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1. nao DEAL N FIGURE 6 36 MANOMETER TESTING IF REQUIRED 4 FS 1108 1 2 10 11 6 32 Connect a manometer that reads up to 14 inches 856 mm of water column to the test hole One inch of water equals 0 58 ounce square inch 250 Pa Energize the solenoid shutoff valve by connecting its insulated lead to a battery positive B source LP gas presents the hazard of AWARNING fire or explosion and it is poi sonous These hazards can result in severe per sonal injury or death Provide adequate ventilation while adjusting regulator to prevent any possible accumulation of LP gas Remove the gas supply hose from the regulator outlet then open the fuel tank shutoff valve Gas should not come from the regulator outlet during testing because ofthe closing action of the regula tor valve Alternately cover and uncover the regulator outlet with the palm of your hand while at the same time observing the manometer If the regulator closes completely the manometer will hold a steady read ing If the manometer reading drops slightly each time you remove your hand it indicates the regula tor is not locking off properly To adjust turn the adjusting screw inward until the manometer read ing holds constant when you repeatedly cover and uncover the regulator outlet Failure to lock off indi cates too high an incoming pressure or a dirty regu lat
2. 9 1 General 9 1 Filter Adaptor 3e 9 1 Cylinder Hads socero one rete UE d vto pud aaa 9 1 Vae eee 9 2 Gear COVEN Scc osea datis tiu Sa t a eee 9 6 GOVEMOl Ka tad rop Os 9 7 Timing Gears and Camshaft 9 7 Lubncation System ae eS ibt 9 8 Piston ASSeImDIV OC LE ROI RR A p ein 9 9 CGranksHall ed o eso etn Mees ict bra dtd 9 12 25 oad ete Sas 9 13 mire NER TREES D Li ll LT 9 15 Oil Seals Eid 9 16 10 SERVICE CHECKLIST 10 1 MOUNINO Dono dne uc wb Ds RU NN 10 1 PUDMCAUON ax sak pede v en e Exi 10 1 da 10 1 Initial Start Adiustmeris soriire ur S 10 1 10 1 QuiDUL CHECK dea sya ene 10 1 Exhaust SVSIOITI Rhe en E e d 10 1 5 10 1 Mechanical dr teres CC VE Rees 10 1 APPENDIX A TROUBLESHOOTING CHARTS A 1 Troubleshooting Electronic Ignition Module
3. as _ REMOTECONTROLSTANDARO Ca Reworecowmoroguxe CONTROLASGY NHE NHEL 5 A1 300 3091 01 REF CONTROL ASSY BGE BGEL 611 1190 FIGURE 8 4 60 HZ BGE NHE GENERATOR SET WIRING DIAGRAM SCHEMATIC Spec G Electronic Ignition 8 6 uc UE LITERAL i 110 120 Zn GAL Icy d TATE mama edel o o e e o o o ELEC amp 220 240 220 240V CB 120V MAX ACROSS VRI CONNECTIONS 2 3 2 GROUNDED AC LEAD REMOVE CONNEC FOR ISOLATED NEUTRAL JUMPER W2 TBI L3 LO AND T JUMPER TBI LO VRI C5 NEG AL hit Ri DESCRIPTION OF MATERIAL VOLTAGE REGULATOR SWITCH LOW OIL PRESS RESISTOR BATTERY CHARGE OTENTIOMETER RELAY LPG ONLY RELAY START SOLENOID CHOKE GASOLINE ONLY GENERATOR FUSE SLOW BLOW 5 UEL PUMP OR FUEL SOL RECTIFIER LPG ONLY CIRCUIT BREAKER AC OUTPUT APACITOR TTERY 12V TARTER MOTOR EMOTE CONTROL STANDARD EMOTE CONTROL DELUXE ONTROL ASSY NHE NHEL ONTROL ASSY BGE BGEL D D O 611 119 FIGURE 8 5 50 HZ BGE NHE GENERATOR SET WIRING DIAGRAM SCHEMATIC Spec G Electronic Ignition 6 7 GENERATOR TROUBLESHOOTING Use the following troubleshooting guide to help locate problems related to the generator Figure 8 1 shows the location of the generator components
4. Service Manual BGE Printed in U S A 965 0528 BGE Spec F through K NHE Spec E through K 9 94 WARNING A The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Supplement 965 1060 Date 11 95 Insert with Title BGE NHE Service Manual Number Date 965 0528 9 94 PURPOSE This Supplement supercedes Supplement 965 1055 It transmits the revisions to the Service Manual necessary for covering all Spec M genera tor sets gasoline fueled and LPG fueled Note that the nameplate on a Spec M generator set will have the statement This engine meets 1995 1998 California emissions regulations for ULGE en gines To satisfy California emissions regulations Spec M generator sets have internal engine modifications and precision manufactured carburetors with tam per resistant fue mixture jets and tamper resistant LPG demand regulators It should therefore be noted that fuel mixture and LPG lock off pressure adjustments should not be attempted Nor should the carburetor or LPG demand regulator be over hauled Instead a malfunctioning carburetor or LPG demand regulator should be replaced see TROUBLESHOOTING ENGINE PRIMARY SYS TEMS in Section 6 Unauthorized modifications or re placement of fuel exhaust air intake or speed control system components that affect engine emissions
5. A 2 Emerald Control Functions A 3 Emerald Control Board Check Out 300 2784 A 5 Emerald Control Board Check Out 300 3056 3687 A 7 Emerald Marquis Control Board Check Out 300 3763 01 02 A 9 APPENDIX SPEC J AND K DIAGRAMS B 1 Spec J BGE NHE 60 Hz 611 1206 B 2 Spec J 50 Hz 611 1207 B 3 Spec J 60 Hz 100 V 611 1208 B 4 Spec BGE NHE 60 Hz 611 1220 B 5 Spec BGE NHE 50 Hz 611 1221 B 6 Spec K BGE 60 Hz 100 V 611 1222 B 7 Section 1 Introduction ABOUT THIS MANUAL This manual provides service information for Onan BGE and NHE series recreational vehicle generator sets This is a complete service manual for the experienced serviceperson covering troubleshooting disassembly repair reassembly and adjustments for the engine generator and control It is recommended that the ser viceperson be thoroughly familiar with the principles of gasoline engine operation and have a basic knowledge of electrical fundamentals Other Onan publications such as Electrical Mechanical Fundamentals 932 0408 Onan Generator Training Manual 932 0404 BGE an
6. 6 12 Crankcase Ventilation System 6 14 Combustion Chamber 6 15 GOVO Bw aes SL ee 6 15 Fuel System Gasoline 6 17 Fuel System LPG Liquid Withdrawal 6 25 Fuel System LPG Vapor Withdrawal 6 31 SIT BT cnt ee hen ae 6 33 7 CONTROL EXERCERE 7 1 lassi ce 7 1 Descrplont iis iet oai E EARS eh eae RR 7 1 ee E eet a bes lea ce ER EAT 7 3 Testing Control Board A1 7 4 Control Troubleshooting 7 6 8 GENERATOR oo er coacta Ra Amd dete bertus 8 1 Generator Contro Component Descriptions 8 1 Generator Operation 8 2 Generator Troubleshooting 8 8 Generator Service 2 2 2 gea E ERA ee ERR E ETE 8 10 Brushes and SID AMOS sso RU bes 8 14 Testing Voltage Regulator 1 8 15 EE 8 15 Table of Contents continues SECTION TITLE PAGE 9 ENGINE BLOCK 5
7. i EXPANDER CT 1066 CY 1047 FIGURE 9 25 PISTON RINGS FIGURE 9 26 INSTALLING PISTON AND CONNECTING ROD 9 11 Rod Bearing Clearance 1 Mark all parts so they can be installed in their origi nal positions and wipe all parts clean of any oil or grease 2 Place a piece ofthe correct size Plasti gage across the full width of the bearing cap about 1 4 inch 6 mm off center 3 Install the bearing cap and tighten to the specified torque Do not rotate the crankshaft after the cap is in place 4 Remove the bearing cap and leave the flattened Plasti gage on the part to which it adheres Com pare the widest point of the flattened Plasti gage with the graduations on the envelope see Figure 9 27 to determine the bearing clearance FIGURE 9 27 MEASURING BEARING CLEARANCE CRANKSHAFT To remove the crankshaft loosen the rear bearing plate screws and remove the bearing plate gasket thrust washer and shims Turn the crankshaft so the crank throw is aligned with the notch in the rear opening ofthe crankcase Carefully slide the crankshaft out of the crankcase Inspection Inspect the rod and main bearing journals If they are worn or scored and cannot be smoothed out by polish ing either the journals should be reground to use one of the standard undersize bearings or the crankshaft should be replaced Remove only as much metal as is required to restore the journal surface while maintaining the re
8. kW 12 Ambient 40 C AC Volts Insulation NEMA Class For Recreational Vehicle Use Only Pour Usage Dans Les Vehicules Recreatifs Onan Corp 1400 73rd Ave NE Made in USA Minneapolis MN 55432 USA LEB FIGURE 1 1 ONAN NAMEPLATE Incorrect installation service or replacement of parts can result in severe personal injury or death and or equipment damage Service personnel must be qualified to perform electrical and mechanical component installation Redistribution or publication of this document by any means is strictly prohibited section 2 Specifications ENGINE Onan opposed 2 cylinder 4 cycle air cooled gasoline fueled and propane fueled models Front mounted control with remote start capability negative ground 12 volt automotive type starter ENGINE DETAILS BGE NHE TEL 0818 0m secti 60 0 in 983 0 cm Compression 1 P ECT T tenes E E 7 0 1 BOIS eens 329 N 8255 3 56 90 42 jj CC 2 871 7290 MM da n es eres 3 00 in 76 20 mm Oil Capacity W Filter Pre Spec J 4 0 Qt 3 81 Pre Spec J NHE 4 0 Qt 3 8 L Spec J 3 5 Qt 331 Spec J NHE 3 5 Qt 3 3 L Ventilation Free Area 85
9. A 5 6 Emerald Control Board Checkout 300 2784 7 8 Emerald Control Board Checkout 300 3056 368 7 9 A 10 Emerald Control Board Checkout 300 3763 01 02 Troubleshooting Electronic Ignition Module Models Performer Emerald Plus Marquis Ensign Check wiring red lead to positive black lead to negative Connect a DC powered test light from the negative coil terminal to ground Turn the ignition switch on and crank the engine over Does the test light flash bright then dim Yes The module is ok do not replace the module No Goto Test 2 ignition Note If the primary winding of the Module ignition coil is open the light will not come on Connect the test light from the positive coil terminal to ground Turn the ignition switch to the on position Does the light come on Yes Crank the engine over Does i the light stay while mu m cranking Yes Replace the module and the trigger ring as a set if the coil tests good No itis not a module problem Check the wiring and Ignition connections to the coil and Module the ignition switch then retest the module A WARNING Use extreme caution when working on operating equipment Operating equipment presents hazards of electrocution burns fire and explosion asphyxiation and entanglement with rotating parts Review Important Safety Instructions in Operator s Manual Pe
10. tact loop to bend the spring back so that each brush can be inserted into the holder Be sure that all brush wires are facing up TORQUE TO 5 101 1 5 57 1 13 Nem POSITIVE TORQUE 25 30 IN LBS 2 83 3 39 Nem BRUSH STUD IMPORTANT THIS INSULATED SHUNT MUST BE ROUTED THRU UNINSULATED SHUNT AS SHOWN TO PREVENT CONTACT WITH COMMUTATOR IN FINAL ASSEMBLY NEGATIVE S P RR CONTACT LOOP NEGATIVE BRUSH TERMINAL IMPORTANT SPRING MUST BE ASSEMBLED UNTING TAB AS SHOWN ae ES 1612 1 FIGURE 6 42 BRUSH ENDCAP 6 35 Ifthe brushes are at least 0 430 inch 10 9 mm long rest the brush springs against the sides of the brushes to keep them clear during armature instal lation See Figure 6 43 Place a washer on the commutator end of the shaft and put the armature into the brush endcap Push the four brushes toward the commutator making sure that the springs are correctly positioned on the brushes Recheck to be certain that the spring is pushed all the way down on the mounting tab Make sure that all brush wires are clear of the com mutator and that uninsulated portions of insulated wires do not touch the inside of the housing or adjacent brush boxes Place the magnetic housing over the armature Hold down the armature and the end cap using a nut driver pressed over the end of the shaft 10 11 12 13 Place a spring washer and a flat washer on the shaft as shown in Figu
11. VALVE SYSTEM Access to the valve system can be obtained by remov A properly functioning valve system is essential for good ing the cylinder heads and the valve covers on top of the engine performance generator sets utilize an L engine A valve spring compressor must be used to head type valve design as shown in Figure 9 3 remove valves see Figure 9 4 from the cylinder block Use the following procedures to inspect and service in the valve system BGE VALVE STEM SEAL VALVE i VALVE CLEARANCE VALVE ADJUSTING SCREW VALVE SPRING TAPPET VANE VALVE CAP VALVE RETAINER INSERT UE KEEPERS 1034 VALVE CLEARANCE VALVE ADJUSTING SCREW cr ys VALVE RETAINER x 2 iu VALVESEAT VALVE SPRING pedi gt Ta et E t eT lt lt n VE VALVE SPRING tel 7 2 i WASHER LOCK 2 O RING LY INTAKE VALVE VALVE EXHAUST ON ONL STEM SEAL OPTIONAL VT 1005 FIGURE 9 3 VALVE SYSTEM Y VT 1018 FIGURE 9 4 VALVE SPRING COMPRESSOR 9 2 Inspection Valve Face Check the valve face for evidence of burn ing warpage out of round and carbon deposits see Figure 9 5 Burning and pitting are caused by the valve failing to seat tightly This condition is often caused by hard car bon particles on the seat It may also be due to weak valve springs insufficient tappet clearance warpage and misalignment VT 1017
12. High Oil Oil viscosity too light or Drain oil and refill with Consumption oil is diluted correct viscosity oil Note New Crankcase breather valve is Clean crankcase breather engines dirty or defective and replace if defective sometimes have high oil Oil leaks Locate source of leak and consumption repair as required during break in Excessive engine wear See Engine Block Assembly section Light loading Don trun set at no load for long periods of time Low 1 Oil viscosity too light or 1 Drain oil and refill with Pressure oil is diluted correct viscosity oil 2 Low oil level 2 Addoilas required 3 Low oil pressure switch 3 Replace oil pressure switch defective see Engine Block Assembly section 4 Faulty oil bypass valve 4 Inspect oil bypass valve and clean or replace as required see Engine Block Assembly section 5 Excessive engine wear or 5 See Engine Block Assembly defective oil pump section 6 4 EXHAUST SYSTEM The condition ofthe exhaust system is extremely critical on RV generator sets because of the possibility of exhaust gases entering the coach The exhaust system must be serviced immediately if inspection reveals leaking joints or connections loose fasteners or broken or damaged components The exhaust system must terminate beyond the perimeter of the vehicle Always replace worn components with new original equipment replacement parts Do notattemptto repaira broken
13. LPG sets only are energized while relays K1 start solenoid and K4 start relay are de energized Energizing K2 opens a set of contacts to de energize K4 and closes another set of contacts to connect B to the generator start disconnect run relay k3 Energiz ing K3 closes a set of contacts which provides an alter nate B circuit to T1 ignition coil and E1 fuel pump fuel solenoid De energizing K4 opens contacts which de energize the K1 start solenoid De energizing K1 disconnects B from the starter motor which stops cranking Opening these K4 contacts atthis time has no effect on engine operation because they are in parallel with the closed K3 contacts which connect B to the ignition coil and the fuel pump fuel solenoid When start stop switch 51 is released and returns to the center run position the engine continues to run Relays K2 generator relay K3 run relay and K5 igni tion relay LPG sets only are energized while relays K2 start solenoid and K4 start relay are de energized Stopping Moving start stop switch S1 to the STOP position grounds resistors R1 and R2 to de energize run relay This opens its contacts to disconnect from igni tion coil T1 fuel pump fuel solenoid E2 and on LPG sets ignition relay K5 De energizing K5 allows its N C contacts to close to ground This prevents K3 from being energized and prevents the set from restarting when switch 51 is released from the STOP positi
14. Prior to spec G only Spec G 1 Faulty ignition due to a incorrect ignition timing 1a Adjust breaker point gap b incorrect spark plug gap b Reset spark plug gap c faulty point condenser c Replace condenser 2 Lean fuel mixture due to 2a Adjust carburetor main and a incorrectly adjusted idle adjustment screws fuel mixture screws b Adjust carburetor float b incorrect float level level c dirt in carburetor c Disassemble carburetor and clean all internal passages 3 Mechanical damage to engine 3 See Engine Block Assembly Gasoline sets only Prior to spec G only 6 1 replace if faulty Replace condenser g Refer to Testing Ignition Module Adjust carburetor main and idle adjustment screws Adjust carburetor float level Disassemble carburetor and clean all internal passages section TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Continued Many troubleshooting procedures present hazards which can result in severe personal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Review safety precautions on inside cover page Trouble Engine Lacks Power Engine Overheats Possible Cause 1 Faulty ignition due to incorrect ignition timing b incorrect spark plug gap Dirty air cleaner Restricted fuel flow due to a plugged fuel filter or b faulty fuel pump
15. Refer to the wir ing diagrams schematics in Figures 8 2 8 3 8 4 or 8 5 for the location of all terminal connections The troubleshooting guide is divided into sections After identifying the problem refer to the guide for the possi ble cause and the recommended corrective action TROUBLESHOOTING THE GENERATOR AWARNING Many troubleshooting procedures present hazards which can result in severe personal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Review safety precautions on inside cover page Trouble No AC Output Voltage Note This condition may cause the generaior set to stop when start switch 7 is released AC Output Voltage Too Low or Too High Possible Cause Open circuit breaker Open circuit between voltage regulator and brush block Open circuit between generator wind ings Q1 Q2 and voltage regulator Open circuit between terminal block TB1 and voltage regulator wiring harness J4 leads Brushes stuck in holder or not making good contact with slip rings Defective voltage regulator Open grounded or short circuit in rotor or stator Engine governor incorrectly adjusted Brushes worn or not making good contact with slip rings Low AC output voltage Poor wiring connections to from voltage regulator If generator frequency is within spec
16. Replace old components with the new parts from the repair kit pum AND WEAR is OCCUR HERE a et FIGURE 6 20 MIXTURE NEEDLE INSPECTION 5 1483 3 6 21 Reassembly and Installation Procedure 1 Slide in the throttle shaft and install the throttle plate using new screws if included in the repair kit Center the plate in the throttle bore before tighten ing the screws To do this back the throttle stop screw out as necessary and close the throttle lever Seat the plate by gently tapping it with a small screwdriver then tighten the screws Install the choke shaft and plate in the same manner 2 Install the idle mixture screw assembly Turn in the screws until lightly seated then turn it out one turn Forcing the mixture adjustment ACAUTION screws tight will damage the needle and seat Turn in only until light tension is felt 3 Install the needle valve and seat fuel bow gasket and float assembly Make sure that the float moves freely without binding see Figure 6 21 and that all clips and springs are placed correctly FLOAT AXLE Sy BUOYANCY POSITION HOOK UNDER TANG ON FLOAT POSITION OF SPRING FS 1610 AFTER INSTALLATION FIGURE 6 21 FLOAT INSTALLATION 4 invert the float and needle valve assembly Check the float level as follows measure from the carbure tor housing to the far side bottom of the float see Figure 6 22 The full weight of the float should rest on the needl
17. ponding increase in generator voltage and frequency A decrease in engine speed will cause a corresponding decrease in generator voltage and frequency The gov ernor tries to maintain a constant engine speed under changing load conditions so that generator voltage and frequency do not vary Preliminary Governor Adjustment Before adjusting the governor system make sure that the length of the governor rod is correct Make this static adjustment with the genset cold Refer to Figure 6 14 1 Loosen the jam nutat the ball joint end of the gover nor rod 2 Disconnect the plastic bali joint from the ball stud 3 With the carburetor throttle fully open and the gov ernor rod in its full counterclockwise position adjust the governor rod length so that the hole in the bail joint aligns with the ball stud 4 Turn the bail joint in shorter one full turn 5 While holding the ball socket the vertical position reconnect the bail joint to the ball stud and tighten the jam nut Governor Adjustment Before making further governor adjustments run the unit about 10 minutes under light load to reach normal operating temperature If governor is completely out of adjustment make a preliminary adjustment at no load to first attain a safe voltage and speed operating range Voltage frequency sensitive equip ACAUTION ment such as VCR s televisions and computers may be damaged by power line frequency variations Some solid state devic
18. second rings 0 112 0 168 mm 0 008 0 018 0 20 0 46 mm Piston Ring 1 top Pre Spec J sets 0 080 0 081 Groove Width Piston Ring 2 Groove Width Piston Ring 3 Groove Width Piston Pin Diameter Piston Pin Clearance In Rod Connecting Rod Side Clearance Connecting Rod Bearing Clearance 2 03 2 06 mm Spec J sets 0 0602 0 0612 1 53 1 55 mm Pre Spec J sets 0 080 0 081 2 03 2 06 mm Spec J sets 0 0602 0 0612 1 53 1 55 mm Pre Spec J sets 0 188 0 189 4 78 4 80 mm Spec J sets 0 1193 0 1203 3 03 3 06 mm 0 6875 0 6877 17 46 17 47 mm 0 0002 0 0007 0 005 0 018 mm 0 0020 0 0320 0 051 0 813 mm 0 0020 0 0033 0 051 0 084 mm 0 178 0 229 mm 0 009 0 019 0 23 0 48 mm 0 080 0 081 2 03 2 06 mm 0 0602 0 0612 1 53 1 55 mm 0 080 0 081 2 03 2 06 mm 0 0602 0 0612 1 53 1 55 mm 0 188 0 189 4 78 4 80 mm 0 1193 0 1203 3 03 3 06 mm 0 7500 0 7502 19 05 19 06 mm 0 00005 0 00055 0 001 0 014 mm 0 0020 0 0160 0 051 0 406 mm 0 0005 0 0028 0 013 0 071 mm MODELS CRANKSHAFT AND CAMSHAFT Crankshaft Main Bearing Journal Diameter Crankshaft Rod Journal Bearing Diameter Crankshaft Main Bearing Diameter Crankshaft Main Bearing Clearance Crankshaft End Play Camshaft Journal Diameter Camshaft Bearing Diameter Camshaft Bearing Clearance Camshaft End Play VALVE AND LIFTERS Valve Spring Free Leng
19. 14 Wiring The ignition system wiring includes e One positive B wire which conducts low voltage from the battery to the primary winding on the coil One negative wire which conducts low voltage to the points and condenser Two wires which carry the high voltage from the sec ondary coil winding to the spark plugs The plugs and coil secondary are grounded to the engine The ignition coil primary low voltage side is grounded when the breaker points close Check all low voltage wiring for loose connections and breaks in the insulation Clean all terminals and connect ions and use an ohmmeter to test them for continuity Use a megger high range ohmmeter to check for breaks in the plug wire insulation CRANKCASE VENTILATION SYSTEM The crankcase breather prevents pressure from building up in the crankcase it prevents oil contamination by rout ing moisture gasoline vapors and other harmful blow by materials from the crankcase to the carburetor and com bustion chamber sticky crankcase breather can cause oil leaks high oil consumption rough idle reduced en gine power and rapid formation of sludge and varnish in the engine and oil in the breaker point box The crankcase breather is vented directly below the gener ator set For this reason the generator set should only be used in environments where oily vapor and dust do not create a problem Crankcase breather vapor contains poisonous carbon monoxide wh
20. As the engine starts and speed increases the rotating field induces a voltage build up in the stator windings A portion of the AC current generated in the stator windings is provided to the voltage regulator VR1 by the quadrature windings Q1 Q2 The AC voltage is rectified to DC by the voltage regulator The DC currentis supplied to the rotating field windings to create the strong magnetic field required for generating the rated current The AC voltage build up stabilizes at approximately 128 volts when the engine reaches governed speed To prevent an excessive voltage drop when a load is applied to the generator a method for regulating the AC output voltage s required The voltage regulator allows the generator to provide a stable AC output voltage under varying load conditions through wire taps from voltage regulator VR1 wire harness J4 2 and 3thatare connected to terminal board TB1 These leads sense voltage changes of the load on the generator During operation adding load increases the current flow through terminal board TB1 and the sensing leads to the regulator The circuitry of the voltage regulator will then adjust the DC excitation voltage to the rotating field to a higher level offsetting the voltage drop that would normally occur when a load is applied In the same manner decreasing the load reduces the DC field current to offset the voltage rise that would normaily occur when a load is removed Continuously adjusting
21. BATTERY CHARGE POTENTIOMETER RELAY CHOKE amp FUEL PUMP RELAY START SOLENOID CHOKE GENERATOR FUSE 10A FUSE 10 SPARK PLUGS FUEL PUMP RECTIFER BATTERY CHARGE CIRCUIT BREAKER OUTPUT CAPACITOR BATTERY 12 ic STARTER MOTOR ap 22 SCHEMATIC ITEM C ao ee ee ns aa io dum dub ep ung Qui MA rub AN 440 944 ke SS GERD AUR A re cus Gu UND gt eA AA MD runs UR UA WT UU D UA a REMOTE CONTROL DELUXE CONTROL ASSY NHE CONTROL ASSY BGE WIRING DIAGRAM NO 611 1221 SPEC K BGE NHE 50 HZ WIRING DIAGRAM SCHEMATIC REV A MODIFIED f s RED S3 Pw WIRING DIAGRAM as cm M ial ir vila es s agi qun am APR MAP n A VAR ds uum inp V UD VR CUR CUP UD AQ AD B UD GR So in De iw m UA NUNC HERO UU ARR GU ED GE eb de wu V S 2 SCHEMATIC SPEC 60 HZ 100 V WIRING DIAGRAM SCHEMATIC VOLTAGE REGULATOR IGN COIL IGN MODULE SWITCH LOW OIL PRESS RESISTOR BATTERY CHARGE POTENTIOMETER RELAY CHOKE amp FUEL PUMP RELAY START SOLENOID CHOKE GENERATOR FUSE 104 FUSE 10A SPARK PLUGS FUEL PUMP RECTIFER BATTERY CHARGE CIRCUIT BREAKER AC OUTPUT CAPACITOR BATTERY STARTER MOTOR REMOTE CO
22. J4 of voltage regulator VR1 and interconnect wir ing to the circuit breaker s CB1 and CB2 if equipped These leads provide generator outputto the voltage regula tor for proper voltage regulation and to the circuit breaker s for power supply to load Voltage Regulator VR1 The voltage regulator helps to provide stable generator output voltage under varying load conditions During initial start of the generator set the voltage regulator receives DC current from the set starting battery and begins excitation of the rotor through leads J4 9 F1 and J4 10 F2 After the generator set starts and runs it provides AC power to the voltage regulator through leads J4 11 Q1 and J4 12 Q2 The AC voltage is recti fied to DC voltage and the proper DC excitation voltage is induced to the rotor in response to changes in load demand The voltage regulator design reduces the risk of com ponent failure by notallowing moisture to contact inter fere with its operation by the printed circuit board con trol being encased in the regulator housing with a potting compound the booted ends of the J4 wiring harness covering the terminals of capacitor C5 mounted to the outside of the regulator housing and the wiring harness plug in P4 being treated with a lubricant prior to connection Further protection is provided by mount ing the voltage regulator assembly inside the generator control housing Control Circuit Breaker s CB1 and CB2 if e
23. LPG FUELED SETS FUEL SOLENOID E2 IS LOCATED HERE FUEL PUMP AUTOCHOKE FUSE F2 MOUNTED ON CONTROL BOX START STOP SOLENOID K1 SWITCH S1 M 1604 14 modified 7 1 Fuse F2 Spec K gensets This 5 amp fuse protects the fuel pump and choke heater circuit It is mounted on the front of the control box see Figure 7 1a F2 FUSE HOLDER FUSE HOLDER BRACKET FIGURE 7 1 AUTOCHOKE FUEL PUMP FUSE F2 LOCATION Start Solenoid K1 The K1 start solenoid opens and closes the circuit between the starter motor and the battery The starting current load requires that the solenoid contacts have a 300 amp contact rating A single terminal connects to the 12 volt solenoid coil Two studs provide connection points to the battery and starter cables the battery B stud connection protrudes through the control panel to the outside of the control housing for convenient access ignition Relay K5 LPG units The 5 ignition relay latches the generator set off when switch S1 is moved to the STOP position This prevents the set from restarting when the switch is momentarily placed in the STOP position then released The K5 relay is located on the choke bracket Fuel Pump E2 gasoline units The E2 fuel pump is initially energized at the same time the start solenoid K1 is energized by closure of start relay K4 contacts After a successful startup the fuel pump then receives its current through the contacts of run rela
24. Run Lamp Time Meter or Battery Condition Meter Condition Meter Does Not Operate Possible Cause Fuel level is below generator set fuel pickup tube or oil level is low Dirty fuel filter restricting fuel flow Faulty choke operation due to sticking choke linkage incorrect choke adjustment open circuit in wiring between choke heater and generator defective choke heater Vapor lock due to a High ambient air temperatures b Faulty fuel pump Breaker points sticking Faulty ignition module Faulty ignition condenser Contaminated fuel Gasoline Sets Only Prior to Spec G Spec and Later 1 Open circuit between control board A1 terminal 6 or 5 of remote connector plug P2 J2 and terminal 6 or 5 on start stop switch 52 2 Open circuit between ground terminals on lamp or meters and terminal 1 on remote start stop switch 3 If battery condition meter and run lamp works but time meter does not operate time meter is defective 4 If time meter works but battery condition meter does not operate connect a voltmeter between the positive terminal on battery charge meter and ground Use the following to determine fault a If reading equals battery voltage minus 10 volts battery condition meter is defective b If reading does not equal battery voltage minus 10 volts zener diode is defective Corrective Action Check
25. SCHEMATIC LOAD NEUTRAL LOAD GND n 120V 120V 1 8 CB1 1213 00 120 T3 L1 T4 L3 4 4 aaa ET ey i 100 120V 200 240V T m 100 120 CB2 NOTES 1 120V MAX ACROSS VR1 CONNECTIONS 2 3 2 GROUNDED AC LEAD FOR ISOLATED NEUTRAL REMOVEJUMPER W2 TB1 L3 LO AND CONNECT JUMPER TB1 LO VR1 C5 NEG VRI VOLTAGE REGULATOR 71 COL S3 154 MODULE S2 SWICH LOW OL PRESS RS POTENTOMETER RELAY CHOKE amp FUEL PUMP RELAY START SOLENGD HT CHOKE G1 GENERATOR F2 FUSE 10A 1 E34 SPARK PLUGS E2 FUEL PUMP CBi2 CRCUT BREAKER AC OUTPUT 120V CAS CAPACITOR NEUTRAL BTI BATTERY 12V GND B1 STARTER MOTOR REMOTE CONTROL STANDARD OPTIONAL A2 REHOTE CONTROL DELUXE 4 CONTROL ASSY NHE 1 CONTROL ASSY BGE DESCRIPTION OR MATERIAL P2 BEGIINNING SPEC BGE NHE 50 2 611 1248 11 e omi ut fe d Redistribution or publication of this document by any means is strictly prohibited Supplement 965 1075 Date 02 01 Insert with Title BGE NHE Service Manual Number Date 965 0528 9 94 This supplement transmits the following corrections to the service manual 1 On Page 6 14 under Direct Testing Coil With Ohmmeter step 6 change 12 6 and 15 4 ohms to 34 0 to 41 6 k ohms at 68
26. Stator lead Q1 from VR1 J4 11 Insulate or position the lead wire ends so they are not touching the generator set housing or other compo nents within control Set the ohmmeter for the highest resistance scale and then connect one test lead to the generator housing Touch the other test lead see Figure 8 16 to the listed generator leads individually A read ing less than one megohm indicates a ground Replace a grounded stator with a new stator TEST LEADS T1 T3 B1 and Q1 FOR GROUNDS G 1214 FIGURE 8 16 TESTING STATOR FOR GROUNDS Open or Shorted Windings Test To test for opens disconnect stator leads T1 T2 and T4 from TB1 B1 and B2 from A1 and Q1 and Q2 from VR1 Set the ohmmeter for the highest resistance scale and then connectthe test leads see Figure 8 16 to the generator lead ends in pairs T1 T2 T3 T4 B1 B2 and Q1 Q2 The ohmmeter should indicate continuity between lead ends A high resistance reading indicates an open wind ing Replace an open stator with a new stator To test for shorted windings use a digital type ohmme ter that reads to within 0 01 ohms Disconnectthe stator leads as specified in Open Test section Connect the test leads see Figure 8 17 to the leads in pairs as specified in the Open Test section The reading for lead pairs should be as follows plus or minus 10 96 60 Hz Models Leads T1 T2 0 327 ohms Leads T3 T4 0 327 ohms Leads B1 B2 0 058 ohms e Lea
27. Voltage regulator VR1 e Terminal board TB1 SPARK PLUGS CHOKE H1 E4 GASOLINE SETS ONLY ON LPG FUELED SETS IGNITION RELAY K5 IS LOCATED HERE NOTE CONFIGURATION AND PLACEMENT OF FUEL PUMP MAY VARY DEPENDING ON GENSET SPEC LEVEL FIGURE 7 1 BGE NHE GENERATOR SET The following sections describe each component and how it functions The control panel assembly consists of Printed circuit board A1 e Start Run Stop switch 51 e Fuse F1 Prinied Circuit Board A1 The printed circuit board controls the engine start start disconnect run and stop functions Itis mounted to the rear of the control panel It contains wiring harness connections to the engine generator and optional remote start control the start stop switch 51 and the control fuse F1 Start Run Stop Switch S1 51 is a SPDT rocker switch which starts and stops the generator set The switch returns to the center run position when released it is mounted on the circuit board and is not field replaceable Fuse F1 This 5 amp fuse protects printed circuit board A1 from overcurrent conditions It is removable from the front ofthe control panel Spare fuses are inside the fuse holder use only Onan supplied fuses IGNITION COIL E1 NEGATIVE BATTERY CONNECTION S DC FUSE F1 EI AC CIRCUIT BREAKERS CB1 CB2 REMOTE CONTROL FUEL PUMP 2 GASOLINE SETS ONLY ON
28. are prohibited by law in the State of California Modification removal or replacement of the generator set label is also prohibited SERVICE MANUAL 965 0528 REVISIONS 1 Insert this Supplement in its entirety under the front cover of the manual Discard any copy of Supplement 965 1055 On Page 1 1 write See Operator s Manual for fuel and engine oil recommendations and Peri odic Maintenance On Page 2 1 write For Spec M and later igni tion timing non adjustable is 12 BTDC On Page 5 4 write See Page S 2 of Supple ment 965 1060 for instructions on how to purge LPG and disconnect the genset from RV sys tems Cross out the instructions under the subheadings LP Gas Propane Purging Pro cedure and Disconnecting Set from RV Sys tems on Page 5 4 On Page 6 15 under the heading GOVER NOR write See Supplement 965 1060 for Spec M and Later On Page 6 17 under the heading FUEL SYS TEM GASOLINE write See Supplement 965 1060 for Spec M and Later Page 6 25 under the heading FUEL SYS TEM LPG LIQUID WITHDRAWAL write See Supplement 965 1060 for Spec M and Later On Page 6 31 under the heading FUEL SYS TEM LPG VAPOR WITHDRAWAL write See Supplement 965 1060 for Spec M and Later A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm D
