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981-0506 Onan KV

1. To test for shorted winding set the onmmeter on the lowest scale Place the test prods on the slip rings as shown in Figure 8 11 A reading of tess than 16 ohms at 77 F 26 C indicates shorted windings Replace rotor if winding is shorted If rotor tests good proceed to stator tests ES 1764 FIGURE 8 10 GROUNDED ROTOR TEST Power ES 1765 FIGURE 8 14 OPEN OR SHORTED ROTOR TEST 8 13 Redistribution or publication of this document by any means is strictly prohibited Generation Stator Test 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 Figure 8 12 shows the stator removed from the genera tor for testing The stator can be tested without removing it from the generator If generator is assembled gain access to the stator by following the Generator Disas sembly procedures this section through the fan hub assembly removal procedure To pertorm stator tests carefully remove all four con nector plugs from the stator lf available itis recommended that a megger or insulation resistance meter be used for ground tests Do not bend or flex stator wire termi nals or breakage can occur Ground Test Set the ohmmeter for the highest resist ance scale and then connect one test prod to the gener ator housing or stack if removed Touch the other test prod see Figure 8 12 to the t
2. amp F2 Battery Charge Resistor R1 Shutdown Circuit K3 K4 K5 Optional Remote Start Control Start Stop Switch The start stop switch S1 is a single pole double throw SPDT rocker type switch used for starting or stopping the generator set Placing the switch in either the start or stop position will initiate the appropriate contro func tion The switch will automatically return to the center Run position when released The switch is mounted on the control panel and is removable for service re placement Start Solenoid The start solenoid K1 is used for opening and closing the circuit between the starter motor and the battery The start solenoid is used because of the high current load imposed during starting The solenoid is made with heavy duty contacts to withstand high current draw during start up The start solenoid is located on the left side of the unit near the base and is not serviceable through the removable access cover Start Disconnect Relay The start disconnect relay K2 energizes once the generator set output reaches 70 volts AC This opens the circuit between the start solenoid K1 and the bat tery and causes the starter motor B1 to stop cranking The start disconnect relay also closes the circuit between the battery and the fuel pump E2 and the K3 relay during generator set operation The start disconnect relay is located on the control panel and is removable for service replaceme
3. and replace ment of worn parts Carburetor repair kits are available that supply new gaskets and replacements for those parts most subject to wear General instructions for overhauling a carburetor are as follows Carefully note the position while removing all parts to ensure correct placement when reassembling Read through all the instructions before beginning fora better understanding of the procedures involved Car buretor components are shown in Figure 6 10 Removal and Disassembly Remove the carburetor and intake manifold assembly as specified in the Carburetor and Intake Manifold Assembly in this section Remove the carburetor from the intake manifold and disassem ble using the following procedure 1 Remove the main and idle mixture screw assemblies 2 Separate the lower section of the carburetor Remove the float chamber by removing the bolt from the bottom of the carburetor NEEDLE gt VALVE CLIP FLOAT FUEL BOWL SPRING 3 Carefully note position of the float assembly parts then slide out retaining pin and remove the float and needle valve 4 Unscrew and remove the main nozzle Do not remove the choke or throttle plates shafts arms or governor i tink bushing unless they are defective Clean and Repair When the carburetor is completely disassembled clean and repair using the following i procedure 1 Soak all metal components not replaced by repair kit in carburetor cleaner D
4. generator set 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 Removing Conventional Compartment Mounted Set from RV When the generator set has been disconnected fromthe 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 housing 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 generator set is to use a forklift truck 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 Removing Underfloor Mounted Set From RV When the generator set has been disconnected from the electrical exhaust and fuel
