7 Ohms At 25 Watts, 2.5

Ohms At 50 Watts (4-1/2”Long) - Keys 5,6

5.7 Ohms At 25 Watts, 1.6Ohms At 50 Watts (4-1/2”Long - Keys 7,10,11

Washer, Flat (l” Screw)Hub, FanScrew, Cap - Hex Head

(5/16-18x5”)Washer, Lock - Spring (5/16”)Washer, Flat (5/16” Screw)Bell, End (Includes 4 Alignment

Pins)Ciip, Bearing Retainer

REFNo.

22

23

2425262729303132

3336373839

4041

4243

4445

4647

484950515253

545556

57

PARTNo.

212-0361212-0345212-0352212-0353815-0341

853-OOOB871-0010B53-0008526-0049214-0095214-0096212-1232B15-0359

402-0475205-0116850-0055B70-0203232-2827

850-0040812-0156

234-0362

33B-0947338-0946338-141933B-0948850-0030

212-0360212-0359.526-0032804-0016

304-0015304-0706812-0118850-0030860-0011815-0333

232-2587234-0530815-0350

526-000998-5713

QTY PARTUSED DESCRIPTIffl

11114

88884

1?17

211

;

44

1

1

i14

2214

221112

i4

41

Block, Generator Brush (In-cludes Parts Marked+)

TopRight SideBottomLeft Side

+Screw. Cap - Hex HeadBrass (#10-32xl”)

+Washer, Lock - ET (#10)+Nut, Hex - Brass (#10-32)+Washer, Lock - ET (#10)+Washer, Flat - Brass (#10+Brush. Commutator (DC)+Brush, Collector Ring (AC)+Spring, Brush

Screw, Cap - Hex Head -Locking - (#10-32x7/8”)

Support, GeneratorFan, CoolingWasher. Lock - Spring (7/16”)Nut, Hex (7/16-20)Cover, Generator

(Includes Parts Marked#)Washer, Lock - Spring (1/4”)Screw, Round Head - Machine

( l/4-20x 1-1/2”)Wrapper, GeneratorHarness, Wiring

3 Phase - Keys 10.111 Phase - Keys 4.73 Phase (6 Wire) - Key 61 Phase - 2 Wire - Keys 2.3

Washer, Lock (#IO)+Block, Generator Brush

Top And Right SideBottom And Left Side

Washer, Flat (7/16” Screw) .Screw, Socket Head

( 10-32x3/8 “ )Washer, Centering - ResistorBracket, Resistor MountingScrew, Pan Head (#10 x 5“)Washer, Lock (#10)Nut, Hex (#10-24)Screw, Round Head

(#10-32xl/2”)#Cover, Fan#Screen, Fan#Screw, Hex Washer Head -

Slotted (#10-32x3/8”)#Washer, Flat (#10 Screw)

Label. Warning (Not Shown)

* - PartS Included In The Armature.+ - parts Included In The Brush 810ck.*- Parts Included In 232-2827 Fan Cover.

27


Control

6

,,

k 7“/5 “ 15 .

-----

\a=\ \\ I 36 ; 3“

t#T \\ II

iI I

“\23

2a


ControlKeys 1,2,3,4,7,8,9,10,11, 12

.. REF PARTNo. No.

1 301-46342

301-4442

301-90113

?.301-4545

301-4894

4 301-44415 332-0142

6 821-0008

7 518-00568 307-1617

10 307-2562

12 870-013113 308-038314

321-0175

15

16.-1718192021

.

2223

2425

321-0175

321-0174321-0146508-0208331-0088508-0191304-0580352-0161812-0087

870-0221821-0004

854-0010

332-0254

332-069926

812-0065812-0066


1

1

1

1

1

11

4

112

41

2

1

21111

:1

15

2

1

1

22

Box, ControlPanel, Control

Units Without IgnitionSwitch

Units With Ignition SwitchCover, Control 80X (Includes

Schematic)

Keys 1,9,10,11,12

Keys 2,3,4,7,8Plate, ControlTerminal, Solderless -

Keys 7,11Screw. Hex - Self-Lock

(1/4-20x5/16”)Screw, Wing (#10-32xl/2”)Relay, Start Solenoid

*Relay, Ignition (Crank AndRun)

Nut, Hex W/ET (#10-32)Switch, Start-StopHolder, Fuse

Units Without IgnitionSwitch

Units With Ignition SwitchFuse

5 Ampere10 Ampere

Bushing, NylonBushing, InsulatingBushing. NylonInsulator, Resistor Mounting

*Resistor, 100-Ohm, 5 WattScrew. Machine - Round Head

(#8-32 xl-l/2”)Nut, Hex W/ET (#8-32)Screw. Cap - Hex Head

(#10-32x5/16”)Washer, Lock - IT (#10)810ck, Terminal

4 Terminal, 50 Amps -Keys 9,12

* 6 Terminal. 20 AmpsScrew, Round Head - Machine

(#6-32x5/8° )(#6-32x3/4”) - Units With

Ignition Switch - KeyOperated

REF PARTNo. No.