29. be flat and uncreased Assemble the valve using a new gasket Do not overtighten the valve cover capscrew The reed valve must be assembled as shown in Figure 6 9 with a washer on top and the breather baffle on the bottom 6 15 Over tightening the valve cover can ACAUTION cause an air leak allowing dirt to enter the engine Be careful not to distort the valve cover when tightening COMBUSTION CHAMBER Examine the spark plugs and test cylinder compression to determine the condition of the valves pistons piston rings and cylinders Cylinder Compression Check 1 Start the generator set and allow it to warm up 2 Stop the generator set Remove and inspect the spark plugs see Ignition System in this section 3 Insert the compression gauge in one spark plug hole 4 Place the throttle and choke in full open position 5 Crank the engine and note the compression reading 6 Stop cranking and perform steps 3 through 5 on the other cylinder Refer to the Specifications section for compression pressures There may be variations due to equipment temperature atmospheric conditions and altitude These pressures apply to a warm engine at cranking speed about 300 r min If further inspection is neces sary refer to Engine Block Assembly section GOVERNOR The governor controls engine speed which directly affects the voltage output and frequency of the genera tor An increase in engine speed will cause a corres
30. being supported and NOT at an angle Ifreplacing the original tailpipe refer to the Recommendations sections to select and locate the tailpipe Attach tailpipe to outlet end of muffler and secure using a U bolt type and automotive muffler clamp marked 1 3 8 ONLY Support the tailpipe using a shock mounted support hanger with clamp Run the generator set for five minutes and check the entire exhaust system for leaks or excessive noise Fire can cause severe personal AWARNING injury or death Do not operate generator set when vehicle is parked in high grass or brush 9 Clean the spark arrester muffler every 100 hours of operation Remove the 1 8 inch pipe plug in the bottom of the muffler and run the set for five minutes Then replace the pipe plug Inspect the exhaust system for leaks at least every eight hours of run ning time Tailpipe Recommendations Tailpipes are supplied by the RV manufacturer and must meet several design specifications to provide safe generator set operation If replacing the tailpipe make certain the replacement part is the same size and con figuration as the original part Refer to the following guidelines for selecting and locating the tailpipe Also refer to recommendations in Installation Manual inhalation of exhaust gases can AWARNING result in severe personal injury or death Exhaust gases can enter the coach interior if the tailpipe is damaged missing or improperly i
31. brackets This may require slight adjustment of the floor jack 5 When the support bracket is removed the floor jack will support all its weight on that side Slowly lower the jack being careful to allow the jack to roll as the generator set swings downward 6 Supportthe drip tray assembly with wood blocks so the floor jack can be removed This will allow more access for the service procedure Make sure generator is resting AWARNING securely before removing floor jack Otherwise the generator set can swing downward causing severe personal injury Complete Set Removal Fuel exhaust electrical and control connections must be disconnected as described previously 1 Park the vehicle on a level surface that is capable of supporting the floor jack wheels Put the transmis sion in its PARK position lock the brakes and remove the ignition key Make sure no one moves the vehicle while performing this procedure AWARNING Dropping the generator set can cause severe personal injury or death Make sure no one moves the vehicle during this procedure and that the procedure is performed very carefully and only as instructed 2 Use a forklift to support the generator set tray at the points shown in Figure 5 4 Place a wooden block on one fork so the set will remain level 3 Raise the forklift so it contacts the drip tray then put slight upward pressure on the tray Make certain that the generator set is supported by the forks
32. conduit connector and pull the load wires and flexible conduit free of the junction box Disconnect the from the exhaust manifold at the flange connection and disconnect any support brackets or hangers that connect the muffler to the set On gasoline fueled sets turn off the fuel shutoff valve in the compartment and disconnect the fuel line at the fuel pump Securely plug the end of the fuel line to prevent fuel leakage or an accumulation of explosive gasoline vapor Gasoline vapor is extremely AWARNING mable and can result in severe personal injury or death if ignited Make certain all fuel line openings are plugged to prevent gasoline vapor from accumulating On LP gas propane fueled sets disconnect the fuel line after purging at the solenoid valve and plug the end of the fuel line to prevent entrance of dirt Removing Conventional Compartment Mounted Set From RV When the generator set has been disconnected from the electrical exhaust and fuel systems examine the set mounting and support system Locate all mounting bolts and support members for the set In most installations the generator set drip tray will be bolted to the coach framework Depending on the installation the set may be removable from the side back or bottom Verify that the generator set is adequately supported before loosening any of the mounting bolts or support members The most satisfactory way to lift or move the generato
33. corrected by mix ture or float adjustments are often caused by blocked fuel passages or worn internal parts The most effective remedy is a complete carburetor overhaul Overhauling a carburetor means complete disassem bly thorough cleaning and replacing worn parts Car buretor repair kits include new gaskets and replace ments for the parts that wear out Carefully note the carburetor position while removing all parts for correct reassembly Read and understand these procedures before beginning Carburetor com ponents are illustrated in Figure 6 19 Gasoline is extremely flammable AWARNING Severe personal injury or death can result if itis accidentally ignited Eliminate all possible sources of ignition including fire flame spark pilot light cigarettes arc producing equipment or other ignition sources before performing this procedure Remove the carburetor and intake manifold assembly as specified in the Carburetor and Intake Manifold Assembly description in this section Remove the car buretor from the intake manifold Disassemble it using the following procedure CHOKE SHAFT ADJUSTMENT SCREW THROTTLE STOP SCREW CHOKE PLATE FUEL INLET BOWL GASKET 5 BUOYANCY SPRING FLOAT FLOAT BOWL MAIN ADJUSTMENT SCREW ASSEMBLY B Q FS 1604 1 FIGURE 6 19 CARBURETOR OVERHAUL THROTTLE Carburetor Disassembly Procedure 1 Remove the air cleaner adapter and the automatic choke assembly 2
34. equipment Keep flames sparks pilot flames electrical arcs and switches and other sources of ignition well away LPG is flammable and explosive and can cause asphyxiation NFPA 58 Section 1 6 requires all persons handling LPG to be trained in proper handling and operating proce dures Air Cleaner Assembly Disassembly 1 Remove the crankcase breather hose and air preheater hose gasoline gensets only from the air cleaner housing 2 Remove the air cleaner housing center capscrew and lift off the housing and air filter 3 Remove the three capscrews that secure the air cleaner adapter to the carburetor and lift off the adapter One of the screws is inside the throat of the adapter Reassembly Reassembly is the reverse of disas sembly Use anew gasket between the adapter and the carburetor Take care notto cross thread the in side adapter mounting screw 5 3 Carburetor And Intake Manifold Assembly Disassembly 1 Remove the air cleaner assembly 2 Disconnect the fuel line and governor rod from the carburetor Large volumes of LPG can be released in the process of disconnecting a liquid withdrawal type of LPG supply sys tem See Disconnecting Set from RV Sys tems Page S 2 for the proper procedures and precautions Remove the intake manifold capscrews the carburetor air preheater gasoline gensets only and the carburetor and intake manifold as an assembly On LPG gensets equipped for liquid wi
35. exhaust pipe or manifold by welding and do not replace worn components with parts that do not meet factory specifications Contact an Onan distributor for proper exhaust kit parts and installation instructions Inhaling exhaust gases can cause A WARNING severe personal injury or death Modifying the exhaust system may allow poisonous exhaust gases to enter the vehicle Use only Onan replacement paris io service the exhaust system Unauthorized modifications will void the Onan war ranty Liability for injury or damages due to unautho rized modifications becomes the responsibility of the person making the change Two basic exhaust systems are used with Emerald ser ies generator sets Figure 6 1 shows a typical exhaust system for a compartment mount generator set Figure 6 2 shows a typical exhaust system for un underfloor mount generator set Separate sections cover the ser vice procedures for each exhaust system Also refer to specific kit installation instructions L BRACKET SCROLL FLANGE a 2 LOCK A x SCREW MUFFLER INLET 9 CLAMP Ve Conventional Compartment Mount Exhaust System A conventional compartment mount exhaust system consists of the exhaust manifold flange connector muffler muffler strap hanger clamps and tailpipe When service is required disassemble and reassemble as specified in the following steps Disassembly Procedure 1 Loosen the front muffler clamp muffler strap and tailpipe
36. for storage area Clean away ali dirt and oil from engine cooling fins Adjust breaker point gap Adjust carburetor main and idle adjustment screws Adjust carburetor float level Disassemble carburetor and clean all internal passages TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Continued Many troubleshooting procedures present hazards which can result in severe personal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Review safety precautions on inside cover page Trouble Black Exhaust Smoke White or Blue Exhaust Smoke Engine Hunts or Surges Possible cause 1 Rich fuel mixture due to a dirty air cleaner b choke sticking c incorrectly adjusted fuel mixture Screws d dirt in carburetor Gasoline Sets Only 1 Lean fuel mixture due to incorrect float level b incorrectly adjusted fuel mixture screws c dirt in carburetor d vacuum leak 2 Contaminated fuel 3 Excessive engine wear Gasoline Sets Only 1 Sticking or binding governor linkage 2 Incorrect governor adjustment 3 Faulty governor spring 4 Incorrect fuel mixture due to a incorrectly adjusted fuel mixture screws b incorrect float level c dirt in carburetor 5 Governor mechanism worn excessively 6 Fuel supply problem caused by a faulty fuel pump b contaminated fuel supply c va
37. frequency sensitive devices as a result of failing to observe this pre caution is not covered under the Onan warranty policy Governor Rod Length Adjustment The length of the governor rod Figure S 2 must be checked and adjusted as follows before other adjustments are at tempted 1 Loosen the lock nut at the ball joint end of the governor rod and unsnap the socket from the ball Push the governor rod gently towards the car buretor full throttle position While keeping it there tum the socket as necessary to lengthen or shorten the rod so that the ball and socket line up Too much pressure on the rod can result in a faulty adjustment of the rod length Snap the socket back over the ball Tighten the lock nut while holding the socket square with the axis of the ball Also the leg at the throttle end of the rod must be kept level Gently rotate the governor arm and check for binding If necessary loosen the locknut and repeat Step 4 until the linkage moves smoothly Binding can cause erratic governor action DETAIL GASOLINE AND LPG VAPOR WITHDRAWAL GENSETS DETAIL LPG LIQUID WITHDRAWAL GENSETS FIGURE S 2 GOVERNOR ROD S 5 Note The following groups of adjustments must be performed in sequence Idle Speed Stop Adjustment The frequency specifications for 60 Hz gensets are followed in pa rentheses by the specifications for 50 Hz gensets 1 Start the genset and let it warm up for ten m
38. fuel and oil levels and refill as necessary Refer to Fuel System Section 6 for test and service procedures Refer to Fuel System Section 6 for test and service procedures Remove any objects or debris that may restrict airflow to and from the set Refer to Fuel System Section 6 for test and service procedures Replace breaker points Replace ignition module Replace condenser Refill tank with fresh fuel Check for continuity and correct if open Check for continuity and correct if circuit is open Replace time meter Replace battery condition meter Replace zener diode AWARNING Many troubleshooting procedures present hazards which can result in severe personal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Review safety precautions on inside cover page Trouble Possible Cause Corrective Action REMOTE 5 Replace remote start stop switch 2 CONTROL if equipped Run Lamp Time Meter or Battery Condition Meter Does Not Operate Continued Meters and switch function properly but run lamp does not illuminate Lamp internal to switch is burned out 6 Check for continuity of remote wiring harness and wiring on remote control in series with terminals 6 and 5 Replace wiring of shorted circuit Remote switch functions properly starting and stopping generator set but meters an
39. gauge or inside micrometer These measurements should be taken at four places top and bottom of piston ring travel and parallel and perpendicular to axis of crankshaft 2 Record measurements taken at top and bottom of piston travel as follows see Figure 9 29 9 13 Measure and record as A the cylinder bore diameter parallel to crankshaft near the top of cylinder bore where greatest amount of wear occurs Also measure and record as B cylinder bore diameter parallel to crankshaft at the bottom of piston travel Measure and record as cylinder bore diameter perpendicular to crankshaft near the top of cylinder bore where greatest amount of wear occurs Also measure and record as D cylinder bore diameter perpendicular to crankshaft at the bottom of piston travel Reading A subtracted from reading B and reading C subtracted from reading D indi cates cylinder taper Reading A compared to reading C and read ing B compared to reading D indicates whether or not cylinder is out of round If out of round exceeds 0 003 inch 0 08 mm the cylinders must be rebored and honed to next oversize A reboring machine is used when going to oversize pistons The following repair data covers honing to oversize by use of a hone RING WEAR AREA BOTTOM OF RING TRAVEL C 1090 FIGURE 9 29 METHODS OF MEASURING THE DIAMETER OF A CYLINDER BORE Reboring t
40. good cylinder wall contact Figure 9 22 SG SS PISTON NS CYLINDER WALL A XE IMPROPER RING CONTACT CT 1062 FIGURE 9 22 NEW RING IN WORN RING GROOVE Replace pistons showing signs of scuffing scoring worn ring lands fractures or damage from pre ignition 9 10 Connecting Rod Inspection Replace connecting rod bolts and nuts with damaged threads Replace connect ing rods with deep nicks signs of fractures scored bores or bores out of round more than 0 002 inch 0 05 mm Use a new piston pin to check connecting rod for wear A push fit clearance is required and varies from engine to engine If a new piston pin falls through a dry rod pin bore as a result of its own weight replace the rod or bushing as required Piston Pin Inspection Replace piston pins that are cracked scored or out of round more than 0 002 inch 0 05 mm Bearing Inspection inspect bearings for burrs breaks pitting and wear Replace bearing inserts that are scored have the overlay wiped out show fatigue failure or are badly scratched If bearings appear to be service able check them for proper clearance Piston Clearance Proper piston tolerances must be maintained for satis factory operation Use a micrometer to measure the piston diameter at the point shown in Figure 9 23 When the cylinder bore is measured see Cylinder Block sec tion subtract the piston diameter from the cylinder bore diameter to obt
41. ignition sources Keep the work area clean well lighted and well ventilated Keep fire extinguishers and safety equipment nearby and be prepared for an emergency Develop safe work habits Unsafe practices cause accidents Be familiar with your tools and machines to use them safely Use the right tool for the job and check its condition before starting Follow all warn ings in this manual and take extra precautions when working around electrical equipment Avoid working alone and take no risks Be prepared for a potential accident The Red Cross and public safety departments offer courses in first aid CPR and fire control Use this informa tion to be ready for an accident Be safety conscious and make safety procedures part of the work routine TABLE 5 1 HAZARDS AND THEIR SOURCE e Fire and explosions Leaking fuel Hydrogen gas from charging battery Oily rags improperly stored Flammable liquids improperly stored Any fire flame spark pilot light arc producing equipment or other ignition sources Burns Hot exhaust pipes Hot engine and generator surfaces Hot engine oil Electrical short in DC wiring system Hot engine coolant Poisonous Gases Carbon monoxide from faulty exhaust LP gas leaking into coach interior Operating generator set where exhaust gases can accumulate State and federal agencies have deter AWARNING mined that asbestos used engine oil and benezene cause cancer or re
42. indicated by the absence of gas pressure on the manometer scale in the pre vious test when it is jumpered across the the bat tery cable connections at the genset Demand Regulator Lock Off Pressure Test Lock off pressure is determined as follows by pres surizing the back vent side of the regulator dia phragm to simulate carburetor venturi vacuum 1 Continue with the test setup for adjusting LPG supply pressure shown in Figure S 11 If the regulator is being tested on the bench connect it to a source of air pressure regulated to 11 inches WC 280 mm WC CAUTION f this is a bench test of the reg ulator make sure the diaphragm is in a ver tical plane see Figure S 10 otherwise the weight of the diaphragm will cause erro neous readings of lock off pressure in two hoses to the end of the hose con nected to the regulator vent fitting 3 8 inch D Use one hose to provide the test pres sure andthe otherto measure pressure by con necting it to an inclined manometer calibrated with 0 01 inch or 0 1 mm divisions and having a range of at least 1 inch 25 mm 3 Disconnect the hose to the carburetor and at tach a soap bubble to the regulator outlet hose fitting While reading the pressure indicated by the inclined manometer and watching the soap bubble blow lightly into the hose being used to pressurize the regulator Regulator lock off pressure is the minimum pressure that will cause gas to flow thro
43. is higher high resistance indicates an open circuit or a poor connection inside the coil Measure resistance in the secondary circuit connect the ohmmeter leads to the two high voltage terminals see Figure 6 12 This resistance should be between 12 6 and 15 4 k ohms Replace the coil if itis not within this specification Lower resistance indicates a shorted secondary winding and higher resistance indicates the coil has excessive internal resistance or an open circuit ES 1373 FIGURE 6 12 TESTING COIL SECONDARY Spark Plugs Spark plug inspection is described under Electronic Ignition Wiring The ignition system wiring includes e One positive B wire which conducts low voltage from the battery to the primary winding of the coil e One negative wire which conducts low voltage to the points and condenser Two wires which carry the high voltage from the secondary coil winding to the spark plugs The plugs and coil secondary are grounded to the engine The ignition coil primary low voltage side is grounded when the breaker points close Check all low voltage wiring for loose connections and breaks in the insulation Clean all terminals and connec tions and use an ohmmeter to testthem for continuity Use a megger high range ohmmeter to check for breaks in the plug wire insulation 6 14 CRANKCASE VENTILATION SYSTEM The crankcase breather prevents pressure from build ing up inthe crankcase It pr
44. least 15 minutes at 50 to 75 of its rated load Then remove the load and let the set stabilize for 10 to 15 seconds Make certain that the set is running with no load 3 With the unit operating at no load adjust the gover nor speed nut to 50 2 Hz 50 Hz sets 40 2 Hz while checking that the idle stop screw is not con tacting the throttle lever Then adjust the idle stop screw to increase the engine speed to 55 1 Hz 50 hz sets 45 1 Hz 4 Run the generator set with no load and adjust the speed adjustment nut to the following frequency 00 Adjust Speed Nut to 60 Hz 120 volts 62 63 Hz 50 Hz 110 220 volts 51 5 52 5 Hz 50 Hz 120 240 volts 51 5 52 5 Hz GOVERNOR SPEED ADJUSTMENT THROTTLE LEVER SC 1625 SEE DETAIL A FIGURE 6 14 GOVERNOR ADJUSTMENT SPEC H 6 16 5 Check the frequency and voltage at no load Fre quency and voltage should stay within the limits shown in Table 6 1 Then apply rated load to the generator set and check frequency and voltage Calculate droop by subtracting the full load fre quency from the no load frequency 6 If the droop is greater than the specified range adjust the governor spring towards the governor shaft by turning the adjusting screw counterclock wise 1 to 2 turns If the droop is less than the min imum specified or if the set is hunting adjust the governor spring away from the governor shaft by turning the adjusting screw clockw
45. not exceed 6 psi 41 kPa under any operating con dition Fuel Pressure Test 1 Disconnect the fuel line at the outlet of the fuel pump and connect a pressure gauge at the pump outlet A gauge calibrated for 0 15 psi 0 100 kPa is recommended Do not tee into the fuel line This is a static pressure test 5 9 2 Push the Start Stop switch to START and hold it there for several seconds until the fuel pres sure stabilizes Fuel pressure should stabilize between 3 5 and 6 psi 24 and 41 kPa 3 Repeat the test with the vehicle engine run ning A fuel pressure greater than 6 psi 41 kPa is not acceptable Find out why the pressure is high Ifitis high when the vehicle engine is not running check to see that the proper Onan supplied pump is being used If itis high when the vehicle engine is running a separate fuel pickup tube in the fuel tank or equivalent means will be required If the fuel pressure is less than 3 5 psi 24 kPa check for fuel restrictions in the system The pump will have to be relocated closer to the fuel tank if itis located more than 3 feet 0 9 meters above the end of the fuel pickup tube in the fuel tank If the pump is defective replace it with the appropriate Onan pump The pump is not serviceable See the Installation Manual for important recom mendations regarding the fuel supply system LPG System Liquid Withdrawal See Figure S 6 For liquid withdrawal systems the LPG container
46. of commercial cleaning solution or hot soapy washing solution 3 Rinse block in clean hot water to remove cleaning solution Inspection When rebuilding the engine thoroughly inspect block for any condition that would make it unfit for further use This inspection must be made after all parts have been removed and block has been thoroughly cleaned and dried 1 Make a thorough check for cracks Minute cracks may be detected by coating the suspected area with a mixture of 25 percent kerosene and 75 percent light motor oil Wipe the part dry and immediately apply a coating of zinc oxide white lead dissolved in wood alcohol If cracks are present the white coating will become discolored at the defective area Always replace a cracked cylinder block 2 Inspect all machined surfaces and threaded holes Carefully remove any nicks or burrs from machined surfaces Clean out tapped holes and clean up any damaged threads 3 Check top of block for flatness with a straight edge and a feeler gauge Cylinder Bore Inspection Inspect cylinder bores for scuffing scratches wear and scoring If cylinder bores are scuffed scratched scored or worn they must be rebored and honed for the next oversize piston When the appearance of cylinder bores is good and there areno scuff marks check cylinder bore for wear or out of roundness as follows 1 Check cylinder bore for taper out of round and wear with a cylinder bore gauge telescope
47. or line boring after installa tion They are available in standard size 0 002 0 010 0 020 or 0 030 inch undersize For putting in either the front or rear main bearing always align the oil hole s in the bearing with the oil hole s in the bearing bore The oil passage must be at least 1 2 open Before installing main bearings expand bearing bore by placing the casting in an oven heated to 200 F 94 C If practical cool the precision bearing to shrink it Rear Bearing Use the combination main and cam bear ing driver and a press fo install the rear main bearing Push the bearing into the bearing plate from the inner side see Figure 9 32 to the depth allowed by the flange on the driver REAR BEARING END PLATE LOCK PIN fa ALIGN BEARING OIL HOLES WITH OIL HOLES IN BEARING M THRUST WASHER SHIM BEARING M 1475 PRECISION TYPE DO NOT LINE BORE OR REAM FIGURE 9 32 REAR BEARING Front Bearing Locktite Bearing Mount is used when installing the front bearing Use the towelette furnished with the bearing kit to clean the outside of the bearing and the bearing bore in the block Allow three to four minutes for drying Breathing vapor from towelette and A WARNING prolonged contact with skin can be harmful Use only in well ventilated area and avoid prolonged contact with skin Apply the Locktite Bearing Mount to the mating surfaces of the bearing and bearing bore Use the combination main and cam bearing drive
48. plug center electrode and the side electrode A weak spark means that the coil or wiring may be defective Direct Testing Coil With Ohmmeter The coil is re moved from the circuit to perform this test 1 2 3 Remove all wires attached to the ignition coil Remove the coil from the engine Inspect the terminals for corrosion looseness cracks dents and other damage Look for carbon runners around the high voltage terminals These indicate electrical leakage Replace a damaged or leaking coil Clean the outside of the coil with a cloth dampened in parts cleaning solvent Measure resistance in the primary circuit connect the ohmmeter leads to the positive and negative terminals on the coil This resistance should be between 3 87 and 4 73 ohms Replace the coil if the resistance is higher high resistance indicates an open circuit or a poor connection inside the coil Measure resistance in the secondary circuit con nect the ohmmeter leads to the two high voltage ter minals see Figure 6 12 This resistance should be between 34 0 and 41 6 k ohms at 68 F 20 C Re place the coil if it is not within this specification Low er resistance indicates a shortened secondary winding and higher resistance indicates the coil has excessive internal resistance or an open circuit ES 1373 FIGURE 6 12 TESTING COIL SECONDARY Spark Plugs Spark plug inspection is described under Electronic Igni tion 6
49. prevent leakage or an ac cumulation of explosive gasoline vapor LPG Fueled Gensets Close the fuel shutoff valve s at the LPG container s and move the vehicle outside and away from below grade spaces where LPG could accumulate To purge the fuel line and genset as much as pos sible run the genset if it starts until it runs out of fue with the LPG valve s closed LPG is flammable and explo sive and can cause asphyxiation NFPA 58 Section 1 6 requires all persons handling LPG to be trained in proper handling and operating procedures LPG sinks when it escapes into the air and can accumulate in explosive con centrations Before disconnecting the LPG fuel line close the fuel shutoff valve s at the LPG container s and move the vehicle outside and away from pits or basements or other below grade spaces where LPG could accumulate ForLPG liquid withdrawal systems see Figure S 6 push the regulator priming button while cranking for 10 seconds to purge some of the remaining LPG Then loosen the threaded flex ible fuel supply hose connector at the fuel filter on the genset just enough to hear gas escap ing Unthread the connector when no more gas is heard escaping Finally cap the end of the fuel supply hose with a 1 4 inch NPTF pipe cap to prevent fuel from escaping if someone inad vertently opens the shutoff valve s at the LPG container s Large volumes of LPG can be released in the process of disconnecting
50. rated load 7 to 1096 CO Install limiter caps as instructed above 6 With unitatno load adjust governor speed to 50 2 Hz 50 Hz sets 40 2 Hz With the throttle lever againstthe idle stop screw adjustthe stop screw to 55 1 Hz 50 Hz sets 45 1 Hz 7 Readjust no load speed to 62 51 5 1 Hz and observe the stability of the set Set the voltage and frequency and adjust the sensitivity of the governor as specified in the Governor section Add and remove a hal load several times to make certain the set does not bog down or hunt Carburetor Overhaul Carburetor problems that cannot be corrected by mix ture adjustments may be caused by dirtin fuel passages or by worn internal parts Normally the carburetor should seldom require cleaning because LP gas vapo rizes completely before reaching the carburetor leaving no residue However a bad fuel supply or fuel filter may let dirt or oil through to the carburetor This may mean that the carburetor should be cleaned to restore satis factory operation Overhauling the carburetor involves its complete disas sembly thorough cleaning and replacement of worn parts Carburetor repair kits are available that supply new gaskets and replacement parts for the components subject to wear Note the position of all components while removing them for correct reassembly See Figure 6 28 for com ponent designations Removal and Disassembly Procedures 1 Remove the carbur
51. related to the control circuits Figures 7 3 and 7 4 show the location of most of the control components Theschematic diagram shown in Figure 7 2 is intended as an illustration of the circuit description However when troubleshooting always refer to the wiring dia gram that corresponds to the model and spec numbers of the generator set The troubleshooting guide is divided into sections After identifying the problem refer to the guide for the possi ble cause and the recommended corrective action A WARNING Many troubleshooting procedures present hazards which can result in severe personal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Review safety precautions on inside cover page Trouble Possible Cause Engine Does 1 Control fuse F1 may be open Not Crank 2 If engine cranks at set but not at remote 2a control panel fault is due to a PC board P2 J2 connection not secure b Open circuit in remote con c Remote start switch faulty 3 If engine cranks at remote control panel trol Corrective Action 1 Replace fuse F1 if open with Onan supplied fuse only Ensure that wiring harness jack connections are fully seated to PC board Check for continuity and correct if circuit is open Replace remote start control switch b C 3 Replace PC board A1 but not at set fault is due to fauity S1 Sw
52. s must be equipped to withdraw LPG as a liquid See the Installation Manual for im portant recommendations regarding the installation of a LPG liquid withdrawal type of fuel supply sys tem AWARNING LPG is flammable and explosive and can cause asphyxiation NFPA 58 Section 1 6 requires all persons handling LPG to be trained in proper handling and operating proce dures Itis important to understand that the fuel filter sole noid shutoff valve vaporizer and demand regulator EXHAUST MANIFOLD LPG VAPORIZER WITH BAFFLE COILS PRESSURE REGULATOR ONE OF TWO REGULATOR TWO STAGE LPG LPG FI NG AND HOSE TO CARBURETOR handle LPG liquid at the same pressure as in the LPG container Depending on ambient tempera ture LPG container pressure can exceed 200 psi 1379 kPa Therefore discharge or leakage from LPG liquid containing components can result in the escape of large volumes of flammable and explo sive gas Purging the LPG System It is imperative that the LPG system be purged before disconnecting fuel system components Large volumes of LPG can be re leased in the process of disconnecting a liquid withdrawal type of LPG supply system See Dis connecling Set from RV Systems Page S 2 for the proper procedures and precautions LPG FUEL SHUTOFF MOUNTING SCREWS SOLENOID LPG uh AND FUEL SUPPLY CONNECTION FIGURE S 6 LPG SYSTEM COMPONENTS FOR LIQUID WITHDRAWAL 5 10 Demand Regulator S
53. slip out of place during installation The crankshaft should turn freely by hand Checking Endplay After tightening two rear bearing plate nuts or cap screws to the specified torque check the crankshaft endplay atthe point shown in Figure 9 28 using a feeler gauge Lightly tap the front of the crankshaft with a plastic faced hammer to take up the freeplay Refer to the Dimensions and Clearances section for the recom mended crankshaft endplay If necessary remove the rear bearing end plate and add or remove shims as required Install the end plate and tighten all nuts or capscrews to the specified torque Make sure the shim and thrust washer are in place and recheck crankshaft endplay Verify that the crankshaft turns freely without binding MEASURE ENDPLAY HERE REFER TO DIMENSIONS AND CLEARANCES CT 108 FIGURE 9 28 CHECKING ENDPLAY 9 12 CYLINDER BLOCK The cylinder block is the main support for all other basic engine parts Crankshaft and camshaft are supported by the block assuring alignment of the crankshaft and cylinder bores Cleaning After removing pistons crankshaft cylinder heads etc inspect block for cracks and extreme wear If block is still serviceable prepare it for cleaning as follows 1 Scrape all old gasket material from block Remove oil bypass to allow cleaning solution to contact inside of oil passages 2 Remove grease and scale from cylinder block by agitating in a bath