5. mounted in the vehicle Hot oil can cause severe burns if AWARNING spilled or splashed on skin Keep hands clear when removing oil drain plug and wear protective clothing 2 Remove the generator set from the vehicle and place it on a sturdy workbench Refer to Set Remo val section 5 for the recommended set removal procedures The generator set is heavy and AWARNING can result in severe personal injury if dropped during removal Use the recom mended removal techniques and keep hands and feet clear while removing mounting bolts 3 Remove side mounting screws from enclosure cover and lift cover off set 4 Disconnect the fuel line from the fuel pump Plug fuel lines to keep fuel from escaping Fuel presents the hazard of fire AWARNING or explosion which can cause severe personal injury or death Do not permit any flame spark pilot light cigarette or other ignition source near the generator set Keep a type ABC fire extinguisher nearby 5 Remove the K3 relay from the iniet baffle assembly Figure 7 2 Disconnect the B lead from the start solenoid 6 Remove the control panel mounting screws and lower the contro panel 7 Remove the two bottom mounting nuts securing the inlet baffle assembly Lift the inlet baffle up and move it to the right side 8 Remove the air filter cover retainer and filter Fig ure 6 7 Remove the three bolts securing the plastic fan to the fan hub assembly and remove the fan and the
6. switch Clean oil pan and use new gasket when reinstalling Torque all mounting bolts to the specified mounting torque see Torque Specifications section Ga Power Generation 9 1 OIL LEVEL SWITCH LS 1172 FIGURE 9 1 OIL PAN REMOVAL Redistribution or publication of this document by any means is strictly prohibited HEAD COVER Remove the head cover to gain access to the cylinder head and valve system Use the following procedure to service 1 Use a 10 mm socket wrench to remove head cover mounting bolts and pull off head cover See Figure 9 2 2 Clean head cover Be careful not to damage outer sealing edge where gasket fits 3 Clean cylinder head cover and cylinder head tho roughly where gasket rests Use new gasket when reinstalling and make sure breather assembly is correctly installed in cylinder head cavity 4 Place head cover in position and torque until all bolts are tightened to the specified torque BREATHER ASSEMBLY LS 1173 FIGURE 9 2 HEAD COVER REMOVAL CYLINDER HEAD Remove the cylinder head for cleaning when poor engine performance is noticed or to inspect the valves Use the following procedures to service 1 Lift breather out of cavity in cylinder head 2 Remove lock nut and adjusting bolts from rocker arms then remove rocker arms and push rods 3 Remove cowling mounting bolts and lift off cowling 4 Use a 12 mm socket wrench to remove the cylinder head mounting
7. 4 Nem BRUSH STUD IMPORTANT THIS INSULATED SHUNT MUST BE ROUTED THRU UNINSULATED SHUNT AS SHOWN TO PREVENT CONTACT WITH COMMUTATOR IN FINAL ASSEMBLY NEGATIVE BRUSH TERMINAL Uf A NEGATIVE BRUSH TERMINAL ES 1 12 2 FIGURE 6 22 BRUSH ENDCAP Assembly 6 Make sure all brush wires are clear of commutator and that uninsulated portions of insulated wires do 1 Wipe off all 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 for removing dirt from bearings Avoid getting oii on brushes or commutator 2 Push negative brush terminals over through bolt holes on brush endcap See Figure 6 22 3 Insert positive brush stud into hole and torque to 25 30 in b 2 8 3 4 Nem 4 Place brush springs into brush holders insert brush tabs into spring ends and slide brushes into brush holders in endcap Be sure all brush wires are fac ing up 5 Place washer on commutator end of shaft and put armature into brush endcap Push the four brushes toward commutator making sure springs are prop erly positioned on brushes Repjacement brushes are supplied preassembled in the end cap Remove brush retainers after installing armatures not touch inside diameter of housing Uninsulated portions of wires must also not touch ad
8. 6 2 TAILPIPE INSTALLATION Power 2 Redistribution or publication of this document Generation 6 7 by any means is strictly prohibited COOLING SYSTEM A constant airflow is critical for engine and generator cooling to prevent excessive heat build up A centrifu gal fan on the generator end of the set provides the required airflow The fan draws cooling air in through the air inlet into the generator and across the engine cooling fins then discharges the heated air through the air outlet See Figure 6 3 Inhalation of exhaust gases can AWARNING result in severe personal injury or death Never use discharged cooling air for heating the vehicle interior since discharged cooling air can con tain poisonous exhaust gases The generator housing air inlet is sized to allow the required flow rate of cooling air The air inlet opening must be kept free of any obstructions to avoid restricting airflow Dirt dust or other debris that may clog the air duct openings should be removed during periodic main tenance Dirt might aiso become lodged between the cooling fins on the engine block and cylinder head If this happens heat transfer is greatly reduced and over heating can occur if the fins are not cleaned The cooling system consists of the set housing and base assembly enclosure insulation duct scroll assembly fan hub assembly air duct and air guide The following section covers service procedures for the cooling system insp