27853-0003854-0006

28 860-000529 323-048830

338-1200

338-16’77

338-1820

31 815-0350

32 332-104333 357-003034

338-1082

338-107835 323-040036 323-050037 508-001538 323-044038A

332-2099

332-2103332-2313

39 320-0540

41 508-002142 332-094243 305-038344 308-078845 307-157546 332-0556

323-1088323-1088


2225

1

1

1

1

;

1

11511

1

11

2

1:1111

32

Washer, LockExternal (#6)Internal (#6)

Nut, Hex (#6-32)#Pin, Connector - Female

Harness, Wiring (Includes PartsMarked*)

Without Key Operated IgnitionSwitch - With Electric Choke

Keys 1,2,3,4,8,9,10,12Without Key Operated Ignition

Switch - Without Electricchoke - Keys 7,11

With Key Operated IgnitionSwitch - With Electric

ChokeScrew, Hex Washer Head

(10-32x3/8”)*Jumper, Terminal Block*Rectifier, Silicon

Harness, Wiring - RemoteIncludes Parts Marked+ -

Key 9Includes Parts Marked#

+Pin, Housing Connector+Pin, Connector - Male

Washer, Insulator#Housing, Socket

Strip, MarkerUse With 332-0254 Block -

Without Ignition Switch -Keys 9,12

Use With 332-0699 BlockUse With 332-0254 Block -

With Ignition SwitchBreaker, Circuit - 15 Amp - .

Keys 9,12Gromoet, Rubber

*Tie, CableRegulator, VoltageSwitch, Ignition - With KeyRelay, Ignition (RY 30 Y-09Z]]Connector, RelayConnector, Wire Nut (Not Shown)

Keys 4,7,8,9,12Keys 2,3

*- Parts Included In Wiring338-1677,338-1820.

# - Parts Included In Wiring+- Parts Included In Wiring

Harness 338-1200,

Harness 338-1078.Harness 338-1082.

/-- .

..’.’

29



ControlKeys 5,6

2

1 234-0664 1 Bracket, Generator Frame2 307-1193 1 Relay, Start Solenoid


3 821-0009 2 Screw, Cap - Hex Washer Head,.( l/4-20x3/8° )

I

-.

.-.,

_--,

30


Labels, Paint And Thread Sealant

REF PARTNO. NO.

98-2899

98-3234

98-3278

98-4856

98-2863

..QTY PARTUSED DESCRIPTION

1 Decal, Warning - Battery -Keys 1,2,3,4,5,7,8,9,10,11,12

1 Decal, Control Panel - Keys 1,2,3,4,7,8,9,10,11,12

1 Decal, Choke Label - Keys 1,4,5,8,10,11

1 Decal, Service Instructions -Keys 2,3,4,5,7,8,9,10,11,12

1 Decal, Service Instructions -Keys 1,6


98-4267 1 Decal, Identification (4.0 RV)Keys 4,8,10,11

98-4690 1 Decal, Identification (4.0 Gen.Set) - Keys 7,9,12

518-0452 1 Sealant, Thread (50cc. 8ottle)525-0305 1 Paint, Enamel Touch-Up - Green

(Non-Metallic) 1302. Pressur-ized Can

—

..

-


Numerical Index

Part No. Page

98-286398-289998-323498-327898-426798-469098-485698-5713

101-0405101-0415101-0432101-0432-02101-0432-10101-0432-20101-0432-30101-0439101-0450101-0450-02101-0450-10101-0450-20101-0450-30102-0889102-0957102-1200102-1275103-0408103-0667104-0032104-0043104-0170104-0575104-0776104-1331105-0332105-0541105-0637110-0068110-0197110-0197-02110-0197-05110-0197-10110-0197-25110-0539110-0639110-0892110-0893110-0893110-0904110-1807 .110-1808

3131313131313127

5555555555555

12121212

9977755766655555555555555

Part No. Page

1“10-1809110-1824110-1824-02110-1824-05110-1824-10110-1824-25110-1879110-1921110-1955110-2274110-2287110-2368110-2561110-2562110-3055110-3148110-3159110-3236112-0186112-0186-05112-0186-10112-0186-20112-0186-30112-0186-40112-0229113-0189113-0189-05113-0189-10113-0189-20113-0189-30113-0189-40114-0240114-0300114-0300-10114-0300-20114-0300-30115-0006115-0006-02115-0006-05120-0140120-0161120-0398120-0413120-0491120-0735122-0320122-0321122-0347122-0360122-0645

5555555555555555558888a8888888888888555

1111111111

51111111111

Part No.