54. so that proper pressure is maintained when brushes contact slip rings Use the following procedure to replace the brushes 1 Disconnect the negative battery cable at the bat tery terminal 2 Remove the air cleaner cover and air cleaner filter element 3 Remove the brush block cover from stator housing 4 Disconnectthe F1 outboard and F2 inboard voltage regulator lead wires from the brush block terminals 5 Remove the brush block mounting screws and lift out the brush block 6 Remove brushes and brush springs from holder and replace with new parts 8 14 10 11 12 13 14 15 Pull and hold both brush lead wires outward from brush holder Place brush block assembly into mounting position inside stator housing While continuing to hold brushes away from slip rings insert brush retainer wire from outside stator housing hole through brush block assembly Release both brush lead wires See Figure 8 12 RETAINER WIRE hed T LE EELS SECTION A A G 1179 FIGURE 8 12 BRUSH REPLACEMENT Install brush block mounting screws and tighten only enough to hold brush block assembly in position Lift both brush lead wires and remove brush retain ing wire completely from stator housing Adjust brush block assembly so that brushes are aligned on slip rings and tighten brush block mounting screws Connect the voltage regulator and brush lead wires t
55. t 16 11 15 1 13 1 VRE VOLTAGE REGULATOR Ti GN CCI S3 iN MOULE 52 SWITCHALOW OL PRESS OPTIONAL RELAY CHOKC X FUEL Ki RILAY START SOLENCIO T81 Hi CHOXE G1 GENERATOR F2 FUSE WA E34 SPARK PLUGS E2 FUEL PUMP 812 BREAKER j CAPACITOR e e l a a BTA BATTERY 12 81 STARTER MOTOR NEUTRAL 120 REMOTE CONTRC STANDAD 4 A2 CONTRIL CELUYE ae atc f i GND CONTROL PZ BEGINNING SPEC N BCE NHE 60 2 611 1244 5 WIRING DIAGRAM 120 120 H wm NEUTRAL GND SCHFMATIC TB1 x NOTES 1 FOR P2 J2 A GROUND B RMT STOP RMT STAR SW 8 SW B VRI VOLTAGE REGULATOR Ti CO S3 MODULE 52 SWITCH LOW OL PRESS R6 RESISTOR BATTERY CHARGE RS K5 RELAY LPG ONLY K1 RELAY START SOLENOID Jg STOP START 61 GENERATOR F1 FUSE SLOW BLOW SA E34 SPARK PLUGS 12 E2 FUEL PUMP OR FUEL SOL E 0 CR6 RECTIFIER LPG ONLY 82 CIRCLAT BREAKER OUTPUT G B C45 CAPACITOR H A BTA BATTERY 12 B1 STARTER MOTOR QPTIONAL REMOTE CONTROL STANDARD A2 REMOTE CONTROL DELUXE 1 CONTROL ASSY NHEL A1 CONTROL ASSY BGEL ITEM DESCRIPTION OR MATERIAL BEGII
56. the Heading Appendix B SPEC J and K DIA GRAMS to Appendix B Later Wiring Dia grams On Page ii under Appendix B Later Wiring Diagrams add the entries Beginning Spec N BGE NHE 60 Hz 611 1244 B 8 BGE NHE 60 Hz LP 611 1253 B 9 BGE NHE 50 Hz LP 611 1254 B 10 BGE NHE 50 Hz 611 1248 B 11 Page 1 of 1 with attachments A 11 B 1 and B 8 through B 11 Redistribution or publication of this document by any means is strictly prohibited CONTROL BOARD TESTING BEGINNING SPEC lf the genset does not crank or cranks but does not start and you think the cause might be a faulty con trol board conduct the following tests to make sure First remove the contro panel and disconnect P1 J1 For easier test connections at P1 it is rec ommended that you make up a test harness with Onan 16 Socket Connector 323 1487 04 and sockets 323 1486 Also use alligator clips on the ends of the leads attached to pins 2 4 7 and 11 to 1 Apply B 12 VDC to P1 7 and B to P1 11 and hold down the control switch in the Start position 2 Continuing Step1 apply B to 1 2 and B to P1 4 to simulate start disconnect and then let go of the Start switch make for easier connections at the battery termi nais Depending on results e Go back to Troubleshooting if a meter or light does indicate B at each pin in both tests PC board 1 is not faulty Replace control P
57. the entire exhaust system for leaks or excessive noise Repair any leaks immediately Fire can cause severe personal AWARNING injury or death Do not operate the generator set when vehicle is parked in high grass or brush 10 Clean the spark arrester muffler every 100 hours of operation Remove the 1 8 inch pipe plug in the bottom ofthe muffler and run the set for five minutes Then replace the pipe plug Inspect the exhaust system for leaks at least every eight hours of run ning time Underfloor Mount Exhaust System An underfloor mount exhaust system consists of the exhaust manifold muffler clamps hanger if required and tailpipe When service is required disassemble and reassemble as specified in the following steps Disassembly Procedure Contact with hot engine parts can A CAUTION cause personal injury The genset should be shut down and allowed to cool before per forming this procedure 1 Loosen the muffler clamp at the muffler inlet see Figure 6 2 and remove the muffler support bracket screws Remove the two 1 4 20 screws and lock washers and muffler and tailpipe assembly Completion of the remaining steps requires that the generator set be partially removed from the vehicle Refer to Preparing to Service Section 5 for the set removal procedures For LPG sets also perform the procedure for purging LP from the fuel line Remove the cooling system scroll and noise shield see Cooling System in this sec
58. the field current as the load changes is how voltage regulation is achieved Efficient generator set performance relies on effective volt age regulation and maintaining proper frequency engine speed Load changes on the generator output can cause engine speed to decrease or increase signif icantly If the governor does not maintain proper engine speed too much of a burden can be imposed on the voltage regulator to provide proper current to load Review the information in Section 6 Engine Primary Systems for governor troubleshooting and adjustments BRUSH GENERATOR BLOCK HOUSING ASSEMBLY STATOR CLAMPS ROTOR CIRCUIT BREAKER S END BEARING CB1 AND CB2 IF EQUIPPED om CONTROL BOARD 1 9 2 o IO w 20 P y p START SOLENOID K1 CONTROL FUSE F1 VOLTAGE gt REGULATOR VRI SLIP RINGS TERMINAL BOARD G 1212 ENGINE TO GENERATOR ADAPTER HOUSING FIGURE 8 1 GENERATOR CONTROL COMPONENTS 8 3 REMOTE PANELS DELUXE STANDARD 1 LOAD NEUTRAL GND 20 20 i i P N ze A ajaja joma a 7 5 START e E CR9 Tea WIRING DIAGRAM 611 1180 PI 6 2 te R7 PK2 P33 P3 6 AP3 4 peze 91 CRE K3 RECTIFIER FUEL PUMP RESI
59. the generator set and allow it to stabilize Measure the field voltage with no load applied and then with full load applied Both readings should fall within a range of 1810 60 volts DC If the set cranks but will not run check to see that battery voltage is being supplied to the volt age regulator pin 7 positive lead and ground negative lead during start up If battery voltage approximately 12 volts is being supplied to the voltage regulator at pin 7 and no output voltage was measured check the voltage at the brushes If the voltage is zero replace the voltage regulator and retest If battery voltage is not supplied to the voltage regulator during starting refer to Control section 7 for troubleshooting procedures Rotor Tests The rotor can be tested for grounded open or shorted windings using an ohmmeter Figures 8 14 and 8 15 show the rotor removed from the generator for testing However itis possibleto testthe rotor without removing itfrom the generator To obtain access to the slip rings remove the brush block cover Lift the brush lead wires and insert a brush retaining wire from outside stator housing through brush block assembly to hold the brushes of the slip rings during testing Ground Test To test for grounds set the ohmmeter for the highest resistance scale Touch one test lead to the rotor shaft and hold it there Touch the other test lead to one of the slip rings See Figure 8 14 A reading less than one
60. to reach this clearance 6 Move the choke lever back and forth to verify that it does not bind or stick 7 Remove the vacuum supply from the diaphragm Install the filter assembly on the carburetor Fuel Pump All gasoline fueled generator sets use electric fuel pumps The electric pump has an integral shutoff valve that prevents fuel flow to the carburetor when the set is idle If the pump malfunctions or supplies insufficient fuel test and repair replace the pump as described below Do not substitute an automotive fuel A WARNING pump for the standard Onan supplied fuel pump Other pumps output pressure is much higher and can cause carburetor flooding or fuel leakage crealing a fire hazard Pump Test Procedure 1 Remove the fuel line from the pump outlet Install a pressure gauge in the line 2 Press the Start switch and hold it for several seconds until the pressure reading is constant A normal pump produces 4 to 5 psi 27 5 to 34 4 kPa Pressure should stay constant or drop off very slowly Ifthe pressure is below 3 1 2 psi 17 2 kPa replace the fuel pump Ifthe pressure 1 zero check the electrical connections then recheck the pressure reading There are no serviceable components in the fuel pump Refer to the generator set Parts Manuals and replace the pump with an Onan supplied unit Do not tamper with the seal at the A CAUTION center of the mounting bracket on the side of the pump because it
61. under all conditions Adjust the supply pressure as follows 1 Close the gas shutoff valve s at the LPG con tainer s Remove the 1 8 inch pipe plug from the regula tor test port Figure S 11 and connect a ma nometer calibrated in inches or mm WC water column having a scale range of at least 14 in ches 350 mm Open the LPG container shutoff valve and try starting the genset While the genset is running check the ma nometer and adjust the LPG supply pressure regulator to obtain 11 inches 279 mm WC If there is a secondary pressure regulator in the supply line adjust the secondary regulator instead of the primary regulator at the LPG con tainer If the genset will not start jumper the fuel sole noid to the battery cable connections on the genset so that it stays open the regulator will keep gas from flowing and then check and ad just the LPG supply pressure If the genset is operable check LPG supply pressure under full load if it drops below the minimum required pressure either the LPG container is too small to provide the rate of va porization necessary or it is less than half full or the supply line is too restrictive 2 5 14 7 Disconnect any jumpers which may have been used to energize the fuel solenoid and thread in and tighten the pressure test port plug unless tests are going to be continued Fuel Shutoff Solenoid Valve Replace the fuel so lenoid if it fails to open as
62. vacuum E 2 Insert a 8 6 mm 0 337 inch drill rod between assembly Replace faulty choke components and the choke plate and the carburetor throat reassemble as shown Adjust the choke breaker as 3 If necessary bend the link at the point shown sembly each time it is assembled to the carburetor until the lip of the choke plate just touches the as follows drill rod Use two pliers to bend the link Make sure VACUUM SUSTAIN IF NECESSARY BEND THIS LINK AT may cause engine to THE CHOKE BREAKER ASSEMBLY flood and does not in terfere with the choke shaft assembly S CHOKE BREAKER ASSEMBLY A Pa d gt S SHAFT P d V lt ASSEMBLY lt 9 P 5 lt 7 9 4 GAUGE THE DISTANCE BETWEEN THE CHOKE PLATE AND THE CARBURETOR THROAT WITH A 0 337 INCH BI METAL HEATER 8 6 mm DRILL ROD WHEN ADJUSTING THE CHOKE CARBURETOR ASSEMBLY BREAKER ASSEMBLY FIGURE S 5 CHOKE ASSEMBLY Fuel Pump Gasoline Gensets The fuel pump delivers fuel to the carburetor at 3 5 5 psi 24 35 kPa and has a lift capacity suc tion of 3 feet 0 9 meters Do not substitute an automotive fuel pump for the standard pump removed from the genset Other pumps can cause carburetor flooding because of the high pressures they de velop Carburetor flooding can cause poor per formance and engine damage and lead to pos sible fire and severe personal injury or death Fuel pressure at the carburetor fitting must
63. vapor withdrawal Electric starter Before considering major inspection of the engine due to abnormal engine performance engine knocks power loss etc refer to the unit Operator s Manual Periodic Maintenance Schedule and per form Cleaning the Carburetor and Combustion Chamber with Onan 4 TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Many troubleshooting procedures present hazards which can result in severe personal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Review safety precautions on inside cover page Trouble Engine Misfires Engine Backfires Possible Cause Corrective Action 1 Faulty ignition due to a worn or fouled spark plugs 1 Replace spark plugs b worn breaker points b Replace breaker points c incorrect ignition timing c Set breaker point gap d faulty ignition coil d Test coil and replace if necessary e faulty plug wires e Test spark plug wires and f faulty point condenser g faulty ignition module 2 Lean fuel mixture due to a incorrectly adjusted fuel mixture screws b incorrect float level c dirt in carburetor d vacuum leak d Locate leak and correct as required 3 Contaminated fuel 3 Drain fuel tank and refill with fresh fuel 4 Carburetor icing 4 In cold weather place air preheater in winter position Gasoline sets only
64. 5 1 BOARD Sequence of Events ignition Run Mode Engine starts oil pressure causes MEE E E4 LOPKO to close sending ground SPARK S3 signal to P3 4 PLUG IGNITION POINTS AC from generator B1 B2 winding enter board at P1 1 and P1 7 These two inputs cause the control to switch from start mode to run mode Starter automatically disengages Field flash automatically removed Start switch released Safeties enabled R7 1 2 powers choke heater 1 RS SS RESISTOR Pump power now from P3 6 i through R7 Se Sequence of Events AC voltage from B1 B2 windings enter board at P1 1 P1 7 Board rectifies AC input to DC out put B charge current from P1 6 flows START to battery SOLENOID RESISTOR 7 R6 on ground side limits charging BT v current to 1 amp maximum page BATTERY ESSE Uc A 4 CONTINUITY Continuous Circuit Good STATIC MODE ud Battery voltage VOLTAGE 12 VDC Good O 4 STATIC MODE Cu Battery voltage VOLTAGE 12 VDC Good 19 20 39 40 50 6 79 80 STATIC MODE EMERALD CONTROL BOARD CHECK OUT 300 2784 Many Emerald control problems are caused by a bad connection between the PC board and the wiring harness Check continuity at the eight terminals STATIC MODE B at P1 6 BATTERY POSITIVE INTO BOARD Ground at P1 7 amp 8 Required 12 14 VDC Working on operati
65. 7500 0 7515 Diameter 19 05 19 09 mm 19 05 19 09 mm Valve Lifter To 0 0020 0 0040 0 0020 0 0040 Block Clearance 0 051 0 102 mm 0 051 0 102 mm Valve Seat Outside 1 4700 1 4710 1 5690 1 5700 Diameter Intake 37 34 37 36 mm 39 85 39 88 mm Valve Seat Outside 1 192 1 193 1 2550 1 2560 Diameter Exhaust 30 28 30 30 mm 31 88 31 90 mm Valve Seat Bore 1 4395 1 4405 1 5645 1 5655 Diameter Intake 36 56 36 59 mm 39 74 39 76 mm Valve Seat Bore 1 189 1 190 1 2510 1 2520 Diameter Exhaust 30 20 30 23 mm 31 78 31 80 mm 3 3 Redistribution or publication of this document by any means is strictly prohibited Section 4 Torque Specifications MODELS TORQUE SPECIFICATIONS Use engine oil as a lubricant for all threads EXCEPT the spark plug and rotor through bolt threads FOOT POUNDS NEWTON METRES Mounting Screws Adapter to Generator 34 Mounting Screws Rear Vibration Isolator Center Screw 30 33 41 45 Flange to Drip 10 12 11 16 Tray Screws Front Vibration isolator Flange to Oil 19 22 26 30 Base Screws 4 1 TORQUE Use engine oil as a lubricant for all threads SPECIFICATIONS EXCEPT the spark plug and rotor through bolt threads FOOT POUNDS NEWTON METRES 18 20 Stud Nuts 24 27 Stud Nuts 15 17 Capscrews 21 23 Capscrews Other 3 8 Cylinder Block 18 23 24 31 Nuts T 10 12 Rotor Through Bolt 45 55 61 75 Starter Mounting
66. C board A1 if a meter or light does not indicate B at each pin in both tests A meter or light should indicate B at P1 1 field flash 1 9 starter P1 6 ignition P1 12 fuel and choke A meter or light should continue to indicate B at P1 6 ignition 1 12 fuel and choke IEEE EXE Pins in Connector P1 on Control PC Board 1 11 Redistribution or publication of this document by any means is strictly prohibited Appendix B Later Wiring Diagrams WIRING DIAGRAM DRAWING No Beginning Spec J BGE NHE 60 Hz BGE NHE 50 Hz BGE 60 Hz 100 V Beginning Spec 611 1206 611 1207 611 1208 BGE NHE 60 Hz 611 1220 BGE NHE 50 Hz 611 1221 BGE 60 Hz 100 V 611 1222 Beginning Spec N sealed remote connector BGE NHE 60 Hz 611 1244 BGE NHE 60 Hz LP 611 1253 BGE NHE 50 Hz LP 611 1254 BGE NHE 50 Hz 611 1248 B 1 20V ad WARING DISGSAH SCREENS e _ OOl 4 871 maei T 4 E3 Moe DAS E ji E4 1 LE I 1524 E 1 3 i 1 6 21 12 21 19 ey F1 3 des CR2 VR 4 CRS CR9 CRE NOTES 7 T __ 1 FOR P2 J2 GROUND RMT STOP K2 RMT START SW gt lt 1 SW YPCZ 7 pL IK4
67. CAUTION which can result in severe personal injury or death if ignited by a spark flame or other ignition source If leaks are detected correct immediately OUTPUT CHECK Apply a full load to make sure the set will produce its full rated output Use a load test panel to apply a progres sively greater load until full load is reached EXHAUST SYSTEM With the generator set operating inspect the entire exhaust system including the exhaust manifold muffler and exhaust pipe Visually and audibly check for leaks at all connections welds gaskets and joints and also make sure exhaust pipes are not heating surrounding areas excessively If leaks are detected correct immediately Inhalation of exhaust gases can AWARNING result in severe personal injury or death Inspect exhaust system audibly and visually for leaks daily Repair leaks immediately CONTROL Stop and start the generator set several times at the set control and remote control if equipped to verify the control functions properly MECHANICAL Stop the generator set and inspect for leaking gaskets loose fasteners damaged components or interference problems Repair as required Inspect the generator set compartmentand verify there are no breaks or openings in the vapor proof wall that separates the compartment from the vehicle interior Seal openings as required Make sure all soundproofing material is in place EXHAUST GAS IS DEADLY Exhaust gases contain c
68. F 20 C Refer to the page 6 14 of your manual and write Refer to Supplement on it Page 1 of 1 Redistribution or publication of this document by any means is strictly prohibited Disconnect the condenser and ignition lead wires at screw A Figure 6 10 Remove the condenser mounted outside breaker points box on engine adapter flange Remove the breaker points mounting screws B and lift out the point assembly Replace the condenser and point assembly and install in a reverse order of removal Use an allen head wrench to adjust set screw C to obtain the gap setting specified in the Specifications section Measure the point gap with a flat thickness gauge see Figure 6 10 Make sure feeler gauge is clean and free of any grease oil or dirt The timing is adjusted during initial engine assem bly and is fixed by the point gap adjustment No oth er adjustment or alignment is necessary Replace the point box cover and hold down wire spark plugs and spark plug leads Connect negative battery cable to negative bat ter terminal 10 CONDENSER LEAD WIRE POINT GAP IGNITION LEAD WIRE B ES 1529 1 FIGURE 6 10 BREAKER POINTS Ignition Coil The ignition coil Figure 6 11 is a transformer that steps up the battery voltage to approximately 20 000 volts to fire the spark plug Keep all ignition coil terminals and connections clean and secure Check for loo
69. FIGURE 9 5 VALVE FACE Warpage occurs chiefly in the upper stem due to its exposure to intense heat Out of round wear follows when the seat is pounded by a valve whose head is not in line with the stem and guide If a valve face is burned or warped or the stem worn install a new one Too much clearance in the intake guide admits air and oil into the combustion chamber upsetting carburetion increasing oil consumption and making heavy carbon deposits Carbon prevents heat dissipation Clean metal is a good heat conductor but carbon insulates and retains heat This increases combustion chamber temperatures which causes warping and burning Unburned carbon residue gums valve stems and causes them to stick in the guide Deposits of hard carbon with sharp points projecting become white hot and cause pre ignition and pinging Valve Stem Seal A valve stem seal is used on the intake valve guides This seal must be replaced each time the valve is removed Stems and Guides Always check valve stems and guides for wear as shown in Figure 9 6 Use a hole gauge to measure the valve guide When clearance with stem exceeds original clearance by 0 002 inch 0 05 mm replace either valve or guide or both as may be necessary Always regrind seat to make concentric with the newly installed guide 9 3 VT 1020 FIGURE 9 6 VALVE STEM amp VALVE GUIDE INSPECTION Springs Check valve springs for cracks worn ends distortion and tens
70. GE REGULATOR CONNECTOR TERMINALS GENERATOR TESTING This section covers the test procedures for the genera tor rotor and stator windings Follow the troubleshoot ing procedures in this section to locate the required corrective action Perform the Field Voltage Test to confirm that field vol tage is availableto the rotor brushes through the voltage regulator for field flashing and voltage buildup Check all wire harness connectors and leads for continuity prior to lesting or generator disassembly Refer to Figure 8 1 for wire locations Field Voltage Test A voltage check can be made to determine if voltage is being supplied to the brushes from the voltage regulator for voltage buildup Connect a DC volimeter positive test lead into the voltage regulator plug P1 at pin 9 and connect the negative test lead into the voltage regulator plug at pin 10 The voltage regulator plug remains connected to the voltage regulator and test leads should be secured so they are not being held during testing See Figure 8 13 Electrical shock can cause severe A WARNING personal injury or death Use extreme caution when working on electrical circuitry Attach and remove meter leads only when generator set is not operating Do not touch meter or meter leads during testing Contact with rotating machinery can AWARNING result in severe personal injury Keep hands clothing jewelry and fingers clear while servic ing slip rings Start
71. IQUID WITHDRAWAL SYSTEM LPG System Vapor Withdrawal See the Installation Manual for important recom mendations regarding the installation of an LPG va por withdrawal type of fuel supply system Gensets equipped for vapor withdrawal of LPG must be equipped with a fuel shutoff solenoid valve and de SOLENOID PIGTAIL 2 th 10 es ES ES SSS ant VENT PRESSURE BALANCE HOSE Must extend outside the genset compartment to prevent accumulation of LPG in compartment in the event the diaphragm leaks and to prevent erratic fuel delivery because of pressure fluctuations cause by the cooling air flow through the compartment GAS SUPPLY HOSE TO CONNECTIONS AT THE GENSET THE CARBURETOR INLET N mand regulator These are available as a kit for mounting near the genset See Figure S 10 AWARNING LPG is flammable and explosive and can cause asphyxiation NFPA 58 Section 1 6 requires all persons handling LPG to be trained in proper handling and operating proce dures FUEL SHUTOFF SOLENOID VALVE MOUNTING BRACKET DEMAND REGULATOR The regulator must be mounted such that the diaphragm is ina vertical plane as shown to maintain calibrated gas pressure FIGURE S 10 LPG SYSTEM COMPONENTS FOR VAPOR WITHDRAWAL 5 13 LPG Supply Pressure LPG supply pressure must be maintained at 9 13 inches 229 330 mm water column WC
72. If granules are embedded in the rubber of the secondary valve wash the valve and seat clean Regulator Test Procedure Use compressed air and an automobile fuel pressure gauge to test the regulator 1 Attach the pressure gauge to the test port on the back of the regulator as shown in Figure 6 32 2 Attach a pressure hose to the inlet opening and open the air pressure valve 3 Ifthe primary seal is sound the gauge should read approximately 1 1 2 psi 10 3 kPa and the pres sure should remain constant A fluctuating pressure reading indicates a bad primary seat 4 Close the air pressure valve and observe the pres sure gauge The pressure should remain constant li the pressure reading drops the secondary seat is leaking If the regulator does not pass either test it must be rebuilt or replaced INLET OPENING 4 1 TEST PORT lt Tm FIGURE 6 32 REGULATOR TEST 5 1599 6 30 Fuel Filter The fuel filter see Figure 6 33 removes solid impurities such as rust and scale from the LP gas before they can clog the regulator and carburetor A magnet within the filter housing traps iron and rust particles and a filter element traps non magnetic particles The fuel filter operates at container pressure it must be carefully assembled to prevent leakage FILTER ELEMENT FILTER GASKETS BODY gt MAGNET FS 1614 FIGURE 6 33 FUEL FILTER Disassembly and Cleaning Procedur
73. Incorrect fuel mixture due to a incorrectly adjusted fuel mixture screws b incorrect float level c dirt in carburetor d vacuum leak Exhaust system blocked or restricted Incorrect valve tappet clearance Excessive engine wear or damage to engine Carburetor air preheater set incorrectly Excessive carbon build up No load speed set too low Gasoline sets only Prior to spec G only 1 Restricted airflow due to dirt or debris blocking air inlet or outlet 2 Dirt or oil covering engine cooling fins 3 ncorrect ignition timing 4 Lean fuel mixture due to a incorrectly adjusted fuel mixture screws b incorrect float level c dirt in carburetor Gasoline sets only Prior to spec G only 6 2 Corrective Action Adjust breaker point gap Reset spark plug gap Replace air cleaner Clean fuel filter Test fuel pump and repair or replace if faulty Adiust carburetor main and idle adjustment screws Adjust carburetor float level Disassemble carburetor and clean all internal passages Repair vacuum leak Locate and remove cause of blockage Adjust valve tappets see Engine Block Assembly section See Engine Block Assembly section In hot weather place air preheater in summer position Clean combustion chamber Adjust governor Clear away any debris that may restrict airflow to set Do not use compartment
74. LD ASSEMBLY 6 26 Carburetor Mixture Screw Adjustments Voltage frequency sensitive A CAUTION equipment such as VCRs televisions computers etc may be damaged by power line fre quency variations Some solid state devices are powered whenever connected to an AC output even if the device is not in actual operation For this reason disconnect all devices that are voltage or frequency sensitive before attempting any carburetor governor adjustments If disconnecting the devices is not possi ble open the circuit breaker s at the distribution panel or at the generator set if so equipped LPG carburetors have three adjustment screws The throttle stop screw sets the width of the throttle plate opening when the throttle is pulled back tothe closed position The idle adjustment screw controls the fuel mixture when the set is operating at no load The main adjustment screw controls the fuel mix ture when the set is operating at full load No other adjustments are necessary with an LPG car buretor because there are no float or choke adjust ments Do not make these adjustments until the ignition system governor and other fuel system components have been checked for correct operation If the carburetor is grossly out of adjustment turn the mixture screws in until they are lightly seated then turn the main adjust ment screw out 2 1 2 1 4 turns and the idle adjust ment screw out 1 1 4 turn This provides a ro
75. MP G MAY VARY DEPENDING ON GENSET SPEC LEVEL FUEL FILTER AIR CLEANER SUMMER WINTER ADJUSTMENT NEGATIVE BATTERY CONNECTION DC FUSE BLOWER HOUSING AC CIRCUIT BREAKERS REMOTE START CABLE CONNECTION OIL FILTER FUEL PUMP FUEL PUMP INLET FUEL PUMP ADJUSTMENTS eae cnore ity F2 MOU enor POSITIVE BATTERY CONTROLBOX START STOP CABLE CONNECTION SWITCH M 1604 14 SPARK BGE NHE PLUG LPG VAPORIZER e sp Vib ew DC FUSE BLOWER AC CIRCUIT BREAKERS HOUSING 4 5 2 4 1 REMOTE START CABLE CONNECTION CARBURETOR gt E ADJUSTMENTS SN Ss OIL FILTER FUEL FILTER AND bear SOLENOID ASSEMBLY OIL DRAIN FUEL INLET NEGATIVE BATTERY TO PLATE CABLE CONNECTION LOCATION OPTIONAL M 1604 9 FIGURE 2 1 TYPICAL EMERALD GENERATOR SETS 2 2 Section 3 Dimensions and Clearances MODELS CYLINDERS AND PISTON ASSEMBLY Cylinder Bore Std size honed Cylinder Taper Cylinder Out Of Round Max Clearance Cylinder BGE NHE All clearances listed at 70 21 C room temperature Values are in inches millimeters unless specified otherwise Dimensions apply to all BGE NHE gensets except as indicated 3 2490 3 2500 82 525 82 550 mm 0 005 0 13 mm 0 003 0 076 mm 0 0044 0 0066 3 5625 3 5635 90 488 90 513 mm 0 005 0 13 mm 0 003 0 076 mm 0 0070 0 0090 Ring Gap top and
76. NNING SPEC BGE NHE 60 HZ LP 611 1253 WIRING DIAGRAM j SCHEMATIC Ip xj l gri 81 CZ 1 CR5 i 1 0 9 10 0 C3 8 22 T C 2 7 rna gt BEGINNING SPEC N 50 HZ 1 511 12 4 yt 1 12 TB1 I L B 10 Ti L1 T2 L3 12 00 120 1413 1 1213 12 200 240V T4 T4 L1 ia T213 100 1201 200 240 T3 L3 100 120V 412 c82 NOTES 1 120 MAX ACROSS YR1 CONNZCTIONS 2 3 x 4 GROUNDED AC LEAD FOR IECLATED NEUTRAL REMOVE JUMPER W2 TB1 L3 LO AND CONNECT JUMPER TB1 LO VR1 CE MEG 3 FOR P2 J2 GROUND RMT STOP RMT START SW B SW B Tm gt VOLTAGE REGULATOR 11 IGN COL MODULE 520 SWITCH LOW G PRESS RESISTOR BATTERY CHARGE RS RELAY LPG ONLY K RELAY START SOLENCID G1 GENERATCR F1 FUSE SLOW SLOW SA E34 SPARK FLLGS EZ FUEL FUM OR FUEL SOL RECTIZIER LPG 512 CIRCUIT BREAKER OUTPUT CAPACITOR 811 BATTERY V a STARTER MOTCS REMOTE CONTRCL STZNOARD A2 REMITE CONTRCL DELUXE amp 1 CONTROL ASSY HENKEL 61 COHTRC ASSY CCI ECEI CEEDS T OR MITERAL zac WIRING DIAGRAM
77. NTROL STANDARD REMOTE CONTROL DELUXE CONTROL CONTROL ASSY BGE DESCRIPTION GR MATERIAL NO 611 1222 REV A MODIFIED y Redistribution or publication of this document by any means is strictly prohibited Onon Cummins Power Generation 1400 73rd Avenue N E Minneapolis MN 55432 763 574 5000 Fax 763 574 8087 Cummins and Onan are registered trademarks of Cummins Inc
78. NTS SPEC K GENSET 6 20 4 Remove the load and verify that frequency is within 62 63 Hz on 50 Hz sets 51 5 52 5 Hz Adjust the governor speed adjustment nut if necessary to obtain required frequency 5 Remove the idle adjustment screw cap limiter Turn the idle adjustment screw inward until voltage and frequency drop and the engine begins to run rough or starts hunting Back outthe idle adjustment screw as required for smoothest operation without hunting Replace the idie adjustment screw cap limiter with the lever located at mid position between lever stops Or for more accurate setting with CO meter if avail able after setting idle and main adjustment screws but before installation of plastic limiter cap setto the following with engine running no load 6 to 8 CO rated load 7 to 10 CO Install limiter caps as instructed above 6 With the unit at no load adjust the governor speed nut to 50 2 Hz 50 Hz sets 40 2 Hz With the throttle lever against the idle stop screw adjust the idle stop screw to 55 1 Hz 50 Hz sets 45 1 Hz 7 Readjust the no load speed to 62 63 Hz on 50 Hz sets 51 5 52 5 Hz and observe the stability of the set Set the voltage and frequency and adjust the sensitivity of the governor as specified under Gov ernor in this section Add and remove a full load several times to make certain the set does not bog down or hunt Carburetor Overhaul Carburetion problems that cannot be
79. OR FUEL SOL ICR6 RECTIFIER LPG ONLY 71 2 CIRCUIT BREAKER AC OUTPUT 5 CAPACITOR BATTERY 12 T LAT 21 426 ge b T e m qum am auum Amm nid Pub ob 4 GER Tua AE Ae Gh i i WA Ve GEO GEM GNE R RP ib aim d GA QUE UMP dus dE um ee SCHEMATIC REMOTE CONTROL STANDARD l WIRING DIAGRAM NO 611 1207 SPEC J BGE NHE 50 HZ WIRING DIAGRAM SCHEMATIC REV A MODIFIED 0 pum s on R6 SCHEMATIC ES B puck WIRING DIAGRAM B 4 SPEC J 60 2 100 V WIRING DIAGRAM SCHEMATIC 186586 VOLTAGE REGULATOR IGN COIL IGN MODULE SWITCH LOW OIL PRESS RESISTOR BATTERY CHARGE POTENTIOMETER RELAY LPG ONLY RELAY START SOLENOIO CHOKE GASOLINE ONLY GENERATOR FUSE SLOW BLOW 5A SPARK PLUGS FUEL PUMP OR FUEL SOL RECTIFIER LPG ONLY CIRCUIT BREAKER AC OUTPUT CAPACITOR BATTERY 12 STARTER MOTOR REMOTE CONTROL STANDARD REMOTE CONTROL DELUXE NO 611 1208 REV A MODIFIED NN WANS a APO MP dio
80. PETS CB2 CIRCUIT BOARD SO 4 Vit an f i Ai T 1 w ni 5 E j 4 M i ii MA FUSE a vont Aes m X i f fy Si n f S lt e e 2 jJ VOLTAGE REGULATOR VOLTAGE ADJUST ES 1775 3 FIGURE 7 3 BGE NHE CONTROL COMPONENTS BATTERY CHARGE RESISTOR R6 RECTIFIER CR10 FUEL PUMP E2 VIEW OF RESISTOR R6 a AND RECTIFIER 10 E e CIRCUIT BREAKER S gt far in 7 joan 3 CB1 CB2 XN eS Gis SSS LY Lent OW START SOLENOID E Ose gt i M ert i 4 CONTROL PRINTED CIRCUIT BOARD A1 VOLTAGE REGULATOR 1 VOLTAGE ADJUST 50 60 Hz 100 VAC DC FUSE F1 MODELS ES 1775 5s modified FIGURE 7 3a BGE NHE CONTROL COMPONENTS SPEC K 7 5 DC FUSE F1 9 SA SLO BLO BATTERY STARTER AND GENERATOR WIRING HARNESS CONNECTOR REMOTE CONTROL WIRING HARNESS CONNECTOR P2 1 bi ENGINE WIRING HARNESS CONNECTOR P3 H t i Panir SE e START STOP SWITCH 1 GN VOLTAGE ADJUST 50 2 ONLY 5 1774 FIGURE 7 4 CONTROL ASSEMBLY 1 7 5a CONTROL TROUBLESHOOTING Use the following troubleshooting guide to help locate problems
81. R LA SETS FS1607 1 FIGURE 6 17 CARBURETOR AND INTAKE MANIFOLD ASSEMBLY Carburetor Fuel Mixture Adjustments The most common cause of poor carburetion is incor rect adjustment of the idle or main mixture adjustments Significant variation from the correct settings may result in serious engine trouble An overly rich mixture not only wastes fuel but can increase engine wear by washing the lubricant from the cylinder walls and diluting the crankcase oil An overly lean mixture results in a loss of power flat spots in acceleration and a greater tendency to burn valves and spark plugs Mixture adjustments should be checked with every tuneup and whenever a carburetion problem is sus pected Before adjusting be sure that the ignition sys tem is working properly and that the governor is set correctly If the carburetor is grossly out of adjustment make these preliminary adjustments 1 Turn both mixture screws in until lightly seated 2 Turn the idle mixture screw out one full turn 3 Turn the main mixture screw out 1 1 4 full turns Voltage frequency sensitive A CAUTION equipment suchas VCRs televi sions computers etc may be damaged by power line frequency variations Some solid state devi ces are powered whenever connected to an AC outlet even if the device is not in actual operation For this reason disconnect all devices which are voltage or frequency sensitive before attempting any carburetor governor adjustm
82. REAKER aC OUTPUT 13 sank 4 5 CAPACITOR SPARK PLUG ooo BATTERY 12 2 220 240 STARTER MOTOR TSL3 m AS REMOTE CONTROL STANOARD T4 En A2 REMOTE CONTROL DELUXE GROUNDED AC LEAD FOR ISOLATED NEU Al 1300 3128 02 C EF CONTROL ASSY NHE NHEL TRAL REMOVE JUMPER wa TBI L3 LO AND AF 307 3128 0 C REF CONTROL ASSY BGE BGEL 611 1183 CONNECT JUMPER 81 10 VRI CB wee FIGURE 8 3 50 HZ BGE NHE GASOLINE FUELED GENERATOR SET WIRING DIAGRAM SCHEMATIC Prior to Spec G Breaker Points and Condenser 8 5 5 5 i ee SCHFMATIC Se BULK SIZE LVOUAGEREGUUMTOR rt ncn SSCS C scr cow On PRESS __ RESSTORSATERYCHARGE L1 LRUaesoMy x LRHAGSIRTSOENOD wm __ f GHOKE GASOLINE ONLY Lm RsesowBOWS Le Te FUEPUMPORFURLSOL ORCUTSREAKERACOUTPUD poss ewe SC Ce B L stanrenmoron