9. BETWEEN BEARING AND COLLECTOR RING gt ASSEMBLY ROTOR BEARING COLLECTOR RING ASSEMBLY G 1216 FIGURE 8 13 ROTOR BEARING SPACING Fa Power i 8 15 Redistribution or publication of this document Generation by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited Section 9 Engine Block Assembly INTRODUCTION This section covers service procedures for the engine block assembly This assembly includes the cylinder block cylinder head valve system piston and connect ing rod crankshaft camshaft and oil pan Performing any major service will require generator set removal from the vehicle see Set Removal section 5 To gain access to the engine block assembly the generator and primary engine systems must be removed Refer to the previous sections for the disassembly procedures A suggested order of disassembly for the engine block assembly follows oil pan and oil level switch head cover breather and cowling rocker arms and push rods cylinder head valve springs and valves crankcase cover and camshaft connecting rod and piston crankshaft and governor lever shaft OIL PAN AND OIL LEVEL SWITCH Remove the oil plug and drain the crankcase oil if not previously drained JO on hf wn Remove the oil pan mounting bolts and remove pan see Figure 9 1 Remove oil level switch mounting bolts and remove
10. E ee 0 025 in 0 64 mm a ie SPT seeeuecouaedeseswerenssas aon sa caren EE E EEEE EE 25 BTC Valve Lash Intake and Exhaust 0 00 cece eect e cence eet cesta peveeeetenen 0 002 in 0 05 mm GENERATOR DETAILS Gasoline Models 1 7 KV 2 0 KV 2 2 KV 2 8 KV Power Watts 1700 2000 2200 2800 Voltage 2 240 220 120 120 AMPS 2 cece cee 7 9 1 18 3 23 3 Frequency Hertz 50 50 60 60 PHASE 0 ccecceeec 18 12 t 1 WIES wea cies acne es 2 2 2 2 Battery Charge 1 Amp 1 Amp 1 Amp 1 Amp LPG Models 2 0 KV 2 5 KV Power Watts 2000 2500 Voltage 08 220 120 AMPS 0 ccce eee 9 1 20 8 Frequency Hertz 50 60 Phase ccc ecenee 10 10 WIFES 2 cc seecees 2 2 Battery Charge 1 Amp 1 Amp Power 2 1 Redistribution or publication of this document Generation by any means is strictly prohibited Power Redistribution or publication of this document Generation by any means is strictly prohibited Section 3 Dimensions and Clearances ITEM INCHES MILLIMETERS CYLINDER HEAD Cylinder Head Deformation Limit 0 00394 3 39370 0 1007 100 0 99 26 he 25 39 Nem VALVE Valve Face Angle intake Exhaust Intake Valve Stem Diameter Exhaust 44 5 45 44 5 45 0 2153 0 2157 0 2142 0 2150 5 468 5 480 5 440 5 460 Valve Guide Inside Diameter 0 2165 0 2170 5 500 5 512 Clearance Between Valve and Guide Stem intake Exhaust Reference
11. Generator overloaded due Replace circuit breaker Overheats to defective circuit Do Not exceed specified breaker load when operating set Airflow restricted due to _ Clean away ail dirt or debris 3 dirt or debris covering as required vent openings in stator housing Stator windings covered Clean stator windings with oil or dirt Open grounded or shorted Test each component for open circuit in rotor or stator grounded or shorted windings and replace if defective Gra Power n 8 6 Redistribution or publication of this document i Generation by any means is strictly prohibited Ta STATOR STATOR HOUSING STATOR HOLDING PINS EARLY PRODUCTION ONLY 7 Hi BEARING ALIGNMENT TABS BRUSH BLOCK ASSEMBLY ALIGNMENT Pa EN KEY SPECIAL WASHER A ROTOR THRU MAGNETO END SELL ASSEMBLY ASSEMBLY FAN HUB FAN l G 1211 SCROLL HOUSING e FIGURE 8 3 GENERATOR Gra Power m Redistribution or publication of this document Generation by any means is strictly prohibited im k ae al 1 ae fai 2 F Em a hal D mS ee Fan J h k GENERATOR SERVICE This section covers generator disassembly and assem biy procedures Refer to Figure 8 3 to identify the var ious generator components described in each sub section Generator Disassembly Use the following procedures to disassemble the generator 1 Drain the engine oil while the generator set is still
12. Valve Allowable Limit Valve Clearance intake Exhaust intake Opening Valve Opening Closing Closing Timing when cool Exhaust Opening Closing Valve Spring Reference Value Free Height Allowable Limit Load and Reference Value Height Allowable Limit Allowable Squareness Limit Valve Seat Intake i Valve Seat Angle Exhaust Reference Vaive Valve Seat Width Allowable limit a Power _ a Generation 0 00079 0 00173 0 00157 0 00283 0 020 0 044 0 040 0 072 0 0039 0 10 0 00079 0 0031 0 00079 0 0031 0 02 0 080 0 02 0 080 78 58 70 before top dead center 118 98 110 after bottom dead center 118 98 110 after bottom dead center 78 58 70 before top dead center 1 299 1 319 33 0 33 5 12 94 b 0 8858 in 11 64 1b 0 8858 in 5 87 kgt 22 5 m 5 28 kgt 22 5 m 0 0591 1 5 45 45 0 0394 0 0512 1 0 1 3 Redistribution or publication of this document 3 1 by any means is strictly prohibited Section 3 Dimensions and Clearances Continued ITEM INCHES MILLIMETERS Valve Lifter 0 31 B Outer Diameter 0 0014 0 0030 0 035 0 075 Reference Value Clearance Between Valve Lifter Allowable Limit And Guide Camshaft Standard Journal Diameter 0 5892 0 5899 14 966 14 984 Glearance Between Camshaft Journal Bearing Flywheel Side 0 0006 0 0020 0 016 0 052 intake 0 9705 24 65 Reference Value Exhaust 0 9705 24 65 Cam Height Allowable