123-0191123-1173123-1174123-1175123-1277123-1400123-1417123-1417123-1429123-1484134-3149134-3418134-3688134-3700134-3701134-3871134-3888134-3928134-4316134-4387140-0495140-1228140-1492140-1494140-1496140-1502140-1503140-1504140-1520140-1521140-1522140-1528140-1529140-1531140-1533140-1672140-1711140-1719140-1736145-0438145-0438145-0438145-0521146-0241146-0322146-0322146-0325146-0326146-0326146-0327

Page

12555

1512151717151313131313

713131313151715171715151515151515151515151715171517191717181919181918

Part No.

146-0327146-0329146-0329146-0331146-0331146-0335146-0335146-0340146-0340146-0341146-0341146-0342146-0342146-0343146-0343146-0343146-0356146-0356146-0404146-0404146-0417146-0418146-0418146-0419146-0419146-0420146-0420146-0440146-0440148-0840149-0003149-1531149-1705149-1828149-1828150-0075150-0078150-0096150-0629150-0630150-0639150-0678150-1187150-1519150-1520150-1542150-1577150-1612152-018d153-0017

Page ,-.

191819181918 ,.,

19181918191819181919181915181918191519 ---

18191719151015171517

66,

10101010

9g

669

10102315

32


Numerical Index

Part No..—.

153-0017153-0058153-0114153-0114153-0440153-0499,,.,153-0539

. 153-0541154-0733154-0733

. 154-0733154-0733154-1446154-1446154-1578154-1725154-1725154-1762154-1762154-1883154-1886154-1947154-1972154-1977

/—, 154-1977154-2061154-2140154-2143154-2146154-2206154-2206154-2310154-2311154-2425154-2554154-2666155-1234155-1239155-1256155-1258

.s 155-1520155-1851155-1851

;. 155-1910160-0558160-1150160-1150160-1151.160-1?83160-1219

,-.

Page

1717151715151717151718191517232223222323232323151723232323151722222323152323222323222323202021202121

. .

Part No.

160-1285160-1303160-1303160-1311166-0554166-0588166-0772167-0298167-1602168-0143168-0144201-2405201-2421201-2504201-2524201-2528201-2531201-2573203-0153203-0153204-0110204-0110204-0125205-0090205-0116211-0364211-0365212-0345212-0345212-0352212-0352212-0353212-0353212-0359212-0359212-0360212-0360212-0361212-0361212-1232212-1232214-0095214-0095214-0096214-0096220-1818220-1820220-1820220-1823231-0164

Page

212021212020202020

55

252525272727272527252727252725272527252725272527252725272527252725272525272725

Part No.

231-0164232-0596232-0596232-2107232-2586232-2587232-2827234-0362234-0362234-0530234-0664301-4441301-4442301-4545301-4634301-4894301-9011304-0015304-0015304-0580304-0706304-0706305-0383307-1193307-1575307-1617307-2562308-0383308-0788309-0077309-0319312-0051312-0246320-0540321-0146321-0174321-0175323-0400323-0440323-0488323-0500323-1088331-0088332-0142332-0142332-0254332-0527332-0527332-0529332-0529

33

Page

2725272527272725272730292929292929252729252729302929292929131120212929292929292929292912292915171517

Part No.

332-0556332-0556332-0556332-0699332-0942332-1043332-2099332-2103332-2313336-23’?8336-3377337-0418337-2055338-0946338-0946338-0947338-0948338-1078338-1082338-1200338-1419338-1419338-1677338-1820338-1852352-0161353-0072353-0072353-0084353-0084357-0030402-0282402-0283402-0290402-0475402-0475402-0477402-0480403-1484502-0002502-0002502-0003502-0003502-0053502-0313502-0313502-0575503-0103503-0107503-0280

Page

15172929292929292921111212252727272929292527292925292527 “25272912121225271212121517151711151715152315


Numerical Index

Part No.