83. Remove a spark plug Reconnect the spark plug wire to the spark plug Ground the spark plug to bare engine metal Crank the engine amp strong spark should appear between the plug center electrode and the side electrode A weak spark means that the coil or wiring may be defective Direct Testing Coil With Ohmmeter The is removed from the circuit to perform this test 1 Remove all wires attached to the ignition coil 2 Remove the coil from the engine 3 Inspect the terminals for corrosion looseness cracks dents and other damage Look for carbon runners around the high voltage terminals These indicate electrical leakage Replace a damaged or leaking coil 4 Clean the outside of the coil with a cloth dampened in parts cleaning solvent 5 Measure resistance in the primary circuit connect the ohmmeter leads to the positive and negative terminals on the coil This resistance should be between 3 74 and 4 57 ohms Replace the coil if the resistance is higher high resistance indicates an open circuit or a poor connection inside the coil 6 Measure resistance in the secondary circuit connect the ohmmeter leads to the two high voltage terminals see Figure 6 8 This resistance should be between 17 45 Kohms and 19 8 Kohms Replace the coil if it is not within this specification Lower resistance indicates a shorted secondary winding and higher resistance indicates the coil has exces
84. Remove the throttle and choke plate retaining screws then remove the choke plates Pull out the throttle and choke shafts being careful notto dam age the Teflon coating on certain throttle shafts 3 Remove the main and idle mixture screw assemblies 4 Separate the lower section of the carburetor fuel bowl from the upper section fuel bowl cover ofthe carburetor 5 Note the position of the float assembly parts Slide out the retaining pin and remove the float assembly springs or clips and the needle vaive 6 Unscrew and remove the needle valve seat Carburetor Cleaning and Repair Procedure 1 Soakall metal components to be reused in carbure tor cleaner Do not soak rubber or plastic parts Follow the instructions on the cleaner container Most parts cleaning solvents are A WARNING flammable and can result in severe personal injury if used improperly 2 Removethe carbon from the carburetor bore espe cially where the throttle and choke plates seat Be certain not to plug the idle or main fuel port 3 Blow out all passages with compressed air Do not use wire or any cleaning utensil that might widen critical passages Wear goggles while performing this procedure 4 Examine any needle valves not included in the repair kit and replace if damaged Figure 6 20 Replace the float if it is damaged or contains fuel 5 Check the choke and throttle shafts for excessive play in their bore Replace them if necessary 6
85. STOR FUEL PUMP FUSE SPARK PLUG FUEL PUMP IGN COIL CIRCUIT BREAKER AC OUTPUT CAPACITOR BATTERY 12V STARTER MOTOR REMOTE CONTROL STANDARD REMOTE CONTROL DELUXE VRI VOLTAGE REGULATOR 53 IGN POINTS 52 SWITCH LOW OIL PRESSURE RESISTOR BATTERY CHARGE Ki RELAY START SOLENOID HI CHOKE G1 GENERATOR 300 3091 01 REF CONTROL ASSY BGEL tem Ss Oty jDescrouonorMatenat FIGURE 8 2 60 HZ BGE NHE GASOLINE FUELED GENERATOR SET WIRING DIAGRAM SCHEMATIC Prior to Spec G Breaker Points and Condenser 8 4 REMOTE PANELS DELUXE STANDARD ov 1 _240 MOT NEUT one LOAD LOAD rcm 9 20 120 E E E c3 E START E4 33 C4 Flt 24 234936 _ 1 m P eje T Te INE 3 c 372953 5 1 STOP START L E3 R7 SWITCH LOW OIL PRESSURE 2 JUMPER SEE NOTE 2 CR9 RECTIFIER FUEL PUMP RESISTOR BATTERY CHARGE L VOLTAGE REGULATOR 7 Pn IGN POINTS WIRING DIAGRAM POTENTIOMETER RESISTOR FUEL PUMP RELAY START SOLENOID CHOKE GENERATOR FUSE SLOW BLOW 5A RECONNECTION CHARTS 4 WIRE xin cr EE 77 GI T2 a 131 4 aa E2 FUEL PUMP vis i3 EI IGN COIL 220 240V CBI2 CIRCUIT B
86. Screws 30 33 41 45 Stator Clamp Screws 10 12 11 16 Adapter to Engine 25 27 34 37 Mounting Screws Adapter to Generator 25 34 Mounting Screws Rear Vibration Isolator 30 33 41 45 Center Screw Flange to Drip 10 12 11 16 Tray Screws Front Vibration Isolator Flange to Oil 19 22 26 30 Base Screws Section 5 Preparing to Service TROUBLESHOOTING Most service procedures require that the genset be removed from the vehicle Because genset installations vary removal procedures vary If removal is a problem contact the vehicle manufacturer or genset installer for assistance Many procedures require that the outer sheet metal cover assemblies of the generator set be removed This section covers this procedure The main service areas are covered in these manual sections Section 6 Engine Primary Systems Section 7 Control System e Section 8 Generator e Section 9 Engine Block Assembly Troubleshooting charts in each section provide fixes for common malfunctions ENGINE TOOLS Torque wrench 0 175 ft lbs 0 240 Nem Feeler gauge Pressure gauge Spark plug gap gauge Cylinder compression tester Carburetor adjustment wrench Points adjustment tool Flywheel puller Snap ring pliers Gear puller with puller ring Cylinder ridge reamer Combination main and cam bearing remover Combination main and cam bearing driver Oil seal loader and driver Piston ring compressor Piston ring sprea
87. Spec G GENERATOR SET Dimensions BGE NHE 14 0 in 356 14 6 in 371 mm m 25 0 in 635 MM uc eros ee ex o morer Deer x 25 3 in 643 mm issu qur edes Unidas eddie vet 18 8 in 478 21 1 in 535 mm Weight Approximate not including exhaust components 5b and 60 5 216 1b 97 9 KO sve ess HC CERERI 230 Ib 104 kg Fuel Inlet Connection BGE amp NHE GASONNG rts 1 4 in barb fitting Propane Withdrawal SI EDO xev ENS 1 4 in NPTF Propane Vapor Witlidr a e Su qp i es olde vb wel 3 4 in NPTF Batory 2 ka unu b CU eU EE NAVI acea d 12 volts Recommended Battery Capacity SAE No 60 360 or equiv minimum 360 cold cranking amperes Cranking GUINEM blend xim dx CREDE NEN UNS EDDIE DE MUSS 100 amperes r min at dues IPAE 1800 OASIS S odisea aol s utto M Lo ctu ae NN quM Gate ce E Ld Nd En 1500 OUMU HAUTS Unity Power Factor Under Floor mount generator set with compartment housing has slightly larger dimensions Refer to Installation Manual 2 1 GOVERNOR ADJUSTMENTS SPARK PLUG BGE NHE fwe NOTE CONFIGURATION AND PLACEMENT OF FUEL PU
88. TION CABLE CONNECTION FIGURE S 1 TYPICAL EMERALD GENERATOR SETS 5 2 3 On Page 7 5 replace Figure 7 3a with Figure on Page of this supplement 5 3 Supplement 965 1069 Date 11 98 Insert with Title BGE NHE Service Manual Number Date 965 0528 9 94 PURPOSE This Supplement transmits the revisions to the Service Manual necessary to cover changes beginning with Spec N genseis Gensets beginning with Spec N have a sealed type remote control connector and single 16 pin connector on the genset control board SERVICE MANUAL 965 0528 REVISIONS ds Do not discard Supplement 965 1060 which covers changes beginning with Spec M Look for statement BGE Spec F through K NHE Spec E through K on the front cover Strike out the K in both places and write in P in both places On Page 6 14 Step 6 change 12 6 and 15 4k ohms to 12 6k and 15 4k ohms On Page A 1 Appendix A write Prior to Spec N In lieu of testing the connec tor pins with a meter use control board tester No 420 0572 and the appropriate adapter har ness to determine whether a contro board needs to be replaced Follow Instruction Sheet 3220 packaged with the tester Beginning Spec N See Page A 11 Insert attached Page A 11 after Appendix A Page A 10 Replace Page B 1 Appendix B with the attached Page B 1 and add the attached Pages B 8 through B 11 On Page ii Table of Contents change
89. a liquid withdrawal type of LPG supply sys tem Before disconnecting LPG fuel con nections make sure the the fuel shutoff valve s at the LPG container s are closed and that the vehicle is outside and away from pits or basements or other below grade spaces where LPG could accumu late ForLPG vapor withdrawal gensets see Figure S 10 disconnect the gas supply hose at the carburetor and the fuel solenoid shutoff valve leads at the control box on the genset If the pressure regulator solenoid valve assembly is also to be removed cap the end of the fuel sup ply line with a threaded pipe cap to prevent fuel from escaping if someone inadvertently opens the shutoff valve s FUEL SYSTEM BEGINNING SPEC M The carburetor mixes air and fuel in the correct pro portion for good performance The governor oper ates the throttle to maintain a nearly constant en gine speed frequency as the load varies Figure S 1 is representative of most of the fuel system parts LPG liquified petroleum gas systems do not use an air preheater or choke and have different fuel connections See Automatic Choke Fuel Pump and LPG System Components in this section for de tails of the other parts of the fuel system Gasoline and LPG are flammable and explosive and can cause severe personal injury or death Do not smoke if you smell gas or gasoline vapors or are near fuel tanks or fuel burning equipment or are in an area sharing ventilation with such
90. ain the piston to cylinder wall clearance Refer to the Dimensions and Clearances section for the recommended piston clearance CT 1063 FIGURE 9 23 PISTON CLEARANCE MEASUREMENT Fitting Piston Rings Before installing new rings on the piston check the ring gap by placing each ring squarely in its cylinder at a position corresponding to the bottom of its travel Figure 9 24 The gap between the ends of the ring is given in Dimensions and Clearances section for the recom mended piston clearance The practice of filing ring ends to increase the end is not recommended If the ring end gap does not meet specifications check for the correctness of ring and bore sizes A cylinder bore that is 0 001 inch 0 03 mm undersize will reduce the end gap 0 003 0 08 mm Rings that are 0 005 0 010 0 020 0 030 and 0 040 inch installing Piston in Cylinder 0 13 0 25 0 51 0 76 and 1 02 mm oversize are to be used on corresponding oversize pistons Rings of the 1 Turn the crankshaft to position on the number one tapered type are usually marked TOP on one side or rod bearing journal at the bottom of its stroke identified in some other manner Install these rings with 2 Lubricate the number one piston assembly and the identification mark toward the closed end of the inside of the cylinder Compress the rings with a ring piston compressor as shown in Figure 9 26 3 Position the piston and rod assembly in the cylinder block Notched s
91. andling the assembly Component Inspection While the generator components are disassembied perform rotor and stator tests as indicated in Generator Testing this section Also check mechanical condition of generator parts rotor end bearing generator hous ing and o ring etc for signs of wear Refer to proper unit Parts Manual and replace any components found to be defective Generator Assembly Use the following procedure to assemble the generator 1 Refer to Figure 8 10 and use the following proce dure to install the stator into the stator housing a Position the stator so the output leads align with access hole to contro housing then carefully lower the stator straight down into the stator housing Careless handling of the sta ACAUTION ior can damage the insula tion on the stator windings Do not brush the windings against the housing as it is lowered into housing and take care not to drop or drag ihe stator on work area outside of stator housing b Install the three stator clamps and capscrews c Draw stator leads into control box Connect stator leads T1 T2 T3 and T4 to terminal board 1 e Q1 and Q2 to voltage regulator VR1 harness J4 e B1 and B2 to control printed circuit board harness J1 e Rotate the stator housing assembly onto a smooth clean surface resting on bel shape of housing end bearing face up 2 Install the brush block assembly into the stator housing Lift the br
92. arbon monoxide an odorless and colorless gas Carbon monoxide is poisonous and can cause unconsciousness and death Symptoms of carbon monoxide poisoning can include Dizziness Throbbing in Temples e Nausea Muscular Twitching Headache e Vomiting Weakness and Sleepiness Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist seek medical atten tion Shut down the unit and do not operate until it has been inspected and repaired Never sleep in vehicle with the generator set running unless the vehicle interior is equipped with an operating carbon monoxide detector Protection against carbon monoxide inhalation also includes proper exhaust system installation and visual and audible inspection of the complete exhaust system at the start of each generator set operation 1 RV 10 2 Appendix A Troubleshooting Charts These pages form an appendix to the service manual This information was prepared by the Onan Service Training Department in the form of simplified guides to troubleshooting a variety of the circuit boards used on the BGE NHE generator sets while this information is accurate make sure to follow the complete procedures outlined in the appropriate service manual sections for reasons of safety and product integrity e A 2 Troubleshooting Electronic Ignition Module 3 4 Emerald Control Functions
93. arentheses by the specifications for 50 Hz gensets 1 Connect rated load A Load watts is the product of volts V and amps A Load watts V x A A 1 0 power factor obtainable with a re sistance load bank is assumed True rated output might not be obtained if appli ances are used as part of the load B See Generator if output voltage cannot be adjusted to within 10 percent of rated volt age Table S 1 TABLE S 1 VOLTAGE SPECIFICATION RATED MAXIMUM MINIMUM OUTPUT NO LOAD FULL LOAD VOLTAGE VOLTAGE VOLTAGE CA 12 2 24 2 Check and adjust droop A If droop from no load frequency is more than 3 Hz 3 5 Hz for Model BGE or 4 Hz 3 5 Hz for Model NHE turn the governor sensitivity adjusting screw Figure S 2 one turn counterclockwise Disconnect the load and if necessary readjust the governor speed adjusting screw to return to 62 63 Hz 51 5 52 5 Hz no load fre quency Check droop again and repeat the adjustments if necessary If droop from no load frequency is less than 2 Hz 2 Hz for Model BGD or 3 Hz 2 Hz for Model NHD turn the governor sensitivity adjusting screw Figure S 2 one turn clockwise Disconnect the load S 7 and if necessary readjust the governor speed adjusting screw to return to 62 63 Hz 51 5 52 5 Hz no load frequency Check droop again and repeat the adjust ments if necessary 3 Check governor response under 1 4 1 2 a
94. ash oil from the walls but leave metal particles 8 Dry crankcase and coat with oil Deglazing Cylinder Bores Deglaze the cylinder bores if there are no scuff marks and no wear or out of round beyond specifications before installing new rings Deglazing gives a fine finish but does not enlarge cylinder diameter so the original pistons with new rings may still be used The reason for deglazing a cylinder is to provide cavities to hold oil during piston break in 1 Wipe cylinder bores with a clean cloth which has been dipped in clean light engine oil 2 Use a brush type deglazing tool with coated bristle tips to produce a crosshatch pattern in the cylinder bore 3 The deglazing tool should be driven by a slow speed drill Move deglazing tool up and down in cylinder 10 to 12 complete strokes rapidly enough to obtain a crosshatch pattern as shown in Figure 9 30 EI Pa qu pt J 4 US B pU y 4 A 2 PP E 4 M a AN EL PRODUCE CROSS HATCH SCRATCHES FOR FAST RING SEATING Cab AVOID THIS FINISH FIGURE 9 30 CROSSHATCHING 9 14 Never use gasoline or commer A CAUTION cial cleaners to clean cylinder bores after deglazing or honing These solvents will not remove abrasives from the walls Abra sives not removed from engine will rapidly wear rings cylinder walls a
95. assembly onto a smooth clean surface resting on end bearing face bell shape of housing facing up b Disconnect stator leads e T1 T2 T3 and T4 from terminal board TB1 e Q1 and Q2 from voltage regulator VR1 har ness J4 e B1 and B2 from control printed circuit board harness J1 c Draw stator leads from control box d Removethethree stator clamps and capscrews e Carefully lift the stator straight up until it clears the stator housing Set stator to reston a smooth clean surface Careless handling of the sta ACAUTION tor can damage the insula tion on the stator windings Do not brush the windings against the housing as it is litted clear and take care not to drop or drag the Stator on work area outside of stator housing G 1213 FIGURE 8 10 STATOR HOUSING DISASSEMBLY Rotor Bearing Removal Use a gear puller to remove the bearing from the rotor shaft Attach the gear puller so that the gear puller arms contact the inner race of the bearing Figure 1 The bearing will be damaged if A CAUTION pulled by the outer race If the bearing is to be reused it must be pulled by the inner race 8 12 ES 1495 G 1175 FIGURE 8 10a BEARING REMOVAL Bearing Replacement 1 Clean the bearing and shaft mating surfaces 2 Apply Loctite 680 adhesive to the shaft mating surface 3 Apply Loctite 747 activator to the bearing mating surface 4 Install the bearing and allow ten minutes curing time before h
96. before continuing 5 6 Remove the bolts that secure the side supportto the drip tray and the underfloor bracket Also remove bolts from the rear support bracket if removing an NHE set Lift the generator slightly until the safety catch on the side support is clear of the tray Pull the support forward and upward until disengaged from the tray and underfloor bracket Remove the side support to provide the clearance needed for lowering the set Remove the safety catch from the center of each hinge assembly then remove the U shaped hinge pin Slowly lower the generator set until it is clear of all obstructions and can be removed from under the vehicle ae NN FORK LIFT FIGURE 5 4 COMPLETE SET REMOVAL M 1601 2 Section 6 Engine Primary Systems INTRODUCTION The engine primary systems inciude the following Exhaust system Cooling system e ignition system Crankcase ventilation system Governor TROUBLESHOOTING The engine primary systems can often be serviced with out removing the generator set from the recreational vehicle and without major disassembly of the set Use the following troubleshooting guide to help locate prob lems related to the engine primary systems Refer to Troubleshooting Generator Set Control in Section 7 for probiems related to starting the generator set Fuel system gasoline Fuel system LPG liquid withdrawal Fuel system LPG
97. by any means is strictly prohibited Supplement 965 1065 Date 1 97 Insert with Title BGE NHE Service Manual Number Date 965 0528 9 94 PURPOSE SERVICE MANUAL 965 0528 REVISIONS 1 Insert this Supplement in its entirety under This Supplement is used in addition to Supplement the front cover of the manual Do not discard 965 1060 It transmits the revisions to the Service supplement 965 1060 Manual necessary for covering all changes made 2 On Page 2 2 replace Figure 2 1 with Figure S 1 since Supplement 965 1060 was issued on Page S 2 of this supplement WARNING A The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 5 1 BGE NHE GOVERNOR SPARK ADJUSTMENTS SPARK PLUG Gasoline PLUG FUEL FILTER AIR CLEANER SUMMER WINTER ADJUSTMENT NEGATIVE BATTERY CONNECTION DC FUSE BLOWER HOUSING 4 A AC CIRCUIT BREAKERS OIL FILTER FUEL PUMP FUEL PUMP INLET ADJUSTMENTS MWA FUEL PUMP J 2 MOU Ry POSITIVE BATTERY CONTROL BOX START STOP CABLE CONNECTION SWITCH REMOTE START CABLE CONNECTION BGE NHE SPARK L P G VAPORIZER NEGATIV BLOWER BATTERY CONNECTION HOUSING CARBURETOR ADJUSTMENTS OIL FILTER FUEL FILTER AND OIL FILL SOLENOID ASSEMBLY OIL DRAIN FUEL INLET REMOTE START CABLE POSITIVE BATTERY CONNEC
98. center pin extends out 3 4 inch 19 mm from the end of the camshaft This distance provides an in and out travel distance of 7 32 inch 5 6 mm 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 in a new pin into place or it will be damaged The camshaft center pin cannot be pulled outward or removed without damage If the center pin extends too far the cup will not hold the flyballs properly 9 7 CRANKSHAFT GEAR TIMING GEARS AND CAMSHAFT If replacement of either the crankshaft gear or the cam shaft gear becomes necessary it is recommended that both gears be replaced To remove the crankshaft gear first remove the snap ring and retainer washer then attach the gear pulling ring using two No 10 32 screws Figure 9 15 Tighten the screws alternately until both are tight Attach a gear puller to the puller ring and remove the gear The camshaft and gear are removed as an assembly Before removing the camshaft and gear assembly remove the cylinder head and valve assemblies Then remove the operating plunger for the breaker points and tappets Each timing gear is stamped with O nearthe edge The gear teeth must mesh so that these marks exactly coin cide when the gears are installed in the engine When installing the camshaft gear and shaft assembly be sure that the thrust washer is pro
99. commended bearing clearance Whenever making major repairs on the engine always inspect the drilled passages of the crankshaft Clean them to remove any foreign material and to provide proper lubrication of the connecting rods Lubrication Lubricate the front and rear main bearings with engine oil Use oil or gear lubricant to hold the front thrust washer in place against the engine block The flat side of the thrust washer goes against the block Position the crankshaft so the crank throw is aligned with the notch atthe rear of the crankcase and install the crankshaft Make sure the front thrust washer did not slip out of place during installation Place the oil seal loader on the oil seal guide and driver and insert into the rear bearing plate Remove the seal guide and driver leaving the loader in the bearing plate The loader prevents the seal from being cut on the crankshaft keyway during installation of the rear bear ing plate Use oil or gear lubricant to hold the shim s and rear thrust washer in position on the rear bearing plate see Figure 9 32 The shim goes against the bearing plate and the fiat surface of the thrust washer goes againstthe shim Place the bearing plate gasket in position on the block making sure the oil hole on the back of the block is exposed Install the rear bearing plate and fasten with two nuts or capscrews tightened to the specified torque Make sure the rear thrust washer and shim s did not
100. d NHE Operator s Manual 965 01 28 and Instal lation Manual 965 0628 are recommended as addi tional sources of information Read all service procedures completely before begin ning any repair work and observe all cautions and warn ings It is extremely important that the generator set installation maintain compliance with the applicable codes and standards for RV installations see Installa tion Manual The most critical areas of concern include the exhaust system fuel system electrical wiring com partment construction and ventilation system Improper servicing can create an unsafe installation that can result in damage to the vehicle and equipment or can cause severe personal injury or death to the user MODEL IDENTIFICATION When contacting an Onan Dealer or Distributor always supply the complete Model Number and Serial Number as shown on the set nameplate Figure 1 1 This infor mation is necessary to identify your set when ordering replacement parts Always use genuine Onan replacement parts obtained from an authorized Onan Dealer or Distributor Univer sal replacementtype parts usually intended for automo tive use often look similar but might not perform to Onan specifications Only genuine Onan replacement parts are designed and tested for the application to provide reliable service and dependable operation The model number is made up of code segments that designate various features or options Model No
101. d run lamp do not operate Current sensing resistor R4 on control board 1 has opened caused by a short in the remote control wiring between control board P2 J2 terminal 6 5 and remote control time meter run lamp battery condition meter Generator Set 1 Faulty set control start stop switch S1 1 Check start stop switch and replace Does Not Stop if defective After Switch is Pushed to Off 2 K5 relay not energizing 2a Check for continuity and correct if circuit Position its N O contacts should be open due to is open a Open circuit to K5 relay coil b Replace K5 relay b Faulty K5 relay Note Always 3 Defective K3 relay 3 Replace control circuit board remove load a few minules before stopping to allow set to cool down LPG Sets Only Section 8 Generator GENERATOR CONTROL COMPONENT DESCRIPTIONS The generator and its control components consist of the following Refer to Figure 8 1 Contro Printed Circuit Board e Brushes e Rotor e Stator and Housing e Terminal Board TB1 e Voltage Regulator VR1 e Circuit Breaker s CB1 and CB2 if equipped e Wiring Harness to Load s Refer to Section 7 Control for further information Control Printed Circuit Board A1 Initial excitation voltage to the generator rotor is supplied by the generator set starting battery BT1 During cranking of the engine DC voltage of the battery is supplied through N C contacts of generator relay K2
102. der Cylinder hone Valve seat cutter Valve spring compressor Valve lock replacer Valve seat driver Valve guide driver Slide hammer Piston groove cleaner Outside micrometer set 0 to 4 in Telescoping gauge set 1 2 in to 6 in Hole gauge 0 300 in to 0 400 in Plasti Gage bearing clearance guide Standard Torx screwdriver a 5 1 GENERATOR AND CONTROL TOOLS Lead or dead blow hammer Battery hydrometer VOM multi tester Frequency meter Armature growler Load test panel Jumper wires Many of these tools are available through the Onan tool catalog publication 900 0019 SAFETY CONSIDERATIONS Be totally aware of generator set hazards Study the safety precautions on the inside front cover of this man ual and know the hazards listed in Table 5 1 Approach the job in a safety conscious manner to avoid injury and death Safeguards to Avoid Hazards Use personal protection Wear protective safety equipment such as Safety shoes Gloves Safety glasses Hard hats Ear plugs Do not wear rings jewelry or loose clothing these might get caught on equipment or conduct electricity Reduce the hazard A safe orderly work area and well maintained equipment reduce hazard Leave all guards and shields in place on machinery and maintain equipment in top condition Store flamma ble liquids in approved containers away from fire flame spark pilot light arc producing equipment and other
103. ders when the generator set is in the lowered tilted position Do not leave the generator set in this position for more than 30 minutes if the oil has not been drained 504 Partial Set Removal Park the recreational vehicle on as level a surface as possible surface must support floor jack wheels Then follow these instructions very carefully Fuel exhaust electrical and control connections must be disconnected as described previously 1 Park the vehicle on a level surface that can support the floor jack wheels Put the transmission in its PARK position lock the brakes and remove the ignition key Make sure no one moves the vehicle while performing this procedure Dropping the generator set can AWARNING result in severe personal injury or death Make sure no one moves the vehicle during this procedure and that the procedure is performed very carefully and only as instructed 2 Position a floor jack under the reinforcement ribs of the drip tray as shown in Figure 5 3 3 Raise the floor jack until it just makes contact with the drip tray then puta little upward pressure under the drip tray REAR SUPPORT BRACKET NHE ONLY FRONT SUPPORT BRACKET SUPPORT BRACKET PLACE FLOOR JACK UNDER DRIP TRAY REINFORCEMENT RIBS BOLTS 4 DRIP TRAY FIGURE 5 3 PARTIAL SET REMOVAL 4 Remove the four bolts from the front support brackets and the rear brackets NHE only and remove the
104. drive in a new roll pin The pin should be driven about 1 10th of an inch 2 5 mm from the edge of the plastic retainer or in such a way that it is evenly spaced from each side B D Place the spring cover over the top of the plastic retainer then place the return spring on top of the retainer E With a washer placed over the point of the plas tic retainer push the metal retainer into the hole of the plastic retainer as far as it will go 15 Mount the starter on the generator stator housing using capscrews lockwashers and nuts Tighten the mounting screws to 30 33 lb ft 41 45 Nem 16 Connect generator set positive battery cable to starter terminal Connect generator set negative termina to generator set starting battery 6 37 Section 7 Control INTRODUCTION The control system governs the following functions Starting Monitoring for fault conditions Instrumentation Stopping This section covers how the control operates where the components are located and basic troubleshooting procedures CONTROL DESCRIPTION The generator set control consists of the components listed below see Figure 7 1 Control panel assembly Printed circuit board A1 e Start Run Stop switch 51 Fuse F1 e Start solenoid K1 Ignition relay K5 LPG units Fuel pump E2 gasoline units e Fuel solenoid E2 LPG units e Remote start control optional e Circuit breaker s
105. ds Q1 Q2 2 089 ohms 50 Hz Models e Leads T1 T2 0 502 ohms Leads T3 T 0 502 ohms Leads B1 B2 0 112 ohms e Leads Q1 Q2 2 873 ohms Areading less than these values indicates shorted wind ings Replace a shorted stator with a new stator 8 18 TEST LEADS T1 T2 T3 14 B1 B2 and Q1 Q2 FOR OPEN OR SHORTED WINDING B1 B2 01 02 G 1214 1 FIGURE 8 17 TESTING STATOR FOR OPENS OR SHORTS section 9 Engine Block Assembly GENERAL The engine block assembly includes the pistons and connecting rods crankshaft camshaft valves and lif ters cylinder heads lubrication system timing gears governor mechanism bearings and cylinder block Per forming any major service on the block assembly will require that the generator set be removed from the coach see Set Removal section In addition to gain complete access to the block assembly the control generator and all primary engine systems must also be removed Refer to the previous sections for the disas sembly and removal procedures FILTER AND ADAPTER Open the oil drain valve and drain the crankcase oil Remove the filter see Figure 9 1 by turning counter clockwise with a filter wrench The low oil pressure cut off switch is installed in a threaded hole in the filter adapter and may be removed if required Loosen the two capscrews that secure the adapter to the engine block and remove the adapter and gasket Assembly is the reverse of d
106. e LPG is extremely flammable Severe AWARNING personal injury or death can result if itis accidentally ignited Eliminate all possible sources of ignition including fire flame spark pilot light arc producing equipment or other ignition sources before performing this procedure 1 Remove the four capscrews and lock washers that hold the filter bowl to the filter body 2 Separate the filter bowl from the filter body and discard the O ring seal 3 Remove the nut and washer from the center stud and pull out the filter element 4 If the filter element is clogged wash the element in kerosene Blow it dry with low pressure 30 psi 207 kPa compressed air Replace the filter element if damaged Wipe the center stud magnet clean of any rust or scale particles that have collected Install a clean filter element using two new gaskets and securely tighten the center stud nut Place anew O ring in the filter bowl sealing groove Align the reference mark on the filter bow with the reference mark on the filter body Install capscrews 4 and lock washers 4 Tighten the capscrews to 56 to 74 in Ibs 6 5 to 8 3 Nem torque When the fuel system is pressurized check the filter for leaks Solenoid Valve The solenoid valve see Figure 6 34 provides a positive fuel shutoff when the generator set is stopped The solenoid must be energized for fuel to flow to the regula tor A faulty valve must be replaced To bench t
107. e Regulator Adjustment information that follows and check that main fuel supply system is supplying fuel to the generator set solenoid valve 3 For satisfactory operation it may be necessary to reset the gas adjustment screw due to variations in the BTU content of local LP gas supplies and for changes in the ambient temperature The idle and main adjustment screws on the gasoline carburetor will have no effect during LP gas operation 2 A T E 7 7 H QM hn la he dli po LOOSEN GAS LOCKNUT ADJUSTMENT SCREW FS 1765 FIGURE 6 35 ADJUSTING FUEL FLOW AT CARBURETOR Demand Regulator Adjustment Procedure Difficult starting may be caused by slow cranking due to a weak battery Temperatures below 32 F 0 C increase the load on the battery at cranking speed Low cranking speed in turn inhibits proper intake vacuum for starting lf the generator set fails to start or operate properly and the starting or ignition systems are not at fault check and adjust the demand regulator inlet pressure and the regulator lockoff as follows 1 Close the gas supply valve at the fuel tank s and remove the 1 8 inch pipe plug from the regulator test hole See Figure 6 36 GAS HOSE MANOMETER 2 GAS REGULATOR ADJUSTING g SCREW N VENT PLUG A lt 1 8 PIPE PLUG r zw ed
108. e personal injury The genset should be shut down and allowed to cool before performing this procedure 1 Remove the muffler and tail pipe assembly see Exhaust System section to access the cooling system 2 Removethe capscrews thatsecure the noise shield see Figure 6 4 to the engine Lift off the noise shield 3 Remove the three nuts along the lower edge of the scroll that hold the fan guard to the scroll 4 Remove the capscrews that fasten the scroll to the backplate and lift it away from the scroll NOISE SHIELD CYLINDER AIR HOUSINGS SCROLL FLYWHEEL FIGURE 6 4 COOLING SYSTEM 5 Remove the screws that fasten the cylinder air housings to the backplate and cylinder heads Lift off the air housings 6 Loosen the flywheel capscrew and back it out several turns 7 Attach the puller tool to the flywheel see Figure 6 5 The tool has two jack screws that fit into the holes tapped in the flywheel 6 9 8 Tighten the puller center screw until the flywheel comes loose Remove the puller flywheel center screw and washer Inspect the flywheel and replace it if any air vanes are missing 9 Remove the lead from the low pressure cutoff switch 10 Remove the exhaust manifold see Exhaust System in this section 11 Remove the capscrews that secure the backplate to the engine Lift off the backplate 12 Use a brush or low pressure compressed air to remove any dirt or debris that may be