13. a megger to check for breaks in the spark plug lead Also check control wiring and relays K3 and K5 for loose or grounded connections If any problems are found cor rect them and repeat the ignition spark check If no problems are found proceed to the Magneto Assembly section Magneto Assembly G2 The magneto asembly is a noncontact breakerless type that is mounted to the generator endbell As the engine cranks two permanent magnets on the fan hub assembly pass very close to the magneto inducing a voltage in the coil of the magneto The voltage from the magneto approximately 16 to 60 VAC when measured with a digital voltmeter is supplied to the primary of the ignition coil Hf no spark was seen in the ignition Spark Check and all accessible ignition wiring checks good perform the Magneto Assembly Check Magneto Assembly Check Use a known good new ignition coil 1 Make sure the cranking circuit and battery are in good condition Redistribution or publication of this document by any means is strictly prohibited Generation 6 9 2 Disconnect the ignition shut down circuit by locat ing relay K3 Figure 7 3 and removing leads G2 1 and 2 1 from K3 30 Separate piggy backed leads G2 1 and 2 1 and insulate them from each other and from ground 3 Remove the spark plug reconnect the spark plug lead and ground the plug side electrode to bare metal on the engine 4 Do not touch the plug or plug wire during tes
14. adjustment screw out an additional 1 4 turn 4 Remove the load and verify that frequency is within 62 5 0 5 hertz 52 0 0 5 hz on 50 hertz units Adjust governor speed adjustment nut if necessary to obtain required frequency 5 When the engine is warm and the set is running at no load turn the speed adjustment screw Figure 6 6 so that the throttle lever on the carburetor is resting against the throttle stop screw Adjust the stop screw to obtain a setting of 55 1 hertz 45 0 i hz on 50 hertz units 6 Turn the idle adjustment screw inward until voltage and frequency drop and engine begins to run rough or starts hunting Back outidle adjustment screw as required for smoothest operation without hunting Recheck setting in step 5 7 Release the governor linkage and observe the sta bility of the set Set the voltage and frequency and adjust the sensitivity of the governor as specified in Governorin this section Add and remove a full load several times to make certain the set does not bog down or hunt Redistribution or publication of this document by any means is strictly prohibited Generation 6 13 Carburetor Overhaul Carburetion problems not corrected by mixture or float adjustments are usually a result of gummed up fuel passages or worn internal parts The most effective solution is a complete carburetor overhaul In general overhauling a carburetor consists of com plete disassembly a thorough cleaning
15. an indica tion that air is flowing through the regulator 4 If more than 0 35 inches of water column pressure is required to induce flow loosen the lock nut on the 1 4 28 lock off adjusting screw back out the screw until air will flow in the 0 25 to 0 35 water column pressure range lf air flows through the regulator without any pressure being applied to the balance line the lock off adjustment screw must be turned in to increase spring pressure When the proper set ting is achieved hold the lock off adjusting screw in position and tighten the locking nut If adjustments do not resolve problems see step 5 5 Ifthe inlet pressure is too high or if there is dirton the regulator intet seat the regulator will flow air even though the adjusting screw is turned all the way in The regulator should not be disassembled or repairs attempied by anyone except the equipment manu facturer s factory trained service technicians Power Fuel Solenoid Valve The fuel solenoid valve Figure 6 19 provides a positive fuel shutoff whenever the generator set is stopped The solenoid must be energized before fuel will flow to the regulator Service is limited to replacing the complete valve assembly if it does not operate properly The fue solenoid can be bench tested by connecting battery positive B to the top terminal and battery negative B to the grounded terminal The plunger assembly should withdraw and open the valve when the solenoid