503-0280503-0769504-0092508-0015508-0021508-0191508-0208509-0008509-0040509-0041509-0065509-0145509-0145509-0145509-0145509-0168510-0013510-0014510-0015510-0047510-0047515-0001515-0001515-0015515-0227516-0072516-0130516-0141516-0182516-0196516-0196517-0048517-0067517-0120518-0004518-0014518-0056518-0311518-0350518-0350518-0387518-0390518-0452520-0732520-0733520-0781525-0305526-0008526-0009526-0014

Page

17151229292929

995

2115151718

5996

2527

67

277595

272527

555

107

298

151717153125272731212712

Part No.

526-0017526-0018526-0021526-0030526-0032526-0038526-0044526-0049526-0049526-0062526-0062526-0063526-0063526-0065526-0065526-0066526-0115526-0115526-0122526-0158526-0195526-0198526-0234526-0286800-0004800-0007800-0010800-0023800-0023800-0026800-0026800-0028800-0028800-0028800-0030800-0032800-0033800-0033800-0034800-0034800-0043800-0043800-0047800-0050800-0050800-0051800-0064800-0082800-0540800-0541

Page

75

151227122725271517

5109

11112527

515121217121011

51517222311151723

91517

9172527122527

5“1212

55

Part No.

801-0050802-0022802-0034804-0016804-0017812-0065812-0066812-0087812-0118812-0118812-0156812-0156813-0111815-0046815-0110815-0110815-0194815-0261815-0285815-0285815-0333815-0341815-0341815-0350815-0350815-0358815-0359815-0359815-0359815-0389815-0421815-0470816-0070816-0197816-0206821-0004821-0004821-0008821-0008821-0008821-0008821-0009821-0009821-0009821-0009821-0010821-0010821-0018850-0030850-0030850-0030850-0030

34

Page

11212127152929292527252715

91517111315172725272729211525271813171512121729131517291517203013231215172527

Part No.

850-0040850-0040850-0040850-0040850-0040850-0040850-0040850-0045850-0045850-0045850-0045850-0045850-0045850-0050850-0050850-0050850-0050850-0055850-0055850-0055850-0055850-2005853-0003853-0008853-0008854-0006854-0010856-0006856-0010856-0012856-0016860-0005860-0011860-0011862-0004862-0015862-0015862-0015862-0015862-0015865-0006865-0019870-0053870-0131870-0131870-0203870-0203870-0212870-0221870-0302871-0010871-0010

Page .–..

111315172125 ,..27151722232527

5122527

712252720292527 ‘--,,,2929121212122925271215172325271715101029

.25271529

825 ‘–’27 ./’


. .,

,,

.. \

I

.—

HARDWARE IDENTIFICATION

[Illustrated hardware items are only for identificationcatalog are steel .!ME grade five (5) or IOWX (ZiiIC

indicates differently. All dimensions are in inches.

WASHER

@cl@

purposes. All hardware items listed throughout this parplated with clear chromate dip) unless parts descriptic

TYPEs : .:- . ...

! ““.”~. @EXTERNALTOOTH INTERNALTOOTH EXTERNAL-INTERNAL COUNTERSUNK

LOCK (ET)

“SPRING “FLATLOCK (IT) TOOTH LOCK (EIT) EXTERNAL TOOTH LOCK

LOCK

● - Flat washer dimensions given are Inside Diameter (ID), Outside Diameter (OD)and Thickness (Thk). -

. ....,

..

BOLT AND SCREW TYPESCARRIAGE BOLT TRUSS HEAD BINDER HEAD PAN HEAD HEXAGON HEAD FILLISTER HEAD FLAT HEAD

ROUND HEAD HEXAGON WASHER OVAL HEAD SQUARE HEAD SOCKET HEAD TWELVE POINT SLOTTED SOCKET

L - Measure length between these points.

&1--1L

INTERNAL DRIVE TYPES

@@j) @”clSLOITED CROSS RECESSED Slx POINT TWELVEPOINT

(PHILLIPS) SOCIG5

NUT TYPES

tu [T T] Qm

FULL HEXAGON JAM HEXAGON HEXAGON WASHER SOUARE

Nominal 5iZe (fractional dimmer Or SCIUW numb(

T

Number of threeds par inch

,:

~~~ [r

LOrlgth in inch=

.,.w-al x 3/4-’

,. ,

1,

WfaWING ACORN

STD. #* Redistribution or publication of this documentby any means, is strictly prohibited.

parts manual 4!%(i3f’a - twinslantwinslan.net/~n0nas/manuals/onan/965-0262 onan 4.0kw bfa (spec...

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