109. e the sharp contact will be destroyed This is especially important where chrome cobalt faced valves and seats are used Valve faces must be finished in a machine to 44 degrees Every valve must have a minimum of 1 32 inch 0 8 mm margin Figure 9 8 If the valve has less margin than this it will heat up excessively It will retain that heat during the compression stroke and pre ignite the mixture causing loss of power and economy This valve is also susceptible to warping and breakage WARPED VALVE WITH KNIFE EDGE KNIFE EDGE GOOD MARGIN 1 0 30 INCH MINIMUM _ 8 MM M 1184 FIGURE 9 8 VALVE MARGIN Not all valves can be reconditioned A badly warped valve must be replaced because the excessive grinding required to make it seat correctly removes the margin To make a valve gas tight every trace of pitting mustbe removed from the valve face and seat Deeply pitted or cut valves must be replaced because the grinding removes the margin Valve seats should be ground with a 45 degree stone and the width of the seat band should be 1 32 inch to 3 64 inch 0 79 to 1 2 mm wide Grind only enough to ensure proper seating Place each valve its proper location Check each valve for a tight seat Make several marks at regular intervals across the valve face using machinists bluing Observe if the marks rub off uniformly when the valve is rotated part of a turn against the seat The valve seat should contact the valve face evenly a
110. e these rings from the piston using a piston ring spreader as shown in Figure 9 19 Mark each piston to make sure the rod will be assembled on the piston from which it was removed Remove the piston pin retainer from each side and push the pin out AU CT 1059 FIGURE 9 19 REMOVING PISTON RINGS Remove dirt and deposits from the piston surfaces with an approved cleaning solvent Clean the piston ring grooves with a groove cleaner or the end ofa piston ring filed to a sharp point Figure 9 20 Care must be taken not to remove metal from the groove sides N CT 1080 FIGURE 9 20 CLEANING RING GROOVES Using a caustic cleaning solvent or ACAUTION wire brush for cleaning pistons will cause piston damage Use only parts cleaning solvent When cleaning the connecting rods in solvent include the rod bore Blow out all passages with low pressure compressed air Inspection The following covers inspection procedures for pistons and connecting rods Piston Inspection Inspect the pistons for fractures at the ring lands skirts and pin bosses Check for wear at the ring lands using a new ring and feeler gauge as shown in Figure 9 21 Replace the piston when the side clearance of the top compression ring reaches 0 008 inch 0 20 mm 1061 FIGURE 9 21 CHECKING RING LAND Improper width rings or excessive ring side clearance can result in ring breakage New rings in worn ring grooves do not have
111. e valve and spring If the setting is incorrect remove the float and bend the tab to adjust Bend the float only at the point indicated Attempting adjustments with the ACAUTION float assembly installed can damage the inlet needle and seat Remove the float assembly before making adjustments 0 59 0 63 IN Usum BEND TAB TO ADJUST BOWL FLANGE TAB CONTACTING HEAD OF PIN WITH FULL WEIGHT OF FLOAT COMPRESSING INLET VALVE SPRING GASKET FS 1611 FIGURE 6 22 FLOAT LEVEL 5 Install the float bow and main mixture screw assembly Make sure the index line on the float bowl altitude scale lines up with the arrowhead castin the mating flange of the carburetor Turn the screw in until lightly seated and then turn it out 1 1 4 turns Forcing the mixture adjustment ACAUTION screws tight will damage the needle seat Turn in only until tension can be felt 6 When carburetor is installed on set make final idle and main mixture adjustments as described in the Carburetor Fuel Mixture Adjustment section Choke The choke assembly consists of a bi metal coil an electric heating element and a choke pulloff diaphragm The coil is connectedto the choke shaft Itturns the shaft to hold the choke plate nearly closed when the engine is cold When the engine starts vacuum from the intake manifold causes the pulloff diaphragm to pull in and partially open the choke As the engine runs the heating element receives elect
112. ea and leave the generator set compartment door open for several min utes before performing this test Use extreme care when performing AWARNING this test procedure To avoid shock do not hold the plug without adequate insulation 1 Make certain that no gasoline fumes or other flam mable fumes are present Park the vehicle in a well ventilated area and leave the set compartment door open for several minutes before performing this test 2 Remove a spark plug 3 Reconnect the spark plug wire to the spark plug 4 Ground the spark plug to bare engine metal 5 Crank the engine A strong spark should appear between the plug center electrode and the side electrode A weak spark means that the coil or wiring may be defective 6 13 Direct Testing Coil With Ohmmeter The coil is removed from the circuit to perform this test 1 2 3 Remove all wires attached to the ignition coil Remove the coil from the engine Inspectthe terminals for corrosion looseness cracks dents and other damage Look for carbon runners around the high voltage terminals These indicate electrical leakage Replace a damaged or leaking coil Clean the outside of the coil with a cloth dampened in parts cleaning solvent Measure resistance in the primary circuit connect the ohmmeter leads to the positive and negative terminals on the coil This resistance should be between 3 87 and 4 73 ohms Replace the coil if the resistance
113. ed outdoor loca tion far from fire or flame 2 Disconnect the vehicle negative battery cable and the generator set negative battery cable from their battery terminals 3 Close fuel shutoff valves at the fuel tank for the generator set fuel supply system and any other fuel supply system Close the fuel shutoff valves for any auxiliary equipment 4 Slightly open the fuel line flexible section at the solenoid valve and allow the LP gas to slowly escape Do not open the fitting widely a large quan tity of gas may be released 5 Disconnect the fuel supply hose from the carbure tor and hold it clear of the set 6 Press and hold the primer button on the regulator to release LP gas from the set fuel system 7 When gas can no longer be heard escaping from the open end of the fuel supply hose reconnect the hose to the carburetor Carburetor Air Filter and Intake Manifold Assembly The carburetor air filter and intake manifold assembly Figure 6 26 consists of Air cleaner housing Air filter Air cleaner adapter K5 relay assembly Carburetor Intake Manifold Disassembly Procedure 1 Remove the crankcase breather hose from the air cleaner housing 2 Remove the air cleaner housing center capscrew and lift off the housing and air filter 3 Disconnectthe lead wires from the K5 relay terminals 4 Remove the three capscrews that secure the air cleaner adapter and lift off the relay a
114. ee Figure S 7 The two stage demand regulator delivers vaporized LPG to SECONDARY the carburetor The primary stage receives LPG va DIAPHRAGM por and liquid at LPG container pressure and re duces it to approximately 1 1 2 psi 10 3 kPa The secondary stage is ademand regulator that delivers LPG vapor at the rate demanded by the carburetor The regulator should require little attention if the SECONDARY genset is operated regularly Most regulator mal VALVE function is due to e Hardened diaphragms and valve seats The pressure regulator in a genset that has been operated and then stored for a long time might PRIMARY require replacement because diaphragms VALVE gaskets and valve seats tend to shrink and harden over time Fuel impurities and oils dissolved in the liquid LPG Impurities can form granules that be come embedded in the secondary valve seat PRIMARY causing it to leak and oils can clog passages in side the regulator The results could be hard starting erratic idling and poor load accep tance Testing the Demand Regulator Use compressed air and a pressure gauge to test the regulator as fol PRIMARY lows DIAPHRAGM 1 Connect a pressure gauge to the test port on the back of the regulator 2 Connect a source of compressed air at least 80 psi 550 to the inlet opening and open FIGURE S 7 DEMAND REGULATOR ASSEMBLY the air pressure valve 3 If the primary valve is sound the gauge wil
115. efficiency is reduced If it is advanced too much over heating results The condenser prevents arcing across the opening breaker points to extend point life An open condenser causes a weak spark and rapid point wear and must be replaced A shorted condenser allows no spark A new condenser is supplied with the engine tune up kit Replace the condenser when replacing the points Breaker Point Replacement Adjustment Procedure Make ignition adjustments with the engine cold and at rest Do not file the points 1 Disconnect the negative battery cable at the bat tery terminal 2 Remove the breaker box cover clip and lift off the breaker box cover 3 Remove the spark plugs to permit easy rotation of the engine and generator assembly Use a socket wrench to turn the rotor through bolt clockwise until the breaker point gap is open as far as possible 4 Disconnect the condenser and ignition lead wires at screw A Figure 6 10 5 Remove the condenser mounted outside breaker points box on engine adapter flange 6 Remove the breaker points mounting screws B and lift out the point assembly 7 Replace the condenser and point assembly and install in a reverse order of removal 8 Use an allen head wrench to adjust set screw to obtain the gap setting specified in the Specifica tions section Measure the point gap with a flat thickness gauge See Figure 6 10 Make sure feeler gauge is clean and free of any grease
116. ents If discon necting the devices is not possible open the circuit breaker s at the distribution panel or at the gener ator sel if so equipped Forcing the mixture adjusiment ACAUTION screws light will damage the needle and seat Turn them in only until light ten sion can be felt Start the engine and allow it to run about 10 minutes Theadjustment screw location is shown in Figure 6 18 6 19 Mixture Adjustment Procedure 1 Stop the set and connect a voltmeter frequency meter and load bank to the generator output leads 2 Start the generator set and apply a full load Adjust the governor speed adjustment nut to obtain 59 49 2 Hz 3 Remove the plastic cap over the main adjustment limiter cap Turn the main adjustment screw inward until the voltage or frequency drops Then turn it outward until the voltage or frequency drops again Locate the point where voltage and fre quency are highest From this point turn the main adjustment screw out another 1 4 turn Replace the main adjustment lever limiter cap so it aligns with the proper attitude position IDLE THROTTLE ADJUSTMENT STOP SCREW SCREW CAP IDLE ADJUST LEVER STOPS THROTTLE n i gt LEVER MAIN ADJUSTMENT SCREW FS 1691 1 FIGURE 6 18 CARBURETOR FUEL ADJUSTMENTS IDLE MIXTURE ADJUSTMENT SCREW CAP IDLE SPEED STOP SCREW ALTITUDE SCALE ALTITUDE ADJUSTMENT MAIN MIXTURE FIGURE 6 18a CARBURETOR FUEL ADJUSTME
117. erator 1 Drain the engine oil while the generator set is still mounted in the vehicle Remove the generator set from the vehicle and place it on a sturdy work bench Refer to Set Remo val in section 5 for the recommended set removal procedure Remove the flywheel guard from scroll opening and the sound shield The carburetor and intake manifold must be removed to provide clearance for lifting the genera tor stator assembly Disconnect the choke heater lead wires throttle linkage fuel line crankcase breather hose and preheater tube Remove the intake manifold screws and lift off the carburetor and intake manifold as an assembly Refer to Fuel System in section 6 for detailed removal procedure Disconnect the lead wires from the charge resistor low oil pressure cutoff switch and B terminal on the ignition coil Remove the brush block cover and disconnect the F1 outboard and F2 inboard lead wires from the brush block terminals Pull each brush lead wire outward from the holder and the same time insert a piece of stiff wire into the small hole in the end of the stator housing see Figure 8 6 Carefully guide the wire through the brush block and then release each brush Verify that each brush is held off the slip rings by the holding wire The brushes will be damaged ACAUTION during disassembly if not held off the slip rings Make certain holding wire s in place before removin
118. es are powered whenever connected to an AC outlet even if the device is not in actual operation For this reason disconnect all devices which are voltage or frequency sensitive before attempting any carburetor governor adjust ments If disconnecting the devices is not possible open the circuit breaker s at the distribution panel or at the generator set if so equipped Equipment required Digital frequency voltmeter with 0 3 frequency 0 5 voltage accuracy Recommended Fluke 8060A or 85 series Digital ammeter Recommended Beekman 4410 Load bank with 8 kW minimum capacity variable 600 watt section GOVERNOR SPRING GOVERNOR 0 SENSITIVITY 7 ADJUSTMENT DROOP BALL AND SOCKET GOVERNOR ROD DETAILA COTTER PIN WASHERS SPRING THROTTLE LEVER GOVERNOR ROD Refer to Figure 6 14 if you are adjusting a spec set For sets prior to spec H refer to Figure 6 15 Adjustments to the governor should be made in the following sequence 1 The carburetor fuel mixture screws must be cor rectly adjusted before governor adjustments are made If the carburetor needs adjusting refer to the Mixture Screw Adjustments in this section before making any adjustments to the governor Touching hot exhaust pipes or AWARNING moving parts can result in severe personal injury Use extreme caution when making adjustments while the engine is running 2 Run the genset at
119. est the valve connect battery positive B to the top terminal and battery negative B to the grounded terminal The plunger assembly should with draw and open the valve when the solenoid is ener gized Replace the solenoid valve if it does not operate properly ES 1553 FIGURE 6 34 SOLENOID VALVE FUEL SYSTEM LPG VAPOR WITHDRAWAL The LPG vapor withdrawal fuel system is very similar to the liquid withdrawal system Main components of the LPG vapor withdrawal fuel system are Air cleaner assembly Carburetor Intake manifold Solenoid valve Demand regulator externally mounted 6 31 Special precautions must be taken to avoid releasing large quantities of highly flammable LP gas when servic ing the fuel system Use the LPG Purging Procedure described in the LPG Liquid Withdrawal Fuel System section to purge the fuel system of LP gas before servic ing any fuel system components Service procedures for the air cleaner assembly car buretor intake manifold and solenoid valve are des cribed in the previous sections The following service procedure applies to the LPG vapor withdrawal demand regulator which is unique to the vapor withdrawal system The fuel supply line pressure to the demand regulator of the genera tor set fuel system components must be in the range of 6 to 8 ounces per square inch equivalent to 10 to 14 inches water column The fuel supply from the primary regulator to the ge
120. etor from the intake manifold as described in the Carburetor Air Filter and Intake Manifold Assembly section Most parts cleaning solvents are A WARNING flammableand can result severe personal injury if used improperly Follow the manufacturer s recommendations when cleaning paris 2 Remove the throttle stop collar and throttle stop lever from the end of the throttle shaft 3 Remove the throttle plate retaining screws and throttle plate Remove the dust seals from the throt tle shaft and carefully pull out the throttle shaft 4 Remove main and idle mixture screw assemblies 5 Separatethe lower section bowl of carburetor from the upper section bowl cover THROTTLE STOP SCREW IDLE ADJUSTMENT SCREW P d FIGURE 6 28 CARBURETOR OVERHAUL 6 28 Cleaning and Repair Procedures 1 Soak all metal components that have not been replaced in carburetor cleaner Do not soak any non metal parts they may be damaged by the clean ing solution Follow the cleaner manufacturer s recommendations Clean all carbon from the throttle bore especially where the throttle plate seats Be careful not to plug the idle or main fuel ports Blow out all passages with low pressure 30 kPa compressed air Do not use wire or other objects for cleaning that might increase the size of critical passages Checkthe condition ofthe mixture screws see Fig ure 6 29 and replace them if worn or damaged Replaceal
121. events oil contamination by routing moisture gasoline vapors and other harmful blow by materials from the crankcase to the carburetor and combustion chamber A sticky crankcase breather can cause oil leaks high oil consumption rough idle reduced engine power and rapid formation of sludge e varnish in the engine and oil in the breaker point OX The crankcase breather is vented directly below the generator set For this reason the generator set should only be used in environ ments where oily vapor and dust do not create a problem Crankcase breather vapor contains AWARNING poisonous carbon monoxide which can cause personal injury or death Do not run the generator sel while parked unless the undercarriage is exposed to a steady airflow Crankcase Breather Service Procedure Oil leaks at the seals may mean that the crankcase is pressurized Use the following procedure to eliminate this condition 1 Remove the breather tube from the valve cover see Figure 6 13 BREATHER HOSE NU HEX HEAD CAPSCREW FLAT WASHER SPRING GASKET On FLAT WASHER C 1101 FIGURE 6 13 CRANKCASE BREATHER 2 Removethe valve cover pack spring washer reed valve and breather baffle 3 Clean all parts in solvent Most parts cleaning solvents are A WARNING flammable and can result in severe personal injury if used improperly Follow the solvent manufacturer s recommendations when cleaning parts The reed valve must
122. from the center stud and pull out the filter element Wash the filter element in kerosene to remove the particles it has collected Blow it dry with low pressure 30 psi 207 kPa compressed air Replace the filter element if damaged Wipe the magnet clean of the particles it has collected Install a clean filter element using two new gas kets and securely tighten the center stud nut Place a new O ring in the filter bowl sealing groove Align the reference mark on the filler bowl with the reference mark on the filter body and torque the capscrews to 65 Ib in 7 2 N m Check for and fix leaks at the filter when connections have been made to the fuel supply system The fuel filter operates at fuel supply tank pres sure Fuel Vaporizer The fuel vaporizer consists of several wraps of tubing around the exhaust mani 2 5 12 fold Exhaust heat vaporizes the LPG liquid The va porizer is not removable from the exhaust manifold Bending the fuel vaporizer tubing could weaken it to the point that it could crack allowing fuel under high pressure to escape which could result in severe personal injury or death Fuel Shutoff Solenoid Valve Test the fuel sole noid by disconnecting its long lead and jumpering it directly to the battery positive terminal on the genset Replace the solenoid if it does not click open when it is powered i FIGURE S 9 LPG FUEL FILTER L
123. ft the entire until it bottoms Install a 9 16 12 x 2 capscrewin the generator set by this method end of the rotor shaft and tighten until rotor breaks loose from crankshaft Remove capscrew from end Remove the capscrew and two EIT lock washers of rotor when complete that secure the ground strap to the drip pan Remove the three vibration isolator center screws from the underside of the drip pan and lift drip pan away from engine generator Disconnect lead wires attached to the starter motor Loosen the fasteners that mount the starter to the CAPSCREW stator housing and remove starter gt 09 162 Remove the four capscrews lock washers and nuts that secure the stator housing to the engine to generator adapter Remove the lifting eye bolt Figure 8 8 Carefully lift the stator assembly straight up until it clears the rotor Set stator assembly to rest on smooth clean surface ROTOR TOOL 10 IN 254 mm 7 16 14 G 1175 FIGURE 8 9 ROTOR TOOL 20 Carefully lift the rotor assembly off the end of the engine crankshaft and remove rotor tool G1175 1 21 Liftthe brush wires and remove brush holding wire from housing Remove the brush block mounting screw and carefully remove the brush block FIGURE 8 8 REMOVE LIFTING EYE BOLT assembly from the stator housing 8 11 22 Refer to Figure 8 10 and use the following proce dure to remove the stator from the stator housing a Rotate the stator housing
124. g stator assembly 10 11 8 10 BRUSH BLOCK HOLE FIGURE 8 6 BRUSH BLOCK ASSEMBLY G 1178 Removethetwo control panel screws from housing lift off control panel and disconnect plug jack con nections P1 J1 and P3 J3 of control printed circuit board Ifthesetis LP gas fueled disconnectthe fuel line at the vaporizer coupling Place a 3 8 inch allen wrench in the head of the rotor through boit Use a rubber mallet and sharply strike the allen wrench so the through bolt is driven in a counterclockwise viewed from generator end direction Several sharp taps should break loose the through bolt Remove the rotor through bolt and thread the spe cial lifting eye 9 16 12 into the end of the housing Refer to Figure 8 7 LIFTING EYE BOLT 9 16 12 G1176 2 FIGURE 8 7 GENERATOR LIFT 13 14 15 16 17 18 Place a pad in front of the engine to cushion and ACAUTION Careless handling of the stator protect the scroll Attach a hoist or other suitable assembly can damage the insu lifting device to the lifting eye Tip up the set as lation on the stator windings Do not brush the shown in Figure 8 7 until it is completely vertical stator windings against the rotor as itis lifted clear and resting on the scroll housing end 19 Install the tool shown in Figure 8 9 Use a screw ACAUTION Careless handling can damage driver to turn the rotor tool in a clockwise direction the rotor Do not li
125. h a light coating of grease before installing the rear bearing plate or gear cover This provides initial lubrication until engine oil reaches the seal Refer to the Crankshaft section for the rear bearing plate installation proce dures Referto the Gear Coversection for the gear cover installation procedures GEAR COVER MOUNTING FACE THIS SURFACE SHOULD BE OF GEAR COVER CLEANED OF ALL OLD SEALING COMPOUND BEFORE INSTALLING OIL SEAL SEAL 0 97 0 02 INCH 24 6 0 5 mm CLEANED OF ALL OLD SEALING DRIVE OR PRESS OIL SEAL TO SHOULDER COMPOUND BEFORE OF THE PLATE BORE INSTALLING SEAL GEAR COVER OIL SEAL REAR BEARING PLATE OIL SEAL M 1477 FIGURE 9 34 OIL SEALS 9 16 Section 10 Service Checklist After servicing inspect and test the complete installa tion to confirm that the generator set will operate prop erly and will pull full rated load Check each of the following areas before putting the set into service MOUNTING Examine all mounting bolts and supporting members to verify that the generator set is properly mounted All fasteners should be tightened securely to prevent them from working loose when subjected to vibration LUBRICATION the engine oil was drained fill the crankcase with oil of the recommended classification and viscosity Refer to the appropriate operator s manual for the specific recommendations and procedures WIRING Verify that all wiring connections are correct and secu
126. hanger Remove the muffler and tailpipe assembly see Figure 6 1 2 Remove the screws that secure the exhaust tube to the exhaust manifold Remove the exhausttube and exhaust gasket Completion of the remaining steps requires that the generator set be removed from the vehicle Refer to Preparing to Service Section 5 for the set removal procedures For LPG sets also perform the procedure for purging LPG from the fuel line 3 Remove the cooling system noise shield and scroll see Cooling in this section to provide access to the exhaust manifold 4 Remove the screw that secures the exhaust mani fold outlet flange to the exhaust manifold support bracket 5 Remove the four exhaust manifold screws and lift off the exhaust manifold and the two manifold gaskets MUFFLER STRAP CUTOUT HANGER BRACKET 3 FT MINIMUM FROM DOWNPIPE AND AT A PERIMETER OF VEHICLE MARKED 1 3 8 FRONT SET VIEW CLAMP MARKED 1 1 2 EXS 1147 3 FIGURE 6 1 CONVENTIONAL COMPARTMENT MOUNT EXHAUST SYSTEM Assembly Procedure Inhalation of exhaust gas can result AWARNING in severe personal injury or death To prevent exhaust leaks install all gaskets clamps Straps and hardware as specified See Tailpipe Recommendations in this section 1 Install the exhaust manifold using new gaskets Tighten the four manifold screws to the specified torque Install the 5 16 18 screw lock washers and nut that secure the manifold outlet f
127. harge resistor low oil pressure cutoff switch and B terminal on the igni tion coil Place new intake manifold gaskets on the engine block and install the carburetor and intake manifold assembly Tighten the intake manifold screws to the specified torque Connect the preheater tube crankcase breather hose fuel lines throttle linkage and choke heater wires Refer to Fuel System in section 6 for detailed assembly procedures install the flywheel guard Scroll opening and the noise shield Install the generator set in the vehicle and securely fasten all mounting screws and hardware Connect the fuel exhaust and electrical system in reverse order of disassembly Refer to Set Removal in sec tion 5 for the recommended procedures Fill crankcase with oil ofthe recommended classifi cation and viscosity BRUSHES AND SLIP RINGS Brush Replacement Remove the brush block cover and inspect the brushes and brush holder for burn marks or other damage If the brushes appear to be in good condition use a piece of wire modified as shown in Figure 8 11 to check for excessive brush wear Insert the wire through the hole above each brush Make sure the wire is resting on the brush and not on part of the spring If the painted part of the wire is not visible the brush is excessively worn and must be replaced gr 1 in 25 mm G 1174 FIGURE 8 11 CHECKING BRUSH WEAR Always replace the brush springs when installing new brushes
128. he Cylinder Rebore and hone engine whenever cylinder bore is worn damaged out of round or if cylinder taper exceeds specifications A worn cylinder bore should be resized to the smallest standard oversize diameter at which it will clean up The final finish and bore diameters should then be obtained by honing If boring bar is operated incorrectly ACAUTION it will produce a rough cylinder sur face that may not clean up even when honed Boring should be done only by qualified service personnel who are careful in their work After boring to the correct oversize cylinder bore dimension piston and ring clearance should be approp riate There is no need to adjust or fit pistons and rings When reboring cylinders take the following pre cautions 1 Make sure cutting tool is properly ground before using it 2 Be sure top of engine block is smooth and deposit free 3 Clean base of boring bar before bar is set up Depos its under boring bar will cause it to tilt and the cylinder will be distorted after boring 4 Make an initial rough cut followed by a finish cut Then hone cylinder bore to the specified oversize Honing Cylinders Using Precision Hones Refer to hone manufacturer s recommended grit size to produce specified surface finish of 20 to 40 RMS Too rough finish will wear out the rings and too smooth of a finish can retard piston ring seating 1 Position block solidly for either vertical or h
129. he secondary stage of the regulator restricts fuel flow through the regulator until the vacuum from the engine creates a demand for fuel Fuel flows through the regula tor only when the engine is cranking or operation it stops flowing when the engine is stopped The regulator should require little attention if the set is used on a regular basis and operated on clean high quality fuel Most regulator malfunctions can be traced to two sources e Hardened diaphragms and seats due to extended periods of non use e Dirtorforeign matter embedded in valves and valve Seats FS 1598 FIGURE 6 30 LP GAS REGULATOR A regulator that has been operated then stored for any length of time may require rebuilding or replacement Diaphragms and gaskets tend to dry shrink and harden with time Use the test procedure specified in the Regulator Test section to check regula tor operation then rebuild or replace as required Repair kits include detailed and illustrated installation instructions SECONDARY DIAPHRAGM SECONDARY lt lt lt VALVE 7 PRIMARY DIAPHRAGM XFS 1600 FIGURE 6 31 REGULATOR DISASSEMBLY 6 29 A regulator with granules of foreign matter embedded in the secondary seat may cause inconsistent starting or idling Foreign matter dissolved in the LPG can form granules as the fuel is vaporized Remove the regulator front cover and diaphragm assembly see Figure 6 31 to check for dirt or oil deposits
130. his document by any means is strictly prohibited 20V F 20V NEUTRAL WIRING DIAGRAM 21 A3 fo 1 1 459 we GD SEED SEND UN UND Rub ume ud uus ee ee WA R6 SCHEMATIC SPEC J BGE NHE 60 HZ WIRING DIAGRAM SCHEMATIC a eal ae a alas VOLTAGE REGULATOR IGN COIL IGN MODULE SWITCH LOW OIL PRESS RESISTOR BATTERY CHARGE POTENTIOMETER RELAY LPG ONLY RELAY START SOLENOID CHOKE GASOLINE ONLY GENERATOR FUSE SLOW BLOW 5A SPARK PLUGS FUEL PUMP OR FUEL SOL RECTIFIER LPG ONLY CIRCUIT BREAKER AC OUTPUT CAPACITOR BATTERY 12 STARTER MOTOR NO 611 1206 REV A MODIFIED I LI 110 120V TAS oe 15 1107 120V 559 240V 110 120 1 CB2 120 MAX ACROSS VRI CONNECTIONS 2 3 2 GROUNDED AC LEAD FOR ISOLATED NEUTRAL REMOVEJUMPER W2 13 LO AND CONNECT JUMPER TBI LO VRI C5 NEG VOLTAGE REGULATOR IGN COIL IGN MODULE SWITCH LOW OIL PRESS R6 RESISTOR BATTERY CHARGE R5 POTENTIOMETER K5 RELAY LPG ONLY Ki RELAY START SOLENOID HI CHOKE GASOLINE ONLY GENERATOR FUSE SLOW BLOW 3 41 SPARK PLUGS E2 FUEL PUMP
131. hould be grounded at connector P1 8 Replace control board A1 if the voltmeter indicates zero volts at either connector If the voltmeter indi cates at least 9 volts at both connectors the prob lem is not with the control board Go back to the Troubleshooting Guide If the engine starts but stops when the Start switch is released the problem could be with the low oil pressure switch or generator no voltage Go back to the Troubleshooting Guide Replace control board A1 if the oil pressure switch and generator are functioning properly Reassemble the control board and cover Wem Description of Materiat S3 Ignition Module S2 Swich LowOilPressue R6 Resistor Battery Charge Ro Poleniometer K5 jReayiPGOny Gasol F1 I BT1 2 1 1 Gi Generator Fi Fuse SlowBlow5A 4 E2 Fuel Pump or Fuel Solenoid Remote Control Standard Remote Control Deluxe Control Assy NHE NHEL Control Assy BGE BGEL FIGURE 7 2 SCHEMATIC BGE NHE CONTROL 611 1190 VOLTAGE REGULATOR FUEL PUMP t GASOLINE 27 we eT t e g c is a A EN i f YOM CR FUEL SOLENOID E2 FS S wo LPG UNITS ONLY ig E TD i 4 1 5 E MET AM d o 4 3 TN L CIRCUIT m 1 y oap uf 7 BREAKER S CONTROL PRINTED
132. hown in the Specifications section For each valve the gauge should just pass between the valve stem and valve tappet see Figure 9 12 VT 1026 GOVERNOR CUP ROLL PIN ROTATE GOVERNOR CUP SO THAT ROLL PIN FITS INTO THE METAL LINED HOLE OR PLASTIC BUSHING IN THE CUP 5 To correct the valve clearance turn the adjusting screw as needed to obtain the right clearance The screw is self locking 6 To adjust valves on the right cylinder turn engine one complete revolution and again line up mark on the flywheel and the TC mark on the gear cover Then follow adjustment procedure given for left cylinder 7 Replace all parts removed Tighten all screws securely Torque manifold bolts GEAR COVER Remove the flywheel key and gear cover mounting screws Gently tap the gear cover with a plastic faced hammer to loosen it see Figure 9 13 When installing the gear cover make sure that the pin in the gear cover engages the nylon lined smooth hole in the governor cup Turn the governor cup so the nylon lined hole is at the three o clock position Use a small amount of grease to assist in holding governor cup in position The rounded side of the governor yoke must ride against the governor cup 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 Be careful not to damage the gear cover oil seal Refer to Oil Seals sec
133. ich can cause per sonal injury or death Do not run the generator set while parked unless the undercarriage is exposed to a steady airflow Table of Contents SECTION TITLE PAGE SAFETY PRECAUTIONS Inside Front Cover 1 INTHODUCTHON ona 1 1 About this Manual 1 1 Model Identification bob EE Ec ade rU ES es Dad e i xd 1 1 2 SPECIFICATIONS secs 2 1 3 DIMENSIONS AND CLEARANCES 3 1 4 TORQUE SPECIFICATIONS 4 1 5 PREPARING SERVICE 5 1 TWOUDIES NOOUNG ote 5 1 ENJING TOOS 5 1 Generator and Control 0 5 5 1 Safety Considerations 5 1 Set REMOVA eux ra hee obedece E 5 2 6 ENGINE PRIMARY SYSTEMS 6 1 Introduclioll hib TDI E ES S REO eI EA ES DS 6 1 EUER erii rae Desa 6 1 Exhaust oed she en E dee 6 5 COOMO SVSIBITI cs eio Re eru detta 6 8 Electronic Ignition System Begin Spec G 6 10 Breaker Ignition System Prior to Spec
134. id Marquis is a trademark of Onan Corporation 1991 Onan Corporation A 9 CRANK amp START MODE With the switch pressed to the Start position Meter Meter Test Lead Reading gt P1 1 42 1 10 12 VDC P1 6 J2 1 10 12 VDC P1 9 J2 1 10 12 VDC P1 12 J2 1 10 12 VDC P1 7 P1 10 10 12 VDC RUN amp GENERATE MODE With the generator set running and the switch in the Center position Meter Meter Test Lead Reading P1 6 J2 1 18 20 VDC P1 7 P1 3 NWA BGD NHD 18 20 VDC 1 7 1 5 10 13 VDC 1 7 1 10 0 VDC 1 12 J2 1 10 13 VDC 42 5 42 1 10 13 VDC 42 6 J2 1 10 13 VDC 1 2 P1 4 18 22 VAC STOP MODE With the switch pressed to the Stop position Meter Meter Test Lead Reading E 1 6 J2 1 0 VDC 1 12 J2 1 0 VDC P1 7 1 10 12 VDC Gensets with K5 relay 909 0265 0 30 91 10 Appendix B Spec J and K Diagrams This appendix contains DC control schematic and wiring diagrams for the Spec J and Spec K BGE and NHE generator sets GENERATOR SET DIAGRAM NUMBER PAGE Spec J BGE NHE 60 2 Bi E B 2 Spec J BGE NHE 50 Hz eO e B 3 Spec J 60 Hz 100 611 1208 B 4 Spec BGE NHE 60 Hz SIUE oo RERO B 5 Spec K BGE NHE 50 Hz Be 6 Spec 60 2 100 V B 7 B 1 Redistribution or publication of t
135. ide of connecting rod must face camshaft Rod bolts are off set toward outside of block 4 Tap the piston down into the bore with the handle end of a hammer until the connecting rod is seated on the journal Check bearing clearance before proceeding with step 5 see Rod Bearing Clearance i FANTAN PISTON RING IN section wx Pape CYLINDER BORE 5 Install the bearing on the rod Install one fastener L2 79 and tighten to 5 ft lbs 7 Nem Repeat this for the vy other fastener Tighten both fasteners down to 14 6 Install the remaining piston and rod in the same manner Crank the engine over by hand to see that all bearings are free CT 1064 FIGURE 9 24 CHECKING RING GAP Piston Assembly Installation NOTCH TOWARD 1 Lubricate all parts with engine oil 2 Position piston on its respective rod and install the pin 3 Install the rings on the pistons starting with the oil N control ring Figure 9 25 Use a piston ring spreader to prevent twisting or excessive expan sion ofthe ring Compression rings have a dotor the word top on one side of the ring to indicate which side faces the top of the piston Unmarked piston rings can be installed either way The oil control ring has an expander install the expander first and then close until the expander ends butt The joint should be 180 degrees from the gap of that ring CT 1048 COMPRESSION oP RINGS A OIL RING