16. any reading indi cates short or open except for pair 10 5 which should indicate open Short is indicated by zero or a number very nearly zero Metera of different make indicate open differently Read the meter instructions Ifin doubt compare with readings of a regu lator of ihe same part number known to be good 4 lf the regulator checks good there is a small chance that it may be bad Recheck it ona genset Also check that the connector pins are secure in both connector ends GENERATOR TESTING This section covers test procedures for the generator rotor and stator windings Follow the troubleshooting procedures in this section to locate the required correc tive action Perform the Field Voltage Test to confirm that field volt age is available to the rotor brushes through the voltage regulator for field flashing and voltage buildup Check all wire harness connectors and leads for continuity prior to testing or generator disassembly Refer io Figures 8 2 and 8 3 wire lacations 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 voltmeter 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 8 1 1 Redistribution or publicati
17. ataan tx enieen E EE E E EEE E EE 10 1 MOUNINO estes ciara nerea a E E ANNEER OREN 10 1 Lubrication 2 0 0 0 cece eee e cece ce nee ceneeseeeeueecetaneneeeeeacnteauans 10 1 aa e sercaxssevar E E A E A 10 1 Initial Start Adjustments 0 00 0 cee cece ccc ccceneencuenaeecessvactsenees 10 1 CO CCG sopira arr nti wtensaasnaduccuecnce EEE Eni 10 1 Exhaust System nacitenne poses eceaweaan ventens secudedasneieesccbemerstatteceder 10 1 PUG OVSION AE E E oes 10 2 COMMON serrati raa seagecaeee neces ENAA EANA DENE EEIE 10 2 MIG CHAMCGN EE EEE E 10 2 Gra Power ay il Redistribution or publication of this document cal Generation by any means is strictly prohibited T Section 1 Introduction ABOUT THIS MANUAL This manual provides service information for the Onan KV generator set It is intended for the experienced serviceperson This manual covers troubleshooting disassembly repair reassembly and adjustments for the engine generator and control The serviceperson should be thoroughly familiar with the principles of gas oline 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 and KV Operator s Manual 981 07 29 and Installation Manual 981 0626 are recommended as additional sources of information Read all service procedures completely before begin ning any repair work
18. body by wearing the appropriate safety equipment Protec tive clothing includes safety shoes gloves safety glasses and hard hats Leave rings and jewelry off and do not wear loose clothing that might get caught on equipment Work to Reduce the Hazard The workshop area and ail pieces of equipment used can contribute to reducing the hazard potential Keep guards and shields in place on machinery and maintain equip ment in good working condition Store flammable liquids in approved containers away from open flame spark pilot light cigarette or other tgnition source Keep the workshop clean and well lighted and provide adequate ventilation Keep fire extin guishers and safety equipment nearby and be pre pared to respond to an emergency Redistribution or publication of this document by any means is strictly prohibited TABLE 5 1 HAZARDS AND THEIR SOURCE Fire and Explosions Leaking or spilled fuel Hydrogen gas from battery Oily rags improperly stored Flammable liquids improperly stored Burns Hot exhaust pipes Hot engine and generator surfaces Electrical short in DC wiring system e Poisonous Gases Carbon monoxide from faulty exhaust pipes joints or hangers QOperating generator set where exhaust gases can accumulate Develop Safe Work Habits Unsafe actions are identified as the cause of most accidents involving the use of tools and machines Be familiar with the equipment a
19. cover on set and when installing the rotor shaft to align the crank secure with side mounting screws shaft and rotor shaft with the Woodruff key in the crankshaft 17 Install the generator set in the vehicle and securely fasten all mounting screws and hardware Connect 6 Attach the stator wire harness connectors to the the fuel line exhaust system and electrical systems stator Be careful not to bend connector terminals or in reverse order of disassembly Refer to Set Remo damage may occur Refer to Figures 8 1 and 8 2 for val section 5 wiring locations Use wire ties to secure stator leads away from rotor and fan hub to prevent rubbing 18 Fill crankcase with oil of the recommended classifi cation and viscosity 7 Prepare endbell for installation Place springs on studs and lubricate o ring Verify that brushes are held in holder with piece of wire See Figure 8 6 BRUSHES AND SLIP RINGS Install endbell onto rotor bearing and secure with This section covers brush replacement and slip ring endbell mounting screws service ACAUTION The brushes will be damaged Brush Replacement during assembly if not held off Follow Generator Disassembly procedures this sec the slip rings Make certain wire s in place before tion through fan hub assembly removal Inspect the installing the generator endbell brushes and brush block for burn marks or other dam age If the brushes appear to bein good condition use 8 Remove the piece of wire