136. ified limits but voltage is incorrect voltage regulator is defective Open grounded or short circuit in rotor or stator Voltage Regulator sensing leads 2 and 3 wired incorrectly 8 8 Corrective Action Locate cause of overload and correct as required Reset breaker Check for good wiring connections and correct as required Check for continuity and correct ff circuit is open Check for good wiring connections and correct as required Check for continuity and correct if circuit is open Check for good wiring connections and correct as required Check for continuity and correct if circuit is open Release brushes if jammed in holder Clean slip rings if dirty Replace voltage regulator Test each component for open grounded or shorted windings and replace if defective Refer to governor adjustments in section 6 Check length of brushes and replace if worn excessively Clean or replace slip rings Check for good wiring connections and correct as required Check for continuity and correct if circuit is open Refer to Testing Voltage Regulator Test each component for open grounded or shorted windings and replace if defective Correct wiring TROUBLESHOOTING THE GENERATOR Continued Many troubleshooting procedures present hazards which can result in severe personal injury or death Only qualified service personnel with knowledge of f
137. ignition rotor and ignition module are located inside the generator housing When the stator in its housing has been removed the ignition rotor can be removed replaced on the crankshaft and the ignition module can be removed replaced on the generator adapter hous ing as follows Ignition Rotor Removal Replacement To remove the ignition rotor simply pry it off using a dull edged pry bar or other implement To install the ignition rotor place it over the end of the crankshaft align the key on the rotor with the corresponding slot in the end of the crankshaft and tap the rotor gently into place Ignition Module Removal Replacement 1 Unscrew the red and black wires extending from the ignition module to the ignition coil Make certain to note which wire attaches to which terminal on the coil 2 Unscrew the two screws holding the ignition module bracket in place on the generator adapter 3 When the ignition module is loose pull the red and black wires through the gap in the generator adapter 4 To replace the module perform the steps listed above in reverse order Be sure to assemble the new module to the bracket as shown in Figure 6 6 Sec tion A A The studs on the bracket must point toward the generator end of the set when assembled and installed Ignition Coil The ignition coil Figure 6 7 is a transformer that steps up the battery voliage to about 20 000 volts firing the spark plug Keep all ignition coil
138. in 5844 2 85 in 5844 cm Fuel L680 FT68 is cote ho etre PR RE ERES QUE ENT Lead Free Propane LPG Liquid or Vapor Withdrawal LPG Liquid or Vapor Withdrawal Cylinder Compression HOU aa des uv SUE 79 115 psi 517 793 kPa 100 120 psi 690 827 kPa TUNE UP SPECS Spark Plug 0 025 in 0 64 0 025 0 64 GAD P 0 016 in 0 41 NHE 0 016 in 0 41 mm Prior to Spec G Only Timing Breaker Point Ignition BTO Goat 20 Timing Nonadjustable Electronic ignition 14 518 14 18 Valve Lash 0 005 0 127 0 005 in 0 127 mm Exhaust 0 013 0 330 0 013 in 0 330 mm GENERATOR Onan built four pole revolving field permanently aligned to engine Frequency 50 Hz 50 Hz 60 Hz Watts 3500 1 00 5000 6500 gasoline 4000 2 6300 propane Volts 110 220 or 120 240 110 220 or 120 240 120 Amps 31 8 15 9 or 29 2 14 6 1 45 5 22 7 or 41 7 20 8 54 2 gasoline 36 4 18 2 or 33 3 16 7 2 52 5 propane Phase 1 1 1 Wires 4 4 1 Prior to Spec G 2 Begin
139. in utes under 1 2 to 3 4 rated load On vapor withdrawal type LPG gensets it might be nec essary to first adjust the supply pressure as in structed under LPG System Components to get the genset to start Disconnectthe load check for zero amps Pull the governor rod so that the tang on the throttle lever bears against the idle speed stop screw Adjust the screw to obtain 54 56 Hz 44 46 Hz On LPG carburetors the stop screw has a lock nut Frequency Adjustments The frequency specifi cations for 60 Hz gensets are followed in parenthe ses by the specifications for 50 Hz gensets 1 2 Set the altitude adjust knob gasoline only on the carburetor to your altitude Disconnect all loads check for zero amps Then check no load frequency necessary turn the governor speed adjusting screw to obiain a no load frequency of 62 63 Hz 51 5 52 5 Hz Check output voltage See Generaior if output voltage cannot be adjusted to within 10 percent of rated voltage Table 5 1 See Troubleshooting if the engine runs roughly IDLE SPEED STOP SCREW L ADJUST KNOB FIGURE S 3 GASOLINE CARBURETOR FUEL INLET VAPOR WITHDRAWAL FUEL INLET LIQUID WITHDRAWAL N lt gt B 2 e IDLE SPEED STOP SCREW AND LOCKNUT FIGURE S 4 LPG CARBURETOR Droop Adjustments The frequency specifications for 60 Hz gensets are followed in p
140. ing pation C ry ate the brush end cap housing from the armature assembly 2 Disconnect the generator set positive battery cable from the starter lug terminal See Figure 6 37 5 Usea 1 8 to 5 32 inch nail setto remove the roll pin When reassembling use a new roll pin Remove the return spring gear and clutch assembly as required See Figure 6 38 ROLL PIN STARTER POSITIVE TERMINAL a A ae a CP aan ae STARTER SPRING THROUGH BOLTS RETAINER ES 1608 FIGURE 6 37 STARTER SUPPORT PLASTIC RETAINER WITH 5 32 to 1 8 NAIL SET VISE OR OTHER x SOLID SURFACE USE CARE NOT TO HAVE SPRING RETURN LEG BETWEEN THE PLASTIC RETAINER amp SUPPORT WHEN DRIVING OUT ROLL PIN SUPPORT FIGURE 6 38 DRIVING ROLL PIN OUT 6 33 Testing Armature for Grounds Touch one ohmmeter lead to a commutator bar then touch the other lead to the armature shaft and the core laminations A low resistance reading indicates a grounded armature Replace a grounded armature with a new one See Figure 6 39 ES 1614 FIGURE 6 39 TESTING ARMATURE FOR GROUNDS Testing for Shorts Use a growler Figure 6 40 to locate shorts in the armature Place the armature in the growler and hold a thin steel blade hacksaw blade parallel to the core and just above the armature while slowly rotat ing the armature in the growler A shorted armature will cause the blade to vibrate and be att
141. ing period and check that carbon is being removed and all grooves or rough ness is smoothed out Contact with rotating machinery A WARNING can result in severe personal injury Keep hands and fingers clear while servic ing slip rings 6 Remove insulating material from ends of voltage regulator lead wires F1 and F2 and then instail brush block assembly Follow steps 6 through 14 in the Brush Replacement section TESTING VOLTAGE REGULATOR VR1 Confirm that voltage regulator VR1 is faulty before replacing it Use a meter with a diode checking function Fluke Model 73 Multimeter to perform the following tests 1 Disconnect the negative battery cable 2 Remove the generator control box cover Figure 8 1 3 Disengage the wiring connector and remove the voltage regulator 4 With the meter on Diode Check test between connector terminal pairs 5 9 7 9 10 9 11 9 12 9 10 5 5 11 5 12 and 5 3 Figure 8 13 It is impor tantthatthe positive lead ofthe meter be connected 8 15 to the firstterminal of each pair Replace the voltage regulator if any reading indicates short or open except for pair 10 5 which should indicate open Short is indicated by zero or a number very nearly zero Meters of different make indicate open differently Read the meter instructions If in doubt compare with readings of a regu lator of the same part number known to be good ES 1952C FIGURE 8 13 VOLTA
142. install the three vibration isolator center screws Note that proper flat washers are used large flat washers attwo generator isola tor positions Tighten the center screws to speci fied torque 8 13 10 11 12 13 14 15 16 17 18 19 20 21 Secure ground strap to drip tray using a capscrew and two EIT locking washers Note that ground strap is installed between locking washers to pro vide a good electrical connection Attach the special lifting plateto the end ofthe stator housing using four 5 16 18 x 1 capscrews See Figure 8 7 Attach a hoist or other suitable lifting device to the lifting plate Carefully tilt the set back until it is rest ing on the drip tray Remove lifting plate when complete if the setis LP gas fueled connect the fuel line at the vaporizer coupling Connect plug jack connections P1 J1 and P3 J3 of control printed circuit board Install contro panel assembly onto generator housing Tighten mount ing screws Pull the brush lead wires outward and remove the piece of wire that is holding the brushes off the slip rings Check the brushes to verify that they are cen tered on the slip rings If brushes are not centered loosen the brush block mounting screws and adjust Retighten mounting screws when complete Connect the F1 outboard and F2 inboard lead wires to the brush block terminals Instali the brush block cover Connectthe lead wiresto the c
143. intake Assembly The air intake assembly Figure 6 16 consists of Air cleaner housing Air filter Air cleaner adapter Choke assembly Disassembly Procedure Contact with hot engine parts can A CAUTION cause personal injury The genset should be shut down and allowed to cool before per forming this procedure 1 Remove the crankcase breather hose and air pre heater hose from the air cleaner housing 2 Remove the air cleaner housing center capscrew and lift off the housing and air filter 3 Remove the choke cover retaining nut and liftoff the choke cover 4 Disconnect the choke lead wires at the choke terminals 5 Remove the three capscrews that secure the air cleaner adapter to the carburetor and lift off the adapter Note that the choke linkage must be disen gaged from the choke assembly as the adapter is removed 6 Remove the two capscrews that secure the choke bracket to the adapter Lift off the choke assembly Assemble Procedure Reverse the order of disassem bly Use a new gasket between the adapter and the carburetor CRANKCASE BREATHER TUBE AIR PREHEATER AIR CLEANER HOUSING AIR FILTER AIR CLEANER ADAPTER FS 1609 3 FIGURE 6 16 AIR INTAKE ASSEMBLY Carburetor and intake Manifold Assembly The carburetor and intake manifold assembly Figure 6 17 consists of Intake manifold Choke pull off assembly Air preheaters Carburetor Fuel filter Gasoline vapor i
144. ion HOUSING ELEMENT COVER BI METAL SPIRAL STRIP 4 Refer to Table 6 2 to determine the number of degrees the element cover must be rotated clock wise from the reference position The marks on the choke housing are spaced at 5 intervals 5 Rotate the element cover as specified then tighten the cover mounting screws 6 Move the choke lever to test its operation The lever should return to the free position when released from the open position without sticking or binding 7 Install the plastic choke cover and tighten the center mounting unit Choke Replacement If the choke does not open remove the protective plastic cover and check the heating element The heating ele ment cover should heat up after a few minutes of opera tion ifthe element cover remains cool start the set then use an AC voltmeter to check the terminals on the cover If roughly 20 VAC is not present check for opens or shorts in the control wiring Check for an open or dam aged element If voltage is present stop the setand remove the heating element cover Inspect the heating element and replace it if burned out or broken Also inspect the bi metal coil and replace it if it is damaged or binding in the housing PLASTIC COVER XFS 1605 FIGURE 6 23 CHOKE ASSEMBLY 6 23 When installing a new bi metal strip maintain the origi nal direction of the spiral see Figure 6 24 The outer tab must point in a clockwise direction Make su
145. ion If spring ends are worn check valve spring retainer for wear Check for spring distor tion by placing spring on a flat surface nextto a square Measure height of spring and rotate it against square edge to measure distortion Check spring tension at the installed heightfor both the valve open and closed posi tion using an accurate valve spring tester Replace any valve spring that is weak cracked worn or distorted Valve Rotators NHE exhaust only Positive type valve rotators prolong valve life and decrease valve repairs When functioning properly the valve is rotated a frac tion of a turn each time it opens While at open position the valve must rotate freely There is no easy way to determine if a valve rotator is good or bad Onan recommends that valve rotators be replaced at each major overhaul or if a build up of carbon is noted on valve face and valve seat See Figure 9 3 NHE Reconditioning Valves and Valve Seats The interference angle method of valve seating is used on all B and N series generator set engines With this method different seat and face angles are used and line contact between the valve face and seat occurs The valve faceangle is 44 degrees The valve seatangle is 45 degrees This 1 degree interference angle results in a sharp seating surface between the valve and top of the valve seat see Figure 9 7 VT 1021 FIGURE 9 7 VALVE INTERFERENCE ANGLE The valves should not be hand lapped becaus
146. isassembly Use a new adapter gasket and install so the two small holes are aligned with the oil holes in the block Gasket should be installed dry Coat the threads of each capscrew with non hardening sealer and tighten to recommended torque LOW OIL PRESSURE SWITCH ADAPTER DRIP SHIELD LS 1175 FIGURE 9 1 OIL FILTER amp ADAPTER OIL FILTER CYLINDER HEADS Remove the cylinder heads for cleaning when poor engine performance is noticed Use the following procedures to service 1 Use a socket wrench to remove the cylinder head capscrews and lift off the head Warpage can occur if the heads ACAUTION are removed while hot Wait until engine has cooled before removing heads After removing heads clean outall carbon deposits Be careful not to damage the outer sealing edges where gaskets fit The heads are made of aluminum and can be damaged by careless handling Use new head gaskets and clean both the heads and the cylinder block thoroughly where the head gaskets rest Place heads in position and follow head torque tightening sequence shown in Figure 9 2 Start out tightening all capscrews or stud nuts to 5 ft Ibs 7 Nem then 10 ft lbs 14 Nem etc until all cap screws or stud nuts are tightened to the specified torque see Torque Specification section Retorque before engine has run a total of 25 hours C 1002 RIGHT M 1871C FIGURE 9 2 CYLINDER HEAD TIGHTENING SEQUENCE
147. isconnecting Set from RV Systems All Specs 1 2 5 First disconnect the negative battery cable from the battery and then disconnect the bat tery cables from the genset Sparks and high current could cause fire and other damage to the battery battery cables and vehicle if the loose ends of cables connected to the battery touch Always disconnect the negative battery cable from the battery before disconnect ing the battery cables from the genset Disconnect the remote control wiring harness connecior at the genset Disconnect the generator output wiring and conduit from the power distribution panel or box on the vehicle Tag all wires to make re connections easier Disconnect the exhaust tailpipe from the outlet of the muffler and then remove the muffler See EXHAUST SYSTEM under Engine Subsys tems Disconnect the fuel line from the genset Follow the applicable instructions depending on the fuel Gasoline and LPG liquified pe troleum gas are flammable and explosive and can cause severe personal injury or death Do not smoke if you smell gas or gas oline or are near fuel tanks or fuel burning equipment or are in an area sharing ventila tion with such equipment Keep flames sparks pilot lights electrical arcs and arc producing equipment and all other sources of ignition well away Gasoline Fueled Gensets Disconnect the fuel line from the genset and securely plug the end of the fuel line to
148. ise 1 to 2 turns 7 Recheck the no load speed setting and readjust if needed Reapply rated load and check the governor droop Repeat these adjustments until droop and no load frequency readings are within the correct ranges and the set is stable no hunting at any load from no load to rated load TABLE 6 1 CHECKING VOLTAGE AND SPEED FREQUENCY 60 Hz 50 Hz 12 2 Wire 12 4 Wire 120 V 110 220 V 120 240 V Voltage Maximum No Load 132 121 242 132 264 Minimum Full Load 112 103 205 112 224 Speed Frequency Maximum No Load Speed r min 1890 Frequency Hz 63 Minimum Full Load Speed r min Frequency Hz Droop Hz 1 5 3 5 SPEED ADJUSTMENT NUT GOVERNOR SPRING GOVERNOR ROD FS 1613 SENSITIVITY ADJUSTMENT SCREW FIGURE 6 15 GOVERNOR ADJUSTMENT PRIOR TO SPEC 6 17 FUEL SYSTEM GASOLINE The fuel system must be properly adjusted and in good condition for efficient generator set operation Main components of the fuel system include Air filter assembly Carburetor Choke e Intake manifold Fuel filter Fuel pump Air preheater Fuel systems present the hazard of AWARNING fire or explosion if accidentally ignited which can cause severe personal injury or death Eliminate all possible ignition sources such as open flame sparks cigarettes pilot lights and arc producing machinery and switches from the work area when performing the following procedures Air
149. itch 4 Insufficient voltage for cranking due to See Low Battery Voltage also a Battery not charged b Terminal connections loose or dirty c Battery cable too small fault is due to a K1 relay not grounded b Defective K1 relay c Defective starter step 5 test fault is due to a Open circuit between K1 relay and control PC board Connect a voltmeter between terminal S 5a on the start solenoid and ground Check for battery voltage when 1 is placed in START position If voltage is present If voltage is not present as described in b Defective control PC board 4a Check condition of battery and recharge or replace Clean and tighten all connections at battery K1 start solenoid and motor Increase cable size Short circuiting the A WARNING battery cables can result in severe personal injury Disconnect the negative battery cable at the battery terminal before servicing b Tighten solenoid bracket mounting Screw Replace K1 start solenoid Refer to Electric Starter Section 6 for test and service procedures b C 6a Check for continuity and correct if circuit is open b Refer to Testing Control Board A1 AWARNING Many troubleshooting procedures present hazards which can result in severe personal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Review safety
150. izes K4 which closes the normally open contacts that connect battery positive B to the following N C contacts of K2 generator relay Generator voltage regulator e Ignition coil 1 Fuel pump or solenoid valve e Start solenoid K1 Connecting B produces the following contro re sponses Flashes the field to ensure that there is adequate residual magnetism to induce voltage buildup Energizes the ignition coil 1 so it can begin pro ducing a spark when ignition module S3 is activated prior to Spec G breaker point ignition is used Energizes the start solenoid K1 which closes its N O contacts in the starter motor circuit e Gasoline units Energizes the fuel pump E2 which begins pumping fuel to the carburetor LPG units Energizes the fuel solenoid E2 which allows LPG to flow to the vaporizer and the regulator e Energizes the stop latch ignition relay K5 to open its contacts to ground which allows run relay to be energized through closure of oil pressure switch S2 after engine startup Closing the K1 start solenoid contacts connects B to the starter motor This energizes the starter motor which begins to crank the engine to initiate starting 7 3 Starter Lockout Run When start stop switch S1 is released and returns to the center run position the engine continues to run Relays K2 generator relay run relay and 5 ignition relay
151. l in CONNECT THE INLET TO A dicate approximately 1 1 2 psi 10 3 kPa and SOURCE OF COMPRESSED AIR the pressure will remain constant Fluctuating pressure indicates a leaking primary valve seat 4 Close the air pressure valve and observe the pressure gauge The pressure should remain constant If the pressure drops the secondary valve seat is leaking 5 Disassemble and clean the regulator assembly if it does not pass either test Replace the regu lator if it still does not pass either test THE GAUGE SHOULD INDICATE APPROXIMATELY Most parts cleaning solvents 1 1 2 PSI 10 3 KPA AND HOLD STEADY are flammable and corrosive and can cause severe burns and inflammation Use only FIGURE S 8 TESTING THE DEMAND REGULATOR as recommended by the manufacturer LIQUID WITHDRAWAL SYSTEM 5 11 Fuel Filter See Figure S 9 The fuel filter removes rust and scale and other solid particles from the LPG liquid to keep them from embedding in the valve seats of the shutoff valve and pressure regu lator and causing them to leak A magnet traps iron and rust particles and a filter element traps non magnetic particles Disassembling and Cleaning the Fuel Filter 1 Purge the LPG system as instructed on Page S 2 before beginning disassembly Remove the four capscrews and lock washers that hold the filter bowl to the filter body Separate the filter bowl from the filter body and discard the O ring seal Remove the nut and washer
152. l old components seals and gaskets with new parts included in the kit gt Lll L DAMAGE AND WEAR OCCUR HERE FS 1483 FIGURE 6 29 MIXTURE NEEDLE INSPECTION Reassembly and installation Procedure 1 Slide in the throttle shaft and install the throttle plate using new screws if furnished in the repair kit Center the plate in the throttle bore before tighten ing the screws To do this move the throttle lever to the completely closed position Seat the plate by gently tapping on it with a small screwdriver then tighten the screws Install the seal the throttle stop lever and the collar on the throttle shaft 2 Install the idle and main adjustment screws and turn them in until lightly seated For preliminary settings turn the idle screw out 1 1 4 turn and screw out 2 1 2 1 4 turns Forcing the mixture adjustment ACAUTION screws light will damage the needle and seat Turn these screws in only until light tension is felt 3 Jointhe upper and lower sections ofthe carburetor and install the bowl plug and washer 4 When the carburetor is installed on the set make final adjustments to mixture screws as specified in the Carburetor Mixture Screw Adjustments section Regulator A two stage regulator see Figure 6 30 delivers vapo rized LPG fuel to the carburetor The primary stage of the regulator receives LP gas at container pressure and reduces itto the low pressure required for set operation T
153. lange to the mani fold support bracket and tighten securely Install the cooling system scroll and noise shield see Cooling System in this section no other service is required install the generator set in the vehicle before completing the remaining steps Install a new gasket between the exhaust manifold and exhaust tube Secure the flange connector to the manifold using 5 16 18 inch capscrews and lock washers Attach the inlet of the muffler to the exhaust tube using a 1 1 2 inch U bolt type automotive muffler clamp Make certain thatthe muffler inlet pipe over laps the exhaust tube a minimum of 1 1 2 inches 38 mm Place the muffler strap on the muffler and position it below the cutout in the bottom of the generator set drip tray Fasten the strap to the set strap bracket using 1 4 20 screw and lock washer Tighten the strap around the muffler using a 1 4 20 screw lock washers and nut Ifreplacingthe original tailpipe refer to the Tailpipe Recommendations sections for selecting and locat ing the tailpipe Attach the tailpipe to the outlet end of the muffler Secure it using a 1 3 8 U bolt type automotive muffler clamp Support the tailpipe using a shock mounted support hanger with clamp To prevent excessive vibration ACAUTION transfer to the vehicle mount muffler and tailpipe hanger brackets directly above the component being support NOT at an angle Run the generator set for five minutes Check
154. level in battery b Long periods of non use 2 Load connected to battery while set is turned off 7 7 Connect a voltmeter between positive Corrective Action Refer to Ignition System Section 6 for test and service procedures Refer to Fuel System Section 6 for test and service procedures Check for continuity and correct if circuit is open Refer to Testing Control Board A1 Check oil level and add oil if low Check for continuity and correct if circuit is open Replace low oil pressure switch Refer to Section 6 Troubleshooting for procedures to follow Check for continuity and correct if circuit is open Replace K5 relay Check for continuity and correct if circuit is open Refer to Generator section for test and service procedures Refer to Testing Control Board A1 Replenish electrolyte and recharge battery Connect a separate battery charger to bring battery up to full charge Turn off disconnect load and recharge battery Many troubleshooting procedures present hazards which can result in severe personal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Review safety precautions on inside cover page Trouble Engine Starts And Runs Then Stops Set Restarts Immediately or Set Restarts After Cooling Down REMOTE CONTROL if equipped
155. lodged on the engine cooling fins FLYWHEEL FLYWHEEL PULLER FLYWHEEL CAP SCREW 5 1000 FIGURE 6 5 FLYWHEEL PULLER Cooling System Assembly Procedure To reassemble the cooling system perform the assembly steps in reverse order When installing the flywheel align its keyway with the woodruff key on the crankshaft Use non hardening sealer on the flywheel capscrew threads and tighten them to the specified torque Refer to the Exhaust System section of this manual to install the exhaust manifold muffler and tailpipe Generator set overheating can result ACAUTION in engine damage To avoid this never operate the generator set with any cooling system components removed ELECTRONIC IGNITION SYSTEM Begin Spec G The electronic ignition system eliminates the breaker points and condenser of the conventional ignition sys tem In normai use the electronic ignition system com ponents should require little or no service or maintenance Ignition System Components Ignition rotor Ignition module Ignition coil Spark plugs e Wiring ignition Rotor The ignition rotor is attached to the engine crankshaft It contains a magnet which rotates past the ignition module inside the generator adapter The ends have opposite magnetic polarity north and south One pole switches on the ignition module and the other pole switches it off once each revolution of the crankshaft The ignition rotor should not normal
156. ls p UEM UAR NND GEM ee sida Gm QU AP Qi ee ee ig ged b uw ra LOAD mas OE eed Aan NEUTRAL I Nu c SCHEMATIC WIRING DIAGRAM SPEC K BGE NHE 60 HZ WIRING DIAGRAM SCHEMATIC WRI VOLTAGE REGULATOR IGN COIL 55 IGN MODULE 9 SWITCH LUM OIL PRESS TRESISTOR BATTERY CHARGE K4 RELAY CHOKE amp FUEL PUMP Ki RELAY START SOLENOID CHOKE GENERATOR FUSE 10 FUSE 104 SPARK PLUGS E2 FUEL PUMP RECTIFER BATTERY CHARGE 21 21 CIRCUIT BREAKER AC OUTPUT C4 55 CAPACITOR BATTERY 12 STARTER MOTOR REMOTE CONTROL STANDARD REMOTE CONTROL DELUXE CONTROL ASSY NHE CONTROL ASSY BGE t MATERIAL NO 611 1220 REV A MODIFIED p ca u eee ON MP AC d E CB TELE 7 213 110 120V 13 2 T2 13 T3 L2 220 240V T4 WE do mom Tl Li 1 To L3 CBI t 10 120 V 220 240 Y MO I20V cae NOTES 1 120V MAX ACROSS VR CONNECTIONS 2 3 2 GROUNDED SOLATED NEUTRAL LEAD FOR I REMOVEJUMPER W2 TBI L3 LO AND CONNECT JUMPER 10 VRI CS NEG VOLTAGE REGULATOR IGN COIL ISN MODULE SWITCH LOW OIL PRESS RESISTOR
157. ly require replace ment during the life of the genset Ignition Module The ignition module is mounted to the generator en gine adapter as illustrated in Figure 6 6 It is an elec tronic switch in the primary circuit of the ignition coil Itis switched on and off once each revolution by the rotor sending a pulse of the proper amplitude and duration to the ignition coil to be stepped up to high voltage to fire the spark plugs The ignition module contains user serviceable parts Testing Ignition Module 1 Remove the spark plugs and fan scroll Figure 6 4 so that the engine can be turned by hand 2 Connect the positive side of a voltmeter to the negative terminal of the ignition coil the larger of the two screw terminals and the negative side of the voltmeter to engine ground 3 Remove all leads from the positive terminal of the coil 4 Use a jumper to connect the ignition module lead the one just removed from the coil to the battery positive terminal 5 Rotate the flywheel clockwise by hand and measure the resultant voltage 6 If the voltage does not switch from about 1 volt to about 12 volts and back again to about 1 volt with each full revolution the ignition module is defective SECTION A A BRACKET ENGINE TO GENERATOR A eg IGNITION MODULE IGNITION ROTOR CRANKSHAFT ES 1862 FIGURE 6 6 IGNITION MODULE AND ROTOR Ignition Module and Rotor Replacement The
158. megohm indicates the rotor is grounded Replace a grounded rotor with a new rotor ES 1558 1 FIGURE 8 14 TESTING ROTOR FOR GROUNDS 8 16 Open or Shorted Windings Test To test for open wind ings set the ohmmeter for the highest resistance scale Place test leads on the slip rings as shown in Figure 8 15 Ohmmeter should indicate continuity between slip rings A high resistance reading indicates a poor con nection or an open winding Check the connection between the slip rings and rotor lead wires Replace rotor if the rotor winding is open To test for shorted windings set the ohmmeter for the lowest scale Place the test leads on the slip rings as shown in Figure 8 15 Resistance reading should be 20 25 to 24 75 ohms at 77 F 25 C Replace a rotor with shorted windings with a new rotor 5 1558 2 FIGURE 8 15 TESTING ROTOR FOR OPENS SHORTS Stator Tests The stator can be tested for grounded or open windings using an ohmmeter Testing for shorted windings requires a digital type ohmmeter that can read to within 0 01 ohms Figures 8 16 and 8 17 show the stator removed from the generator for testing However it is possible to test the stator without disassembling the generator Remove the control panel to obtain access to the specified lead wires during testing Ground Test test for grounds disconnect the follow ing stator leads e Stator leads 1 and T3 from TB1 Stator lead B1 from A1 P1 1 e
159. nd 3 4 rated loads See Troubleshooting if hunting is unacceptable Carburetor Replacement Other than turning the altitude adjust knob shown in Figure S 3 which changes the main fuel mixture within a limited range gasoline carburetors only fuel mixture adjustments should not be attempted on gasoline or LPG carburetors Nor should the car buretor be overhauled Instead a malfunctioning carburetor should be replaced Before replacing a carburetor however make certain 1 that all other necessary engine and generator adjustments and repairs have been performed and 2 that the carbu retor is actually malfunctioning by carefully follow ing the troubleshooting procedures in Trouble shooting LPG carburetors are usually not the cause of prob lems Make certain all other possible causes of the problem have been eliminated before replacing an LPG carburetor Unauthorized modifications or re placement of fuel exhaust air intake or speed control system components that affect engine emissions are prohibited by law in the State of California See the instructions on how to remove and replace the carburetor under the subheadings AIR CLEAN ER ASSEMBLY and CARBURETOR AND INTAKE MANIFOLD ASSEMBLY in this section Automatic Choke Gasoline Sets 1 Apply a vacuum of at least 100 mm 4 inches of mercury to fully pull in the choke breaker arm See Figure S 5 The automatic choke is operated b a bi metal heater assembly and a
160. nd bearing surfaces of all lubricated parts 4 Clean cylinder bore thoroughly with soap water and clean rags Continue cleaning until a clean white rag shows no discoloring when wiped through cylinder bore BEARINGS With camshaft and crankshaft removed use a microme ter to measure diameter of bearing journals Use a dial bore gauge or a telescopic gauge and micrometer to measure inside diameter of bearings Refer to Dimen sion and Clearance section to determine if clearances are within specifications Any bearing that is scored chipped pitted or worn beyond the specified limits must be replaced Camshaft Bearings Replacement camshaft bearings are precision type and do not require line reaming or line boring after installa tion Coat the bearing with lubricating oil Position the front bearing so the oil hole in the bearing is aligned with the oil hole see Figure 9 31 in the block Position the rear bearing so the elongated slot ts aligned with the breaker point plunger hole in the top of the block ALIGN HOLE IN BEARING veo 7 32 FROM OUTSIDE WITH HOLE IN BEARING BORE 1474 FIGURE 9 31 CAMSHAFT BEARING Use the combination main and cam bearing driver anda press to install the front and rear cam bearings Push in the bearings to the depth allowed by the flange on the driver 9 15 Crankshaft Bearings New crankshaft main bearings are precision type which do not require line reaming
161. nera tor setfuel system components must be dedicated to the generator set only not shared with any appliances LP gas presents the hazard of fire or ACAUTION explosion and it is poisonous These hazards can result severe personal injury or death If flameout occurs with an unvented appliance LP gas can accumulate inside the vehicle and create a safety hazard If the generator set fuel supply line is shared by any vehicle appliances do not continue with any further service procedures Obtain a copy of the Instruction Sheet G65 Assembly Instructions for ihe Installation of LP Vapor Kit for Use with and Generator Sets Compare the instruction sheet proce dures and applicable codes to the generator set and fuel supply system installation Correct as necessary before continuing service work LP Fuel Supply at Carburetor Adjustment Open the fuel supply shutoff valve at the supply tank and proceed as follows 1 Loosen the lock nut on the gas adjustment screw located near the LP gas inlet see Figure 6 35 2 Turn the LP gas adjustment screw inward until seated Push the generator set start button while the set is cranking slowly turn the adjusting screw out coun terclockwise 1 4 to 1 2 turn until set starts This adjustmentis critical for proper operation of the set If the set does not start reseat the gas adjustment screw and repeat the adjustment procedure If the set still does not start refer to th
162. ng generator sets presents hazards of electrocution burns fire and explo sion asphyxiation and entaglement with rotating parts Review Important Safety Instructions in Operator s Manual ES20503 A 5 START MODE Push S1 switch to start B at P1 2 P1 3 and P1 5 Required 10 12 VDC B AT 1 2 TO START SOLENOID b AT P1 3 TO IGNITION COIL B AT P1 5 TO POS BRUSH 5 FIELD FLASH 12 14 VDC Good DC V M RUN MODE 1 AC voltage at P1 1 to P1 7 18 26 VAC BAT CHARGER O 2 B at P1 3 to IGNITION COIL 3 Ground at P1 4 FROM LOPKO Required 18 26 VAC 12 14 VDC 00000900 0 amp 69 fA ot STOP MODE Push 1 switch to stop 0 volts at P1 3 lt lt 2 STOP STATIC MODE ES2050 1s EMERALD CONTROL BOARD CHECK OUT 300 3056 3687 REMOVE CIRCUIT BOARD To perform the following tests the circuit board must be removed from the control cover CONTINUITY TEST Place the circult board on a non conductive surface with the component side of the board up Check for a good circuit between the board and the wiring by checking continuity between the J and P connectors with the battery disconnected For the following tests the battery must be connected STATIC MODE With the switch in the Center position Meter Meter Test Lead Reading 1 6 1 8 12 VDC 1 6 2 1 12 VDC CRANK amp START MODE With the switch pressed to the Start posi
163. nishes lubrication to the camshaft drive gears Normal oil pressure should be 13 14 psi 89 6 96 5 kPa or higher when the engine is at normal operating temperature If pressure drops below this value at gov speed inspect the oil system for faulty components Check the oil pump thoroughly for worn parts Oil the pump to prime it before reinstalling Except for gaskets and pick up cup the component parts of the pump are notavailable individually install a new pump assembly if any parts are worn 9 8 Oil Bypass Valve The bypass valve located to the right and behind gear cover Figure 9 17 controls oil pressure by allowing excess oil to flow directly back to the crankcase Nor mally the valve begins to open about 13 14 psi 89 6 96 5 kPa HEX CAP SCREW FLAT WASHER SPRING VALVE LS 1110 FIGURE 9 17 OIL BY PASS VALVE The valve is non adjustable and normally needs no maintenance To determine if abnormal high or low oil pressure is caused by improper valve operation inspect as follows 1 Remove 3 8 24 capscrew located behind gear cover and under governor arm Remove spring and plunger with a magnetic tool Determine proper valve operation by checking the spring and plunger according to the following measurements 2 3 Plunger Diameter 0 3105 to 0 3125 in 7 89 to 7 94 mm Spring Free Length 1 00 in 25 4 mm LOA uer edt 2 6 0 2 165 11 6 0 9 when comp
164. nstalled Be sure to follow the recommended exhaust system replacement procedures Use 1 3 8 inch I D 18 gauge rigid steel tubing for tailpipe Do not use flexible exhaust tailpipe because itis vulnerable to road shock and vibration Install an exhaust tailpipe at least 3 inches 76 mm away from the fuel tank and from any combustible material If 3 inches clearance cannot be main tained install heat shielding between the tailpipe and the fuel tank or any combustible material to prevent excessive heating Do NOT terminate the exhaust tailpipe in these positions A Under a window door or any opening that might allow exhaust gases to enter the vehicle interior Ahead of or underneath the generator com partment air intake which might recirculate exhaust gases Terminate the tailpipe atthe rear of the compartment air intake if possible Under the fuel tank fill spout so spilled fuel cannot be ignited by a hot tailpipe Under the vehicle so exhaust gases cannot enter the vehicle interior through small open ings in the underside of the vehicle Extend the tailpipe at least one inch 25 mm beyond the perimeter of the vehicle Direct exhaust gases down and away from the vehicle and away from windows doors or compartment openings Do not connect the generator set exhaust tailpipe to the vehicle exhaust system Exhaust gases will be forced into the non running engine and might be released through the ca
165. o brush block terminals F1 with outboard brush lead and F2 with inboard brush lead Install brush block cover onto stator housing Install air filter element and air cleaner cover Connect negative battery cable to battery terminal Slip Ring Service Remove the brush block cover and inspectthe slip rings for grooves pits or other damage Ifthe slip rings are not in good condition they may be refinished using a com mutator stone Use the following procedure to service 1 Remove the air cleaner cover and air cleaner filter 2 Discconnect voltage regulator lead wires F1 and F2 from the brush blockterminals and then insulate the lead wire ends Tie the lead wires to one side to allow clear access to the slip rings 3 Remove the brush block mounting screws and lift out the brush block assembly 4 Insert a 3 8 inch allen wrench into rotor through bolt and rotate engine and generator one full turn While rotating inspect condition of slip rings If slip rings require refinishing continue to next step If slip rings do not require refinishing follow steps 6 through 14 in the Brush Replacement section 5 Press the Start Stop switch to START position to crank the engine During this step only crank the engine for 3to 6 second cranking periods with a rest period between so not to overheat starter During engine cranking hold a commutator stone against rotating slip rings Remove commutator stone after each crank
166. oil or diri The timing is adjusted during initial engine assem bly and is fixed by the point gap adjustment No other adjustment or alignment is necessary 9 Replace the point box cover and hold down wire spark plugs and spark plug leads 10 Connect negative battery cable to negative bat tery terminal CONDENSER LEAD WIRE POINT GAP A IGNITION LEAD WIRE B ES 1529 1 FIGURE 6 10 BREAKER POINTS Ignition Coil The ignition coil Figure 6 11 is a transformer that steps up the battery voltage to approximately 20 000 volts to fire the spark plug Keep all ignition coil terminals and connections clean and secure Check for loose seams dents punctures and other mechanical damage If ignition is poor and other ignition components are not at fault test the coil as described below Make certain of coil polarity the nega tive terminal connects to the breaker points and the positive terminal connects to a battery positive source within the control HIGH VOLTAGE TERMINAL LOW VOLTAGE TERMINAL SECONDARY WINDING PRIMARY WINDING 4 IRON CORE ES 1666 FIGURE 6 11 IGNITION COIL ignition Coil Quick Test This test checks the coil with the rest of the ignition system Gasoline vapor is extremely flam AWARNING mable and can result in severe per sonal injury or death if ignited Make certain that no gasoline or other flammable fumes are present Park the vehicle in a well ventilated ar
167. oltage regulator is protected from moisture reduc ing the risk of component failure The printed circuit board control is encased in the regulator housing with a potting compound the ends of the J4 wiring harness are booted covering the terminals of capacitor C5 mounted to the outside of the regulator housing and the wiring harness plug in P4 is treated with a lubricant prior to connection More protection is provided by mounting the voltage regulator assembly inside the generator control housing Terminal Board TB1 The AC output power leads from the generator T1 T2 T3 and T4 are connected to termina board TB1 These connections may differ between models Refer to the proper Wiring Diagram Schematic for specific information AC power at TB1 terminals is tapped by leads of wiring harness J4 of voltage regulator VR1 and interconnect wiring to the circuit breaker s CB1 and 2 if equipped These leads provide generator output to the voltage regulator for proper voltage regulation and to the circuit breaker s for power supply to load CONTROL OPERATION The schematic diagram shown in Figure 7 2 is intended as an illustration of the circuit description However when troubleshooting always refer to the wiring dia gram that corresponds to the model and spec numbers of the generator set Starting Placing the Start Run Stop switch in the Start position connects battery ground B to the K4 start relay This energ
168. on Without ignition or fuel the engine stops As the genera tor output voltage drops generator relay K2 also de energizes All components return to their de energized position following set shutdown TESTING CONTROL BOARD 1 Confirm that control board A1 is faulty before replacing it Use a DC voltmeter and an ohmmeter to perform the following tests 1 2 Disconnect the negative battery cable Remove the control box cover Figure 7 3 and separate it from control board A1 by removing the four screws on the back of the board With an ohmmeter check for electrical continuity across each P1 J1 and P3 J3 connector on the control board Figures 7 2 and 7 4 Replace the socket portion of each connector that has a measu rable resistance greater than zero ohms or has begun to corrode Reconnect the battery and try to start and run the set If the engine does not crank measure voltage at connector P1 2 while pressing the panel start switch the negative test probe of the voltmeter should be grounded at connector P1 8 If the meter indicates zero volts and if fuse F1 is good replace control board If the voltmeter indicates at least 9 volts the problem is not with the contro board Go back to the Troubleshooting Guide If the engine cranks but does not start measure voltage at connectors P3 3 and P3 6 while the engine is cranking the negative test probe of the voltmeter s
169. on coil primary winding High voltage wiring from the ignition coil secondary winding to the spark plugs 6 12 The plugs and coil secondary are grounded to the engine completing a circuit to the battery When the ignition rotor passes the ignition module it causes the module to ground its B connection sending a low voltage pulse through the coil primary A high voltage pulse is induced in the ignition coil secondary firing the spark plug Check all low voltage wiring for loose connections and breaks in the insulation Clean all terminals and connec tions and use an ohmmeter to test them for continuity Use a megger high range ohmmeter to check for breaks in the plug wire insulation BREAKER IGNITION SYSTEM Prior to Spec G The ignition system consists of the following elements Breaker points Condenser e ignition coil e Spark plugs e Wiring This section provides service and adjustment proce dures for the ignition system Refer to the Specifications section for the correct dimensions for adjustment Breaker Points and Condenser The breaker points and condenser are mounted on the engine block A small plunger rides on an ignition cam at the end of the camshaft This plunger actuates the points which open and close twice with every revolu tion of the camshaft The point gap setting determines when the points will open and consequently deter mines ignition timing If the timing is retarded too far
170. on control board A1 through the voltage regulator to the brushes and slip rings ofthe rotor Upon successful engine start and genera tor voltage build up generator relay K2 becomes ener gized which opens theN C contacts in the battery B circuit to the voltage regulator and closes a set of N O contacts in the start disconnect run relay K3 circuit of board A1 This circuit keeps relay K3 energized while the set is in operation If relay K2 becomes de energized the set will shut down Brushes DC excitation voltage is induced through the brushes and rotor slip rings to the rotor windings The brush block assembly consists ofa single brush block with two brushes The brush block mounts inside the generator housing direcily over the rotor slip rings and can be accessed by removing the small plate at the rear of the housing Rotor The 4 pole rotor provides the rotating magnetic field that s required for generating an AC voltage potential in the stator windings The DC current required for field excitation is supplied through two slip rings that mounton the rotor shaft The inner end ofthe rotor is connected directly to the engine crankshaft using a tapered seat shaft coupling and through bolt The outer end of the rotor is supported by a single bearing that is pressed onto the rotor shaft The bearing fits inside the generator housing Cooling airflow for the generator is provided by a centrifugal fan that mounts on the inne
171. or sets that use a liquid withdrawal system are intended to share the vehicle LPG fuel tank The LPG fuel tank mustbe designed with a dip tube to permit liquid fuel withdrawal This section provides basic information about LPG fuel systems and service proce dures for each fuel system component LPG Liquid Withdrawal Fuel Systems LPG liquid withdrawal fuel systems typically operate at pressures as high as 200 psi 1379 kPa when the ambient temperature is 110 43 3 C Because of the high pressure special precautions must be taken to avoid releasing large quantities of highly flammable LP gas when servicing the fuel system Use the procedure described below to purge the fuel system of LP gas before servicing any fuel system components LP gas Propane is extremely flam A WARNING mable Severe personal injury or death can result if it is accidentally ignited Eliminate all fire flame spark pilot light arc producing equip or other ignition sources before purging LP gas from the fuel system Provide adequate ventilation to dissipate LP gas as it is released LPG Purging Pressure 1 Open the AC load circuit breaker and close the shutoff valve at the fuel tank 2 Start the generator set and run it until it stops for lack of fuel 3 Crank the seta few times after it stops to make sure the fuel system is purged of fuel If the generator set cannot be operated do the following 1 Move the vehicle to a well ventilat
172. or valve and seat A soap bubble placed over the A WARNING regulator outlet will not accu rately lest regulator closing and will cause the very sensitive demand regulator to shut off Close the gas supply shutoff valve at the fuel tank A WARNING gas presents the hazard of fire or explosion and it is poi sonous These hazards can result in severe per sonal injury or death Cranking the engine or dis connecting the solenoid valve will create sparks that can ignite accumulated gas vapors Make sure that any gas vapors accidentally released during testing have been safely and completely dissi pated before proceeding De energize the solenoid valve and reconnect the solenoid lead to its control lead Connectthe gas supply hose to the regulator outlet fitting and secure it with a clamp Remove the manometer and install a 1 8 inch plug in the test hole Verify that the vent hose is properly routed through the opening in the compartmentfloor then open the gas supply shutoff valve Adjust the gas adjustment screw as described in the previous section Operate the generator set to test that it starts correctly ELECTRIC STARTER 3 Remove the starter mounting screws Carefully dis Removal and Disassembly Procedure engage the starter from the stator housing 4 Remove the starter through bolts Carefully separ 1 Disconnect the generator set negative batte cable from the set start
173. orizontal honing Use either a drill press or heavy duty drill which operates at approximately 250 to 450 rpm 2 Follow hone manufacturer s instructions for the use of oil or lubricant on stones Do not use lubricants with a dry hone 3 Insert hone in bore and adjust stone to fit snugly to the narrowest section When adjusted correctly the hone should not shake or chatter in cylinder bore but will drag freely up and down when hone is not running 4 Connect drill to hone and start drill Feel out bore for high spots which cause an increased drag on stones Move hone up and down in bore with short overlapping strokes about 40 times per minute Usually bottom of cylinder must be worked out first because it is smaller As cylinder takes a uniform diameter move hone up and down all the way through cylinder bore 5 Check diameter of the cylinder regularly during hon ing dial bore gauge is the easiest method but a telescoping gauge can be used Check size at six places in bore measure twice at top middle and bottom at 90 degree angles 6 Crosshatch formed by the stones should form an included angle of 23 degrees This can be achieved by moving the rotating hone 250to 450 rpm up and down in cylinder bore about 40 times per minute 7 Clean cylinder bores thoroughly with soap water and clean rags A clean white rag should not become soiled on wall after cleaning is complete Do notusea solvent or gasoline sincethey w
174. ossible sources of ignition such as open flame sparks pilot lights cigarettes and arc producing machinery or switches before purging LP gas from the fuel system Provide adequate ventilation to dissipate LP gas as it is released Propane gas will sink to the ground and is not easily detected Slightly open the fuel line flexible section at the sole noid valve just enough to allow the LP gas to slowly escape Don t open the fitting too much or a large quan tity of gas will be released Disconnect the fuel supply hose from the carburetor and hold it clear of the set Press in and hold the primer button on the regulator to release LP gas from the set fuel system When no more gas can be heard escaping from the open end of the fuel supply hose reconnect the hose to the carburetor and proceed to the appropriate set removal section Disconnecting Set from RV Systems Disconnect the following items from the generator set 1 Disconnect the vehicle negative battery cable at the battery terminal Disconnect the generator set negative battery cable at the battery terminal Disconnect the generator set positive battery cable from the start solenoid Disconnect the remote control wire plug from the generator set control Disconnect the generator load wires at the RV elec trical system junction box Tag the RV circuit wires if necessary for positive identification when reconnecting 2 3 5 4 6 Loosen the
175. perly in place behind the camshaft gear Then install the crankshaft retaining washer and lock ring o t u 8 a ATIS THESE MARKS MUST 94 ALIGN WHEN INSTALLING TIMING GEARS Tb 1029 FIGURE 9 15 TIMING GEAR REMOVAL AND INSTALLATION LUBRICATION SYSTEM All generator set engines use an oil pump to provide a constant flow of oil to the engine parts The oil supply collects in the oil base where it is picked up by the oil pump pick up cup A bypass valve is used to control oil pressure Drain the oil before removing the oil base and always use a new gasket when replacing the oil base Oil Pump The oil pump Figure 9 16 is mounted on the front ofthe crankcase behind the gear cover and is driven by the crankshaft gear The inlet pipe and screen assembly is attached directly to the pump body A discharge pas sage in the cover of the pump registers with a drilled passage in the crankcase Parallel passages distribute oil to the front main bearing rear main bearing and pressure control bypass valve OIL PUMP PICK UP CUP OIL PUMP ASSEMBLY CRANKCASE TURNED ON LEFT SIDE 15 1109 FIGURE 9 16 OIL PUMP ASSEMBLY Circumferential grooves in the main bearings supply oil to the connecting rod bearings through drilled pas sages from each main journal A drilled passage con nects the front main bearing oil supply to the front cam shatt bearing The oil overflow from the bypass valve fur
176. por locking d plugged fuel filter 7 Carburetor icing Gasoline Sets Only 6 3 Corrective Action Replace air cleaner Clean choke and choke linkage Adjust carburetor idle and main adjustment screws Disassemble carburetor and clean all internal passages Adjust carburetor float level Adjust carburetor idle and main adjustment screws Dissemble carburetor and clean all internal passages Repair vacuum leak Drain and replace fuel See Engine Block Assembly section Clean governor linkage Check that linkage does does not touch other parts Adjust governor speed and sensitivity Replace governor spring Adjust carburetor main and idle adjustment screws Adjust carburetor float level Disassemble carburetor and clean all internal passages See Engine Block Assembly section Check fuel pump and replace if defective Drain and refill fuel supply Check for cause of overheating Replace fuel filter In cold weather place air preheater in winter position TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Continued AWARNING Many troubleshooting procedures present hazards which can result in severe personal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards Should perform service procedures Review safety precautions on inside cover page Trouble Possible cause Corrective Action
177. ppliance Faulty generator set wiring Rotating Machinery Flywheel fan guard not in place Slippery Surfaces Leaking or spilled oil Heavy Objects Removing generator set from RV Removing heavy components Because of the wide variety of generator set installa tions it is not possible to specify the exact removal procedures for each generator set If after examining the installation a satisfactory method for removing the set cannot be determined contact the RV coach manu facturer to obtain their recommendations before attempting to remove the set from the coach The generator set is heavy and can AWARNING result in severe personal injury if dropped during removal Use adequate lifting devices to provide sufficient support for the set Keep hands and feet clear while lifting Special fuel handling procedures are required when removing an LP gas propane powered set The fuel system must be purged of LP gas before the set can be safely removed from the coach Follow the purging procedure before attempting to remove an LP gas powered set If the generator setis powered by gasoline proceed to the appropriate set removal section LP Gas Propane is extremely AWARNING flammable and poisonous and can result severe personal injury or death if accidentally ignited or inhaled Eliminate all possible sources of cigareties and arc producing machinery or switches before purging LP gas from the fuel system Provide adeq
178. precautions on inside cover page Trouble Engine Cranks But Does Not Start Engine Starts But Stops When Start Switch is Released Low Battery Voltage Possible Cause 1 Faulty ignition due to worn or fouled spark plugs faulty plug wires faulty ignition coil breaker worn points or faulty ignition module Faulty fuel system due to low fuel level in tank supply valve not open sticking choke faulty fuel pump faulty fuel solenoid or carburetor mixture screws incorrectly adjusted terminal T1 ignition coil and ground Check for battery voltage when S1 is placed in the START position If the voltage is not present fault is due to a Open circuit between T1 coil and control Defective control PC board b Gasoline Sets Only PG Sets Only Prior to Spec G Spec G and Later 1 Low oil pressure switch S2 not closing due to a Low oil level b Open circuit between switch and control Defective low oil pressure switch Low oil pressure Ignition relay K5 contacts not opening due to a 5 relay circuit open Defective K5 relay Output voltage from generator not being supplied to control due to a Open circuit in wiring between generator and control b No output voltage from generator Defective control PC board A1 PG Sets Only 1 Weak or discharged battery due to a Low electrolyte
179. productive toxicity When adding changing or working with fuel or asbestos gaskets take care not to breathe ingest or come into excessive contact with these substances Wash hands after use Wear protective clothing and equipment Provide adequate ventilation SET REMOVAL Some service procedures will require that the generator set be removed from the coach While there are many variations generator set installations are generally classified as either conventional compartment mountor below the floor mount In a compartment mount instal lation a special compartment see Figure 5 1 is built into the coach to house the generator set The com partment is constructed with a vapor tight barrier that seals off the generator set from the coach interior The generator set is usually fastened to the floor of the com partment which must be able to support the weight of the set Access to the compartment is through a door located in the exterior of the coach below the floor mount installation see Figure 5 2 a special housing is used to suspend the generator set from the underside of the coach The housing bolts to special support members that are built into the coach framework The housing is mounted near the exterior of the coach and limited access is provided through a door panel located in the exterior of the coach e Electrical Shock AC Improper generator set load connections Faulty RV wiring Faulty electrical a
180. quipped The output power from the generator set is supplied to the control circuit breaker s located on side of the control right housing The ampere rating of the circuit breaker s may differ depending on generator set model frequency Be sure to refer to proper Parts Man ual when ordering any replacement parts Wiring Harness to Load s A separate wiring harness is provided for connecting the generator set to the RV electrical system All lead wires are stranded copper wire to withstand vibration The lead wires must be protected with flexible conduit from the generator set control housing to the RV swit ching disconnect device which must be provided by the RV manufacturer The lead wires exit the control housing behind the fuel pump solenoid The load con ductors are black the neutral conductors are white and the ground conductor is green GENERATOR OPERATION Generator operation involves all control components previously described The wiring diagrams schematics examples shown in Figures 8 2 8 3 8 4 and 8 5 reflect representative generator set models and are intended for reference only Always refer to the specific wiring diagram schematic that corresponds to the specific generator set when troubleshooting problems 8 2 When the start stop switch is placed in the START posi tion the rotating field rotor is momentarily connected to battery positive B to provide adequate residual magnetism for voltage build up
181. r and a press to install the front bearing Push the bearing in to the depth allowed by the flange on driver Wipe off any excess Locktite and allow one hour for hardening at room temperature Engines shipped from the factory have separate thrust washers and main bearings for both front and rear of engine Front bearing replacement part is one piece bearing with attached thrust washer as shown in Figure 9 33 Do not add an additional thrust washer to this front bearing NOTE DO NOT ADD ADDITIONAL THRUST WASHER WHEN anne REPLACING FRONT BEARING BORE a Ys i LOCK PIN E P nd 2 2 el l ALIGN BEARING NOTCHES WITH LOCK PINS AND MATCH OIL HOLES FRONT MAIN BEARING PRECISION TYPE DO NOT LINE BORE OR REAM OR BORE 1476 FIGURE 9 33 FRONT BEARING USE GREASE IN SPACE BETWEEN SEALS TO IMPROVE SEAL OIL SEALS Remove the rear bearing plate to replace the rear oil seal Remove the gear cover to replace the front oil seal Use an oil seal removed to pry out the front or rear oil seal Usean oil seal guide and driverto press or drivethe rear seal into the rear bearing plate until it bottoms against the shoulder of the plate see Figure 9 34 Press or drive the front seal into the gear cover until it is 0 97 0 02 inch 24 6 0 5 mm from the mounting face of the cover Lubricate the lips of the replacement seal wit
182. r end of the rotor shaft The fan also serves as a mount for the starter ring gear Stator and Housing During generator set operation AC current is produced in the windings ofthe stator All stator winding leads are routed into the generator set control housing compartment for control component connection as follows Leads T1 T2 T3 and T4 to Terminal Board TB1 for supplying power to load Leads B1 and B2 to Control Board A1 wiring harness J1 for supplying power to generator relay K2 Leads Q1 and Q2 to Voltage Regulator VR1 wiring harness J4 for excitation voltage of rotor AC voltage from stator is rectified to DC voltage in VR The stator mounts inside the generator housing and is held in position with clamps and capscrews A series of air intake openings in the end of the housing allow cool air to be drawn inside the housing for generator cooling The hous ing also provides a mounting point for the engine starter rear rotor bearing exciter brush block control components and fuel pump or solenoid LPG The complete stator and housing assembly bolts to the engine to generator adapter Terminal Board 1 8 1 The AC output power leads from the generator T1 T2 T3 and T4 are connected to terminal board TB1 at terminals L1 LO connection configuration is model dependent refer to proper Wiring Diagram Schematic for further informa tion AC power at TB1 terminalsistapped by leads of wiring harness
183. r set is to use a forklift truck The generator set is heavy and can A WARNING result in severe personal injury if dropped during removal Use the recommended remo val techniques and keep hands and feet clear while removing mounting bolts Removing Underfloor Mounted Set From RV When the generator set has been disconnected from the electrical exhaust and fuel systems the set may be partially removed for limited service or completely removed from the RV for major service The generator set is mounted on a support tray which serves as the bottom of the underfloor housing The inner edge of the support tray is hinged to the rear panel assembly The outer edge of the support tray is bolted to a support bracket NHE and NHEL models have two support brackets A front and rear panel assembly serve as sides to complete the housing The generator set is completely suspended underneath the RV coach by the housing assembly To avoid drop ping the set during removal follow the recommended set removal procedures The generator set is heavy and can AWARNING result in severe personal injury if dropped during removal Use the recommended remo val techniques and keep hands and feet clear while removing mounting bolts lf generator set will be left in the down tilted position for more than 30 minutes first drain the oil Oilin the engine cylinders can cause ACAUTION engine damage during starting attempts Oil can enter the engine cylin
184. racted to the core Replace a shorted armature with a new one HACK SAW ES 1615 FIGURE 6 40 TESTING ARMATURE FOR SHORTS 6 34 Testing for Opens Touch one ohmmeter lead to a commutator bar then touch the other lead to each of the other commutator bars in turn A high resistance indi cates an open circuit between the commutator bars and armature windings Replace an open armature with a new one Brush Inspection Measure brushes Figure 6 41 and replace them if worn less than 0 425 11 mm 0 425 INCH 11 mm WEAR LIMIT NEW 0 570 INCH 14 5 mm 5 1610 FIGURE 6 41 BRUSH INSPECTION Assembly 1 Wipe dirt and oil from starter components using a clean cloth or blow off dirt with filtered low pressure compressed air Oil on armature will damage ACAUTION starter Do not immerse bear ings in cleaning fluid Use a brush dipped in clean engine oil to remove dirt from bearings Avoid get Mountthe brush springs on tabs as shown in Figure 6 42 Using a small screwdriver turn the spring counterclockwise to torque it so the contact loop is inside the brush holder The spring should be pushed down to the mounting tab shoulder Push the negative brush terminals over the through bolt holes on the brush endcap Inserta positive brush stud into the hole and torque to 25 30 in Ib 2 83 3 39 Nem ting oil on brushes or commutator 5 inserta small screwdriver into the brush spring con
185. rburetor air inlet Water vapor from the exhaust might also damage the non running engine COOLING SYSTEM Emerald generator sets use the Vacu Flo cooling sys tem to provide a constant air flow over the engine and generator to minimize heat buildup A flywheel fan draws cool air in from the generator end of the com partment see Figure 6 3 This air passes over the cool ing fins on the engine absorbing the heat Heated air is discharged through the opening in the bottom of the generator set housing 6 8 Inhalation of carbon monoxide can AWARNING result in severe personal injury or death Never use discharged cooling air for heating the vehicle interior because discharged cooling air can contain poisonous exhaust gases AIR OUT M 1609 2 FIGURE 6 3 COOLING AIRFLOW The size of the generator compartment air inlet see Specifications determines the air flow rate The air inlet and discharge openings must remain free of any obstructions to avoid restricting airflow Regularly remove any dirt dust or debris clogging the duct open ings Remove any dirt lodged between the cooling fins on the engine block and cylinder heads If the fins are dirty heat transfer is greatly reduced and overheating can occur The cooling system consists of Noise shield Cylinder air housings e Scroll e Flywheel Scroll backplate Cooling System Disassembly Procedure Contact with hot engine parts can ACAUTION caus
186. re Check each of the following e Load Wires Control Wires e Ground Strap e Battery Cables INITIAL START ADJUSTMENTS Adjust the carburetor idie and main adjustment screws as specified in the Fuel System section Before attempting any carburetor governor adjustments disconnect all devices which are voltage or frequency sensitive Some solid state devices such as TV s or VCR s are powered whenever connected to an AC outlet even if the device is not in actual operation If disconnecting the devices is not possible open the circuit breaker s at the distribution panel or at the genset if so equipped Failure to heed this advisory may result in consequen tial damage to voltage frequency sensitive equipment such as VCR s TV s computers etc Repair replace ment of damaged devices is not covered under Onan warranty policy Start the set and immediately adjust the governor speed adjustment nut to obtain a safe no load operating speed With no load applied listen for any unusual sounds or vibrations When the choke is completely open adjustthe carburetor and governor as specified in the Fuel System section 10 1 FUEL SYSTEM With the generator set operating inspectthe fuel supply lines filters and fittings for leaks Check any flexible sections for cuts cracks and abrasions and make sure they are not rubbing against anything that could cause breakage Leaking fuel will create a fire hazard A