20. governor speed adjustment screw 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 adjust the carburetor and governor as specified in the Fuel System section 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 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 or corroded areas are detected shut the genera tor set down and 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 Redistribution or publication of this document by any means is strictly prohibited 10 1 Generation FUEL SYSTEM With the generator set operating inspect the fuel supply line filter and fittings for leaks Check any flexible sec tions 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 AWARNING which can result in severe personal injury or death if
21. intake 0 9665 24 55 Limit Exhaust 0 9665 24 55 Allowable Side Clearance Limit 0 0079 0 20 Bending Limit 0 0020 0 05 Timing Gear Reference Value 0 0036 0 0056 0 092 0 141 Allowable Limit 0 0079 0 20 Reference Value 2 6378 2 6386 67 00 67 02 Backiash Cylinder inner Diameter Allowable Limit Minimum Clearance Between 0 0016 0 04 Cylinder and Piston Piston Outer Diameter Skirt Diameter 2 6354 2 6362 66 94 66 96 Piston Ring Reference Vaiue 0 0079 0 0157 0 20 0 40 Gap Allowable Limit 0 0354 Clearance Reference Limit 0 0008 0 0024 0 02 0 06 Between Ring And Ring Allowable Limit 0 0039 Groove ra Power Redistribution or publication of this document Generation 3 2 by any means is strictly prohibited Section 3 Dimensions and Clearances Continued ITEM INCHES MILLIMETERS Piston Pin Outer Diameter 0 5906 0 5907 15 000 15 005 Connecting Rod Small End Inner Diameter Reference Value 0 5911 0 5915 15 015 15 025 Clearance Reference Value 0 0004 0 0010 0 010 0 025 between small end And Piston Pin Allowable Limit 0 0039 0 10 Connecting Rod Bending Limit 0 0016 0 04 Torsion Limit 0 0016 0 04 Bolt Tightening Torque 10 1 14 5 ft lb 13 7 19 6 Nem Crankshaft Pin Diameter Reference Value 1 1798 1 1804 29 967 29 982 Wear Limit Reference Value 0 0007 0 0021 0 048 0 054 Crank pin oil Clearance 0 0039 0 983
22. is energized Replace the solenoid valve if it does not operate properly FS 1850 FIGURE 6 19 FUEL SOLENOID VALVE 6 1 9 Redistribution or publication of this document by any means is strictly prohibited Generation LPG Carburetor LP gas carburetors have three adjustment screws that must be properly set for satisfactory operation The throttle stop screw controls how much the throttle plate remains open when the throttle is pulled back to the 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 mixture when the set is operating atfull load No other adjustments are required with an LP gas carburetor since there are no float or choke adjustments Carburetor Mixture Screw Adjustments Mixture screws should not be adjusted until the ignition system governor and other fuel system components have been checked for correct operation If the carbure tor is totally out of adjustment turn the mixture screws in until lightly seated Fora preliminary adjustmentturn the main adjustment screw out 4 to 5 turns and the idle adjustment screw out 2 to 3 turns ACAUTION Forcing the mixture adjustment ACAUTION screws tight will damage the needle and seat Turn in only until light tension can be felt start the engine and allow it to run for about 15 minutes at half load Figure 6 20 shows the location of the adjustment screws Use th
23. it seat correctly removes the margin To make a valve gas tight every trace of pitting must be removed from the valve face and seat Deeply pitted or cut valves must be replaced gt ja 1716 INCH 1 6 mm MINIMUM REFER TO SPECIFICATIONS FOR CORRECT DIAMETER 44 5 45 CHECK FOR BENT STEM FIGURE 9 8 VALVE MARGIN VT 1040 Valve seats should be ground with a 45 degree stone to the specified width Grind only enough to provide proper seating See Figure 9 9 Piace each valve in its proper location Check each vaive 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 dropped against the seat The valve seat should contact the valve face evenly at all points The line of contact should be at the center of the valve face VT 1041 FIGURE 9 9 VALVE SEAT Intake Vaive Seal Replacement A worn or cracked valve seal can cause high oil con sumption and spark plug fouling Replace a defective intake valve seal as follows 1 Pull the old valve seal out carefully to avoid damag ing the valve guide Coat the intake valve stem with engine oil and insert it into the valve guide Press valve seal into valve guide by hand After insertion use a special tool made for installing the seal Figure 9 10 to press the seal into the valve guide until the shoulder of the seal rests against the cylinder
24. oxide white lead dissolved in wood alcohol H cracks are present the white coating will become discolored at the defective area Always replace a cracked cylinder block Clean the block and proceed 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 cylinder head mounting area for flatness with a straight edge and a feeler gauge Cylinder Bore Inspection Inspect cylinder bore for scuffing scratches wear and scoring If cylinder bore is scuffed scratched scored or worn the block must be replaced When the appearance of the cylinder bore is good and there are no scuff marks check cylinder bore for wear or out of round as follows 1 Check cylinder bore for taper out of round and wear with a dial bore gauge telescope 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 e piston travel as follows see Figure 9 26 A Measure and record as A the cylinder bore diameter paraliel to crankshaft near the top of cylinder bore where greatest amount of wear occurs B Also measure and record as B cylinder bore diameter parallel to crankshaft atthe bottom of piston travel Redistribution or publication of this docume
25. publication of this document by any means is strictly prohibited TROUBLESHOOTING THE CONTROL 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 Run Lamp Time 1 Open circuit between terminal 6 1 Check for continuity and correct if Meter or Battery on remote connector plug and circuit is open Condition Meter terminal 6 on remote start stop Inoperative switch terminals on lamp or meters circuit is open and terminal 1 on remote start stop switch and remote connector terminal 1 3 If battery condition meter 3 Replace time meter works but time meter does not operate time meter is defective 4 lf time meter works but battery 4a Replace battery condition meter condition meter does not operate 4b Repiace zener diode verify that jumper wire is connected between terminals 5 and 6 on remote start stop switch If jumper is in place 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 meter is defective b if reading does not equal battery voltage minus 10 volts zener diode in remote control
26. 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 set is powered by gasoline proceed to the appropriate set removal section AWARNING LP Gas Propane is extremely flam mable and poisonous and can result in severe personal injury or death if accidentally ignited or inhaled Eliminate all possible 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 5 2 Redistribution or publication of this document by any means is strictly prohibited FUEL AND ELECTRICAL CONNECTIONS LEFT SIDE ae BARRIER E x MOUNTING fit SS IEN N i Ka ae k 4 SS COMPARTMENT FLOOR mites FIGURE 5 1 TYPICAL COMPARTMENT MOUNT INSTALLATION FLOOR OF COACH FUEL AND ELECTRICAL CONNECTIONS LEFT SIDE MOUNTING BARRIER BRACKETS M 1724 FIGURE 5 2 TYPICAL UNDER THE FLOOR INSTALLATION Power er Redistribution or publication of this document Generation 5 3 by any means is strictly prohibited Disconnecting Set from RV Systems Disconnect the following items from the generat
27. s and lower exhaust pipe 4 The generator set must be removed from the vehicle and the outer housing removed to access the muffler for servicing See Set Removal section 5 5 Remove the mounting nuts securing the muffler flange to the engine and remove the exhaust gasket 6 Remove the bolts securing the mounting brackets to the muffler Power _ Generation TYPICAL SIDE EXHAUST EXS 1170 2 TYPICAL REAR EXHAUST TAILPIPE NOT FURNISHED BY ONAN EXS 1170 3 FIGURE 6 1 COMPARTMENT MOUNT EXHAUST SYSTEM Assembly Obtain the required replacement parts then proceed as indicated Exhaust gas can cause severe per AWARNING sonal injury or death To prevent exhaust leaks install gaskets clamps straps and hardware as specified Inspect all components even if noi replaced or worked on 1 Install a new exhaust gasket Mount the muffler flange to the engine and tighten mounting nuts to the specified torque 2 Install muffler support bracket mounting bolts and secure to the specified torque 3 Instail generator set housing and reinstall the generator set 4 If replacing the original exhaust tailpipe refer to the Tailpipe Recommendations section Redistribution or publication of this document by any means is strictly prohibited 5 Attach the exhaust pipe to the outlet of the muffler using a U bolt type automotive muffler clamp marked 1 1 8 inch I D 6 Attach an automotive type tailpipe hanger every
28. serviced Refer to Set Removal instructions in section 5 ROLL PIN cetri SPRING RETAINER SUPPORT PLASTIC RETAINER WITH A VISE OR OTHER SOUD SURFACE i USE CARE NOT TO HAVE SPRING RETURN LEG BETWEEN THE PLASTIC RETAINER amp SUPPORT WHEN DRIVING OUT ROLL PIN b Disassembly Verify that the generator set starting battery has been disconnected negative cable first before proceeding Remove the generator set outer hous ing and disconnect the positive cable from the Starter lug Remove the starter mounting bolts Remove the rear support mounting nut and loosen the rear starter support bracket mounting bolt 3 Carefully disengage the starter from the end bell 4 Usea 1 8 to 32 inch nail setto remove the roll pin from the armature shaft Remove the return spring gear and clutch assembly as required When reas sembling always use a new roll pin See Figure 6 21 Remove the starter through bolts and carefully separate the brush end cap housing and armature assembly STARTER POSITIVE TERMINAL STARTER THROUGH BOLTS STARTER S 1603 5 32 TO 1 8 NAIL SET Vidi SOUD SUPPORT ES 1603 1 FIGURE 6 21 DRIVING ROLL PIN OUT Power _ Generation Fi b Pa al s maani p 6 21 Redistribution or publication of this document by any means is strictly prohibited TORQUE TO 5 10 IN LBS 57 1 13 Nem POSITIVE TORQUE TO 25 30 IN LBS 2 8 3