187. re 6 44 Place the mounting bracket on the motor facing the exposed end of the sleeve bearing and throughbolt lead ins toward the inside of the motor The flat near one mounting hole should line up with the positive stud on the end cap so the through bolts can line up Insert the through bolts and torque to 35 45 16 3 96 5 09 Nem Wipe dust from the helix and gear and apply a light coat of GE Versilube 322 L to the outside diameter of the helix the inside diameter of the gear and the unchamfered end of the gear Place the clutch and helix assemblies on the motor shaft with flats engaged in the clutch hole ES 1611 FIGURE 6 43 RESTING BRUSH SPRING ON BRUSH SIDE 6 36 METAL SPRING CLUTCH amp WASHER SPLINE ROLL PIN ASSEMBLY 1 16 INCH WASHER SEN SPRING RETURN P COVER PT pm RETURN SPRING a 22 n M _ WASHER SPRING WASHER FLAT WASHER ARMATURE BRUSH ENDCAP THROUGH BOLT HOUSING FIGURE 6 44 STARTER ASSEMBLY 14 ifthe return spring is unassembled do the following Placea1 1 16 inch O D washer over the end of the shaft With the chamfered side of the shaft hole facing up place a plastic retainer on the shaft and line up the hole with a hole in the shaft Support the plastic retainer with a vise or other solid surface Using a 5 32 or 1 8 inch nail set and hammer
188. re that the coil sits squarely in the housing and that the inner end of the coil engages the slot in the choke shaft The slotted tang on the element cover must engage the bi metal strip 2 85 rr FS 1606 OUTER TAB FIGURE 6 24 BI METAL SPIRAL STRIP Choke Pulloff Diaphragm Adjustment The choke pull off diaphragm partially opens the choke plate after engine startup This inhibits flooding and promotes smooth engine operation as the set warms up Choke Pulloff Diaphragm Adjustment Procedure 1 Removethe air intake assembly as described in Air Intake Assemblyin this section to access the choke plate 2 Disconnect the diaphragm hose from the intake manifold Apply 4 to 18 inches 13 5 to 60 8 kPa Hg vacuum to the diaphragm CHOKE LEVER CHOKE PLATE CLOSED PULL OFF LINKAGE PULL OFF DIAPHRAGM ded 4 DISTANCE DIAPHRAGM MTG BRKT BEND HERE j FS 1603 1 FIGURE 6 25 CHOKE PULL OFF DIAPHRAGM 6 24 3 Apply light finger pressure against the choke lever to take up all free play in the pulloff linkage see Figure 6 25 4 Check and correct the alignment of the diaphragm stem pulloff linkage and slot in the choke lever viewing them from above 5 Measure the distance between the choke plate and the bottom of the carburetor at the point indicated in Figure 6 25 There should be 0 39 to 0 43 inches 9 9 to 10 9 mm clearance here if necessary bend the diaphragm mounting bracket
189. ressed to 0 500 in 12 7 mm Gheck the valve seat and clean away any accumula tion of metal particles which could cause erratic valve action Verify that the valve seat is concentric with the larger diameter valve bore Clean plunger and spring in parts cleaning solvent and install PISTON ASSEMBLY The piston assembly consists of the piston piston rings piston pin connecting rod assembly and bearing After removal from the engine all parts must be carefully inspected for damage and wear before replacing Removal and Disassembly Remove carbon from top of cylinder bore and check for a ridge Remove ridge see Figure 9 18 with a ridge reamer before attempting piston removal improper use of a ridge reamer can ACAUTION damage the cylinder bore CT 1058 FIGURE 9 18 REMOVING WEAR RIDGE To remove the piston and connecting rod assemblies turn the crankshaft until a piston is at the bottom of the stroke Remove the nuts from the connecting rod bolts Lift the rod bearing cap from the rod and push the rod and piston assembly out the top of the cylinder with the handle end of a hammer Be careful not to scratch the crankpin or the cylinder wall when removing these parts Mark each piston and rod assembly so they can be returned to their respective cylinders after overhaul Keep connecting rod bearing caps with their respective rods The pistons are fitted with two compression rings and one oil control ring Remov
190. retains the dry gas which surrounds the electrical system Electrical system components are not serviceable Choke Spec K 1 Apply a vacuum of at least 4 inches 100 mm of mercury to fully pull in the choke breaker arm Figure 6 25a illustrates the Spec choke components for 2 Insert a 0 337 inch 8 6 mm drill rod between the gasoline carburetors Replace faulty choke components choke plate and the carburetor throat and reassemble as shown Adjust the choke breaker as Ifnecessary bend the link at the point shown until the sembly each time it is assembled to the carburetor as fol lip of the choke plate just touches the drill rod Use lows two pliers to bend the link i i IF NECESSARY BEND THIS LINK AT Make sure this hose is TS PONT WEEN ADJUSTNA TTE not kinked otherwise the engine may flood CHOKE BREAKER ASSEMBLY VACUUM SUSTAIN VALVE ASSEMBLY CHOKE SHAFT ASSEMBLY GAUGE THE DISTANCE BETWEEN THE CHOKE PLATE AND MAIN THE CARBURETOR THROAT WITH A 0 337 INCH 8 6 mm CARBURETOR BI METAL DRILL ROD WHEN ADJUSTING THE CHOKE BREAKER BODY ASSEMBLY ASSEMBLY FS 1872 1s FIGURE 6 25 CHOKE ASSEMBLY SPEC K 6 24 FUEL SYSTEM LPG LIQUID WITHDRAWAL The fuel system must be properly adjusted and in good condition Components of the fuel system are Air cleaner assembly Carburetor e intake manifold Fuel filter e Solenoid valve e Vaporizer e Two stage regulator LPG generat
191. rformer Emeraid Plus Marquis Ensign are trademarks of Onan Corporation 1991 Onan Corporation A 2 900 0261 Emerald Control Functions A1 Control Board 300 3056 3687 Sequence of Events Battery pos at P1 6 Battery neg at P1 8 Operator pushes start button at A1 B from P1 2 to start solenoid S terminal Solenoid contacts close send B to starter Sequence of Events Operator pushes start button on A1 Safeties are bypassed B from P3 3 to ignition coil Breaker points open close path to ground High voltage jumps spark plug gap B supplied to fuel pump from P1 2 A WARNING Use extreme caution when working on operating generator sets Operating generator sets presents hazards of elec trocution burns fire and explosion as and entanglement with rotat Ing paris Heview Important Safety In structions in Operator s Manual A 3 Engine Cranking Start Mode ignition Start Mode 4 SPARK S3 z PLUG IGNITION POINTS JE IGNITION COIL 9 K1 START SOLENOID r enba ulich 2 FUEL PUMP Field Flash Start Mode ROTOR Sequence of Events VAI VOLTAGE REGULATOR Operator pushes start button on 1 B from 1 5 to voltage regulator P4 7 B from voltage regulator P4 9 to positive brush F1 B from voltage regulator P4 10 to negative brushes F2 Win 4
192. ric current Heat from the element causes the bi metal strip to coil turning the choke shaft to gradually open the choke plate and keeping the plate open while the engine is running The choke becomes very hot during AWARNING normal operation and can cause severe burns if touched Do not remove the choke cover while the set is operaling If the engine starts but runs rough and gives off black smoke after a minute or two of operation the choke is set for too rich a mixture If the engine starts but sputters or stops before it warms up the choke is set for too lean a mixture 6 22 Choke Adjustment Table 6 2 lists choke settings for various ambient temperatures Stop the set and allow it to cool before adjusting the choke 1 Remove the plastic choke cover see Figure 6 23 and loosen the heating element cover screws 2 Rotate the heating element until the choke plate is halfway open 3 Slowly rotate the cover counterclockwise while tapping the carburetor choke lever to make it bounce Continue until the lever no longer bounces This is the fully closed reference position TABLE 6 2 CHOKE ADJUSTMENTS Ambient Air Rotation From Temperature Reference Mark 40 F 4 C 45 F 7 C 50 F 10 C 55 F 13 C 60 F 16 C 65 F 18 C 70 F 21 C 75 F 24 C 80 F 27 C 85 F 29 C 90 F 32 C 95 F 35 C 100 38 C Each mark on choke housing equals 5 angular rotat
193. s extremely flam AWARNING mable and can result in severe per sonal injury or death if ignited Make certain all fuel line openings are plugged to prevent gasoline vapor from accumulating Eliminate all possible sources of igni tion including fire flame spark pilot light arc producing equipment or other ignition sources before working in this area Disassembly Procedure 1 Remove the air intake assembly as described in the Air intake Assembly section 2 Disconnect the fuel line and governor control lin kage from the carburetor 3 Remove the intake manifold capscrews and lift off the carburetor air preheater Lift off the carburetor and intake manifold as an assembly 4 Remove the two intake manifold gaskets and plug the intake ports with a rag to prevent loose parts from accidentally entering the ports 5 Remove the two capscrews that secure the carbure tor and choke pull off assembly to the intake mani fold Disengage the choke pull off linkage from the carburetor and carefully separate the carburetor from the intake manifold Assembly Procedure Reverse the order of the disas sembly steps Use new gaskets between the intake manifold and the engine and between the intake mani fold and the carburetor Do not use sealer on the gaskets Tighten the intake manifold capscrews to the specified torque 6 18 AIR PREHEATER INTAKE MANIFOLD DETAIL OF THROTTLE LEVER CHOKE PULL OFF CARBURETO
194. se seams dents punctures and other mechanical damage If ignition is poor and other ignition components are not at fault test the coil as de scribed below Make certain of coil polarity the negative terminal connects to the breaker points and the posi tive terminal connects to a battery positive source within the control HIGH VOLTAGE TERMINAL LOW VOLTAGE TERMINAL SECONDARY WINDING 4 A PRIMARY WINDING IRON CORE ES 1666 FIGURE 6 11 IGNITION COIL Ignition Coil Quick Test This test checks the coil with the rest of the ignition system Gasoline vapor is extremely flammable and can result in severe personal injury or death if ig nited Make certain that no gasoline or other flam mable fumes are present Park the vehicle in a well ventilated area and leave the generator set compart ment door open for several minutes before perform 6 13 ing this test Use extreme care when performing this test procedure To avoid shock do not hold the plug without adequate insulation 1 Make certain that no gasoline fumes or other flam mable fumes are present Park the vehicle in a well ventilated area and leave the set compartment door open for several minutes before performing this test Remove a spark plug Reconnect the spark plug wire to the spark plug Ground the spark plug to bare engine metal Crank the engine A strong spark should appear between the
195. serts If seats are loose cracked severely pitted new inserts must be installed Remove valve seat inserts using a valve seat removal tool Removal Remove carbon and combustion deposits from valve seat Select the proper size puller deter mined by the inside diameter of the valve seat The puller jaws must expand into the cylinder block at the point where the bottom of the valve seat insert rests on the cylinder block Figure 9 10 Using the new seat insert as a guide adjust the puller depth Position the puller on the valve seat and tighten hex nut Clamp cylinder block to a solid bench Attach slide hammer to puller Between blows with the slide hammer tighten the hex nut HEX NUT PULLER JAWS CT 1104 FIGURE 9 10 VALVE SEAT REMOVAL Replacement After the old seat has been removed clean out any carbon or metal burrs from the seat insert recess Use a valve seat insert driver and a hammer to install the insert Insert the pilot of the tool into the valve guide hole in the cylinder block Quickly drive the valve seat insert in so that the insert goes evenly to the bottom ofthe recess in the cylinder block Make certain that the valve seat insert rests solidly on the bottom of the recess all the way around its circumference Figure 9 11 The valve seat must be staked to ensure a tight fit and eliminate the danger of its loosening in the bore Insert valve seat staker in the cylinder block valve guide hole Ro
196. sive internal resistance or an open circuit ES 1864 FIGURE 6 8 TESTING COIL SECONDARY 6 11 Spark Plugs Gasoline is extremely flammable AWARNING Severe personal injury or death can result if itis accidentally ignited Eliminate all possible sources of ignition including fire flame spark pilot light arc producing equipment or other ignition sour ces before performing this procedure Spark plug problems Remove and inspect the spark plugs at the intervals listed in the operators manual Carefully examining the plug can often determine the source of an engine problem e One plug carbon fouled Check for an open ignition cable or low compression Black soot deposits Check for faulty choke tion overly rich fuel mixture or dirty air filter Oil fouled Check for faulty crankcase breather worn rings or worn valve guides Burned or overheated Check for leaking intake manifold gaskets or lean fuel mixture Chipped insulator Check for advanced timing Bend only the side electrode when setting the gap Splash fouled Check for accumulated combustion chamber deposits Refer to the Cylinder Head sec tion of this manual Light tan or gray deposits Normal plug color ES 1374 FIGURE 6 9 CHECKING PLUG GAP Ignition Wiring The ignition system wiring includes Low voltage wiring from B to the ignition module Low voltage wiring from the ignition module to the igniti
197. ssembly 5 Remove the two capscrews that secure the K5 relay bracket to the adapter and lift off the relay assembly 6 Disconnectthe fuel hose and governor control link age from the carburetor 7 Remove the two capscrews that secure the carbure tor to the intake manifold Lift off the carburetor 6 25 8 Remove the intake manifoid as follows Assembly Reverse the order of the disassembly steps Use new gaskets between the exhaust manifold and A Disconnect the flexible fuel supply line fromthe engine the intake manifold and engine and the car fuel vaporizer buretor and intake manifold Tighten the exhaust and B Remove the exhaust manifold as described in intake manifold capscrews to the specified torque this section to provide clearance to lift off the Tighten the fuel vaporizer fittings and checks for leaks intake manifold Bending the fuel vaporizer ACAUTION tubing weakens the meial enabling cracks to form Do not bend the vapo rizer tubing to remove the intake manifold C Remove the intake manifold capscrews and lift off the intake manifold D Remove the two intake manifold gaskets from the block and plug the intake ports with clean rags to prevent loose parts from accidentally entering the ports CRANKCASE BREATHER HOSE AIR CLEANER HOUSING INTAKE MANIFOLD AIR FILTER FS 1612 2 CARBURETOR 2 AIR CLEANER ADAPTER KS RELAY FIGURE 6 26 CARBURETOR AIR FILTER AND INTAKE MANIFO
198. t all points The line of contact should be at the center of the valve face Valve Guide Replacement Worn valve stem guides can be replaced from inside the valve chamber a seal is provided behind the intake valve guides only The smaller diameter of the tapered valve guides must face toward the valve head Tappets are also replaceable from the valve chamber after first removing the valve assemblies Removal Before removing valve guides use an electric drill with a wire brush to remove carbon and other for eign material from top surface of guides Failure to per form this operation may result in damage to the guide bores Drive the guides out with a hammer and valve guide driver Driving out old guides can damage ACAUTION the tappet bores Be careful not to strike bores with driver Installation Run a smail polishing rod with crocus cloth through valve guide holes to clean out carbon and other foreign materials Place a new gasket on the intake valve guide and coat the outer edge of each new guide with oil Place guide notch up in cylinder block and press in until shoulder of guide rests against the cylinder block A suggested method of installation is shown in Figure 9 9 5 16 18 HEX NUT 2 REQUIRED 9 178 mm 7 32 5 16 FLAT WASHER 1 1 4 2 REQUIRED 5 16 18 THREADED ROD 60 mm 5 8 16 1023 FIGURE 9 9 VALVE GUIDE INSTALLATION Valve Seat Inspect valve seat in
199. tate the staking tool until it drops to the original stake marks Rotate staking tool another 60 degrees 1 6 turn Using a lead hammer strike the staking toola sharp blow to wedge the new valve seat securely in place Before installing valves it will be necessary to refinish valve seat inserts VALVE SEAT INSERT DRIVER USE PROPER TOOL CHECK THIS SURFACE FOR BURRS BEFORE INSERTING SEAT T i VALVE SEAT gt t 2 aa 2 i ne a ud m P 4 L a 4 2 VAY VT 1025 ATSC NI FIGURE 9 11 INSERTING NEW VALVE SEAT Tappet Adjustment The engine is equipped with adjustable valve tappets Adjust the valve clearance only when engine is at ambient temperature Proceed as follows 1 Remove all parts necessary to gain access to valve tappets 2 Remove spark plugs to make turning the engine easier 3 Place a socket wrench on the flywheel capscrew and rotate the crankshaft in a clockwise direction until the left intake valve viewed from flywheel end opens and closes Continue turning the crankshaft until the TC mark on the flywheel is lined up with the mark on the gear cover This should place the left piston 1 at the top of its compression stroke Verify the left intake and exhaust valves are closed and there is no pressure on the valve lifters 4 Clearances are s
200. terminals and connections clean and secure Check for loose seams dents punctures and mechanical damage If ignition is poor and the other ignition components are not at fault test the coil as described below Make certain of coil polarity the nega tive terminal connects to the ignition module black lead and the positive terminal connects to the igni tion module black lead and the positive terminal connects to a battery positive source within the con trol to the ignition module red lead and to filter capaci tor C4 HIGH VOLTAGE TERMINALS LOW VOLTAGE TERMINALS PRIMARY WINDING SECONDARY WINDING ES 1863 FIGURE 6 7 IGNITION COIL Ignition Coil Quick Test This test checks the coil with the rest of the ignition system Gasoline vapor is extremely flamma AWARNING ble and can result in severe personal injury or death if ignited Make cerlain that no gasoline or other flammable fumes are present Park the vehicle in a well ventilated area and leave the generator set compartment door open for several minutes before performing this test Use extreme care when performing AWARNING this test procedure To avoid shock do not hold the plug without adequate insulation 1 Make certain that no gasoline fumes or other flam mable fumes are present Park the vehicle in a well ventilated area and leave the set compartment door open for several minutes before performing this test
201. th Valve Spring Compressed Lengt Valve Spring Tension Open Valve Spring Tension Closed 1 9992 2 0000 1 9992 2 0000 50 78 50 80 mm 50 78 50 80 mm 1 6252 1 6260 1 6252 1 6260 41 28 41 30 41 28 41 30 2 0015 2 0040 2 0015 2 0040 50 84 50 90 50 84 50 90 mm 0 0024 0 0042 0 0024 0 0042 0 061 0 107 mm 0 061 0 107 mm 0 006 0 012 0 006 0 012 0 152 0 305 0 152 0 305 1 3740 1 3745 1 3740 1 3745 34 90 34 91 34 90 34 91 mm 1 3757 1 3787 1 3757 1 3787 84 94 35 02 mm 34 94 35 02 mm 0 0015 0 0030 0 0015 0 0030 0 038 0 076 mm 0 038 0 076 mm 0 011 0 048 0 0011 0 048 0 279 1 219 mm 0 279 1 219 mm 1 600 1 6620 40 64 mm 42 21 mm 1 346 1 375 34 19 mm 34 93 mm 55 Ibs 71 Ibs 25 kg 32 kg 25 5 38 Ibs 11 kg 17 kg 3 2 un ie Valve Stem 0 2795 0 2800 0 3425 0 3430 Diameter Intake 7 099 7 112 mm 8 700 8 712 mm Valve Stem 0 2780 0 2785 0 3410 0 3420 Diameter Exhaust 7 061 7 074 mm 8 661 8 687 mm Valve Guide Intake Exhaust Intake and Exhaust Diameter 0 2810 0 2820 0 2805 0 2815 0 3440 0 3460 7 137 7 163 mm 7 125 7 150 mm 8 738 8 788 mm Valve Stem 0 0010 0 0025 0 0010 0 0025 Clearance Intake 0 025 0 064 mm 0 025 0 064 mm Valve Stem 0 0020 0 0035 0 0025 0 0040 Clearance Exhaust 0 051 0 089 mm 0 064 0 102 mm Valve Lifter Diameter 0 7475 0 7480 0 7475 0 7480 18 99 19 00 mm 18 99 19 00 mm Valve Lifter Bore 0 7500 0 7515 0
202. thdrawal if will first be necessary to disconnect the fuel vaporizer the tube wrapped around the exhaust manifold at both ends remove the pressure regulator discon nect the vaporizer line from its support bracket and rotate the vaporizer line out of the way Bending the fuel vaporizer tub ing can weaken it to the point that it can crack allowing LPG under high pressure to escape resulting in possible severe per sonal injury or death Remove the two intake manifold gaskets and cover the intake ports to prevent loose parts from accidentally entering the ports 5 Unbolt the carburetor from the intake manifold Reassembly Reassembly is the reverse of disas sembly Use new gaskets between the intake mani fold and the engine and between the intake mani fold and the carburetor Do not use sealer on the gaskets Tighten all fasteners according to Assem bly Torques AIR PREHEATER AN gasoline gensets only O RING Slip the O ring over the end of the preheater hose and insert it into the collar 4 HOSE CRANKCASE BREATHER HOSE AND CLIP 2 ae AIR AIR FILTER GENE ELEMENT ADAPTOR CARBURETOR GASKET INTAKE MANIFOLD M i T MANIFOLD N GASOLINE 4 CARBURETOR CHOKE ASSEMBLY DETAIL OF GOVERNOR ROD THROTTLE LEVER CONNECTION gasoline fuel line from a remote or mounted pump NT d is connected here through an elbow fitting FIGURE S 1 TYPICAL FUEL SYSTEM S 4 Governor and Carb
203. tion Meter Meter Test Lead Reading 1 2 2 1 9 10 VDC 1 5 2 1 10 11 VDC P3 3 2 1 9 10 VDC RUN amp GENERATE MODE With the generator set running and the switch in the Center position Meter Meter Test Lead Reading 1 6 2 1 12 13 VDC P1 6 P1 4 18 20 VDC 2 5 P2 1 12 13 VDC P2 6 2 1 12 13 VDC P3 3 P2 1 10 12 VDC P3 4 P2 1 0 VDC P3 6 P2 1 10 12 VDC P1 1 P1 7 18 22 VAC STOP MODE With the switch pressed to the Stop position Meter Meter Test Lead Reading E P3 4 P1 8 0 VDC P3 4 P2 1 0 VDC A 8 EMERALD MARQUIS CONTROL BOARD CHECK OUT 300 3763 01 02 MODELS Spec amp BGEL Spec amp NHEL Spec amp BGM NHM Spec BGD Spec A amp B Spec amp REMOVE CIRCUIT BOARD P1 plug turned for better viewing To perform the following tests the circuit board must be removed from the control cover Place the circuit board on a non conductive surface with the component side of the board up For the following tests the battery must be connected STATIC MODE With the switch in the Center position Use extreme caution when working on operating Meter Meter generator sets Operating generator sets presents Test Lead Reading hazards of electrocution burns fire and explosion asphyxiation and entanglement with rotating parts 1 7 1 11 12 VDC Safety Instructions Operator s P1 7 42 1 12 VDC Emera
204. tion to provide access to the exhaust manifold Remove the four exhaust manifold screws and lift off the exhaust manifold and the two manifold gaskets Assembly Procedure Inhalation of exhaust gas can result AWARNING in severe personal injury or death To prevent exhaust leaks install all gaskets clamps straps and hardware as specified See Tailpipe Recommendations in this section 1 Install the exhaust manifold using new gaskets and tighten the four manifold screws to the specified torque Replace the noise shield and scroll refer to the Cooling System section if no other service is required install the generator set in the vehicle before completing the remaining steps Place a U bolt type automotive muffler clamp marked 1 1 4 in position on the exhaust manifold near elbow prior to installing the muffler Place the muffler in position on the set making certain that the muffler inlet pipe overlaps the exhaust manifold a minimum of 1 1 2 inches 38 mm NOISE SHIELD EXHAUST ELBOW MUFFLER CLAMP MARKED 1 1 4 BRACKET 1 4 20 SCREWS SCROLL EXS 1120 1 FIGURE 6 2 UNDERFLOOR MOUNT EXHAUST SYSTEM Install the two 1 4 20 screws and lock washers that secure the muffler support bracket to the set and tighten the muffler clamp To prevent excessive vibration ACAUTION transfer to the vehicle mount muffler and tailpipe hanger brackets directly above the component
205. tion if replacing the gear cover oil seal GOVERNOR GOVERNOR ARM GOVERNOR SHAFT GOVERNOR SHAFT YOKE SMOOTH SIDE TOWARD CUP IF FEELER WILL ENTER HOLE 1 2 IN 13 mm BALL HAS FALLEN OUT OIL SEAL 1027 FIGURE 9 13 GEAR COVER ASSEMBLY GOVERNOR CUP With the gear cover removed the governor cup can be taken off after removing the snap ring from the camshaft center pin see Figure 9 14 Catch the flyballs while sliding the cup off WHEN GOVERNOR 15 PROPERLY ASSEMBLED THE DIMENSION SHOWN ON DRAWING WILL BE AS INDICATED z E SP NES CEO 3 ie OR a ERE I A Chas CENTER PIN SNAP RING CAMSHAFT GOVERNOR CUP GOVERNOR FLYBALL gt T VT 1028 FIGURE 9 14 GOVERNOR CUP Replace with a new part any flyball which is grooved or has a flat spot the ball spacer if its arms are worn or otherwise damaged the gear spacer assembly if loose on gear hub and the governor cup if the race surface is grooved or rough The governor cup must be a free spinning fit on the camshaft center pin but without any excessive play The governor cup and flyballs are easily installed when the camshaft assembly is removed from the engine If necessary the engine may be tilted up to install the cup and flyballs Put the flyballs between the spacer arms and install the cup on the center pin Lock the cup in place with the snap ring The camshaft
206. uate ventilation to dissipate LP gas as it is released Propane gas will sink to the ground and is not easily detected BARRIER o P DOOR COMPARTMENT FLOOR EXS 1121 1 MOUNTING HOLES FIGURE 5 1 TYPICAL COMPARTMENT MOUNT INSTALLATION FLOOR OF COACH REAR PANEL ASSEMBLY SUPPORT TRAY SUPPORT BRACKET 5 1122 2 FIGURE 5 2 TYPICAL UNDER THE FLOOR INSTALLATION 5 3 LP Gas Propane Purging Procedure To purge the LP gas from the set fuel system close the shutoff valve at the fuel tank and then start the generator set Allow the generator set to operate until it runs out of fuel Crank the set a few times after it stops to make sure the fuel system is completely purged of all LP gas fuel If the generator set cannot be operated move the RV coach to an outdoor location that is well ventilated and is away from open flame sparks pilot lights cigarettes and arc producing machinery or switches Disconnect both the vehicle negative battery cable and the generator set negative battery cable from their respective battery terminals Close the fuel shutoff valves at the fue tank for both the generator set fuel supply system and the appliance stove heater etc fuel supply system In addition close the fuel shutoff valves at each appliance LP Gas Propane is extremely AWARNING flammable and poisonous and can result in severe personal injury or death if accidentally ignited or inhaled Eliminate all p
207. uels electricity and machinery hazards should perform service procedures Review safety precautions on inside cover page Trouble Noisy Generator Generator Overheats Possible Cause Loose brush holder Worn generator end bearing Rotor and stator rubbing together due to a Varnish lumps b Rotor misaligned with crankshaft Generator overloaded due to defective circuit breaker Airflow restricted due to dirt or debris covering vent openings in stator housing Stator windings covered with oil or dirt Open grounded or short circuit in rotor or stator Defective voltage regulator Corrective Action Tighten brush holder Replace end bearing Check for varnish lumps between rotor and stator remove as required Follow specified assembly procedures to correct rotor to crankshaft alignment Remove part of load and replace circuit breaker Ciear away all dirt or debris as required Clean stator windings Test each component for open grounded or shorted windings and replace if defective Refer to Testing Voltage Regulator VR7 GENERATOR SERVICE This section covers generator disassembly and assem bly procedures Refer to Figure 8 1 to locate and identify the various generator components described and Fig ure 8 2 8 3 8 4 or 8 5 for wiring interconnect information Generator Disassembly Use the following procedure to disassemble the gen
208. ugh preliminary adiustment Forcing the mixture adjustment A CAUTION screws tight will damage the needle and seat Turn in only until light tension can be felt Start the engine and allow itto run for 10 minutes at light load Figure 6 27 illustrates the location of the adjust ment screws IDLE ADJUSTMENT SCREW THROTTLE STOP SCREW MAIN ADJUSTMENT SCREW FS 1601 FIGURE 6 27 MIXTURE SCREW ADJUSTMENTS 6 27 Adjustment Procedure 1 Stop the set and connect a voltmeter frequency meter and load bank to the generator output leads 2 Start the generator set and apply a full load Adjust the governor speed adjustment nut if necessary to obtain 59 49 2 Hz 3 Turn the main adjustment screw inward until the voltage or frequency drops then outward until the voltage or frequency drops again Set the main adjustment screw at the point where the voltage and frequency are highest 4 Remove the load Adjust the governor speed adjustment nut if necessary to obtain 62 51 5 1 Hz 5 Turn the idle adjustment screw inward until the volt age and frequency drop and the engine begins to run rough or starts hunting Back out the idle adjustment screw until the engine runs smoothly without hunting Or for a more accurate setting with CO meter if available after setting idle and main adjustment screws but before installation of plastic limiter cap setto the following with engine running no load 6 to 896 CO
209. ugh the regulator as indi cated by the expanding soap bubble At first the soap bubble may expand due to diaphragm movement but will stop expanding if gas or air is not flowing through the regulator Replace the demand regulator if the lock off pressure does not fall between 0 15 and 0 25 LOCK OFF ADJUSTING SCREW Beginning Spec M this screw is not accessible for adjustments LPG INLET 11 inch WC pressure HOSE FOR 7 TESTING FOR TEST PRESSURE LPG OUTLET TO CARBURETOR Place soap bubble on end of hose fitting inches WC 3 8 and 6 4 mm WC Unauthorized modifications or replacement of fuel exhaust air intake or speed control system components that af fect engine emissions are prohibited by law in the State of California If the genset is mounted in a compartment make sure the vent pressure balance hose is routed properly to the outside Reconnect the hose to the carburetor discon nect any jumpers which may have been used to energize the fuel solenoid and thread in and tighten the pressure test port plug MANOMETER CONNECTED TO LPG SUPPLY PRES SURE TEST PORT IN 1L la A 2 1 O 1 2 a sl 4 VENT PRESSURE BALANCE HOSE See Figure S 10 for a view of the vent hose fitting when it is located on the other side FIGURE S 11 LPG SUPPLY PRESSURE AND REGULATOR LOCK OFF PRESSURE Redistribution or publication of this document
210. uretor Adjustments Careful adjustments of the carburetor and governor are essential for top performance Perform all nec essary engine and generator maintenance and re pairs before making these adjustments These adjustments require the use of meters to measure voltage frequency and amperage and a stepped load bank of at least 8 KW where a portion of at least 600 watts is variable Digital meters are recommended Accuracy should be atleast 0 3 per cent for frequency measurement and 0 5 percent for voltage measurement It is recommended that the genset be disconnected from the AC service panel of the vehicle If the gen set is not disconnected disconnect or unplug all voltage and frequency sensitive devices throughout the vehicle to protect them from the variations in fre quency and voltage that occur during these adjust ments Disconnect or unplug all voltage and frequency sensitive devices such as TV s VCR s computers and other solid state elec tronic devices before making governor and car buretor adjustmenis Typically some internal circuits are powered when these types of de vices are plugged in even if the device has been switched OFF These circuits can be dam aged by variations in voltage and frequency GOVERNOR GOVERNOR SPRING GOV RNOR SENSITIVITY ADJUSTING SCREW DROOP BALL AND SOCKET GOVERNOR SPEED ADJUSTING SCREW Consequential damage to TV s VCR s comput ers and other voltage and
211. ush wires and install brush hold ing wire into housing The wire holds the brushes off the slip rings during assembly See Figure 8 6 Carefully place the rotor assembly onto the end of the engine crankshaft and replace the rotor through bolt Tighten rotor through bolt only enough to hold rotor in place Tightening the rotor through ACAUTION bolt to specified torque before the stator assembly is installed can result in rotor shaft misalignment Follow recommended installa tion procedures to avoid any possiblity of shaft misalignment Carefully place the stator assembly straight down over the rotor and into position for assembly to the engine to generator adapter The rotor end bearing should fit snugly into the bearing hole Careless handling of the stator ACAUTION assembly can damage the insu lation on the stator windings Do not brush the stator windings against the rotor as it is lowered into position Install the four capscrews lock washers and nuts that secure the stator housing to the engine to generator adapter Tighten capscrews to specified torque Note that each locking washer is installed under capscrew head Tighten the rotor through bolt to specified torque Mount starter on generator stator housing using capscrews lock washers and nuts Tighten to spec ified torque Connect lead wires to starter terminal stud Hold the drip pan in position for mounting to the underside of the set and
212. y K3 Fuel Solenoid E2 LPG units solenoid valve provides a positive fuel shutoff when ever the generator set is stopped The solenoid must be energized before fuel will flow to the regulator It is energized in the same manner at the same time as the fuel pump is energized in gasoline units 7 2 Remote Start Control optional The remote start control is an optional accessory that enables the generator set to be operated from a remote location The deluxe contro includes a running time meter and battery condition meter Control Circuit Breaker s CB1 and CB2 if equipped AC output from the generator is supplied to circuit breakers CB1 and CB2 located on the right side of the control housing Ampere rating of these breakers may differ depending on generator set model frequency Refer to the proper Parts Manual when ordering replacement parts Voltage Regulator VR1 The voltage regulator helps provide stable output vol tage under varying loads During initial start of the set the voltage regulator receives DC currentfrom the start ing battery and begins excitation of the rotor through leads J4 9 F1 and J4 10 F2 After the generator set starts and runs it provides AC power to the voltage regulator through leads J4 11 Q1 and J4 12 Q2 for the excitation system The AC voltage is rectified to DC voltage and the proper DC excitation voltage is induced to the rotor in response to changes in demand The v

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