29. sets only Engine Hunts Sticking or binding Check linkage alignment and straighten or Surges governor linkage or replace Clean and lubricate governor linkage Incorrect governor adjustment Adjust governor speed and sensitivity Faulty governor spring Replace governor spring Incorrect fuel mixture due to Adjust carburetor main a incorrectly adjusted and idle adjustment screws fuel mixture screws 4b Adjust carburetor float level b incorrect float level or 4c Disassemble carburetor and clean c dirt in carburetor all internal passages Governor mechanism worn 5 See Engine Block Assembly section excessively or motion spring faulty Fuel supply problem caused by a Faulty fuel pump 6a Check fuel pump and replace b Contaminated fuel supply if defective c Vapor locking 6b Drain and refill fuel supply d Piugged fuel filter 6c Check for cause of overheating 6d Replace fuel filter 7 Carburetor icing In cold weather place air preheater in winter position Gasoline sets only ra Power EF 6 3 Redistribution or publication of this document o s Generation by any means is strictly prohibited TROUBLESHOOTING ENGINE PRIMARY SYSTEMS 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 perfo
30. 2 to 3 feet 0 6 to 0 9 meters In addition the exhaust system must be supported at or near the perimeter of the vehicle to prevent the tailpipe from being damaged and pushed up under the vehicle skirt Excessive vibration transfer and ACAUTION exhaust pipe damage can be caused be angular mounting Tailpipe hanger clamps must be mounted directly above the com ponent being supported and not at an angie 7 Run the generator set for five minutes and check the entire exhaust system visually and audibly for leaks or excessive noise Shut down the generator set and correct any problems immediately Tailpipe Recommendations Tailpipes must meet several design specifications to provide safe generator set operation It is necessary to use an Onan specified exhaust kit designed specifically for use with this generator set Kits are available in two exhaust lengths 18 to 25 inches 457 635 mm and over 25 inches 635 mm Refer to the following guidelines for selecting and locat ing the tailpipe Inhalation of exhaust gases can AWARNING result in severe personal injury or death Exhaust gases can enter the vehicle interior if the tailpipe is damaged missing or improperly installed Use the appropriate Onan specified exhaust kit and install according to the instructions provided with the kit Use 1 1 2 inch O D 18 gauge aluminized or stainless steel tubing for tailpipe Do not use flexible tailpipe since it might break due to r
31. 5 0 9840 Allowable Limit Reference Value 24980 24993 Journal Dia Wear Limit Reference Value 0 0008 0 0039 0 02 0 10 Side Clearance Allowable Limit Bending Limit Reference Value 0 0 0039 Axial Play Allowable Limit 0 0079 Ignition Plug Standard Gap 0 0236 0 0276 0 6 0 7 ra Power m Redistribution or publication of this document i i Generation 3 3 by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited Section 4 Torque Specifications TORQUE SPECIFICATIONS FOOT POUNDS NEWTON METERS Connecting Rod 10 14 14 20 Head Cover 3 3 6 4 4 8 Cylinder Head Cold 18 24 25 33 Endbell to Stator Housing Mounting Screws 6 9 8 12 to T Do Engine Cooling Shrouds Fan Mounting Screws 6 9 B 12 Gearcase Cover 11 14 44 19 oe Generator Housing to Engine Mounting Nuts 6 7 8 9 Intake Manifoid 6 8 7 13 Carburetor Mounting Nut 8 15 11 20 Muffier Bkt to Engine 14 20 l Q b r 7 12 i Muffler Flange to Engine Oil Base and Generator Housing to Mounting Stud 22 27 30 37 Oil Base to Engine 6 9 8 12 Qil Drain Plug 18 24 25 33 co t nh Oil Watch bolt 6 9 Rotor Through bolt 40 50 54 68 Spark Plug 8 18 10 24 Starter Bkt to Engine 6 9 8 13 p Starter Bkt to Starter 2 5 3 3 3 4 4 5 Starter Flange to Endbeli Mounting Screws 16 24 22 33 Governor Le
32. F1 providing fuel flow to the carburetor As the engine begins to run the start stop switch should be released The switch will automatically return to the center Run position and the engine will continue to run The start disconnect relay K2 will remain ener gized and the start solenoid K1 remains de energized Charging Circuit The charging circuit supplies generator battery charge voltage 20 2 volts that is rectified to DC by diode CR2 and supplied to the battery through the charge resistor R1 This charges the battery at a variable rate 1 ampere maximum during set operation The charge rate varies with the generator load and battery condition Stopping Placing the start stop switch S1 in the stop position energizes the K3 relay which causes the K3 30 K3 87 contacts to close and ground the output from the mag neto assembly G2 and stops the engine As the generator output voltage drops the start discon nect relay K2 de energizes apening contacts K2 3 K2 5 This causes the E2 fuel solenoid to open and stop fuel flow to the regulator Diode CR2 prevents the battery from discharging through the generator windings when the set is not running Power _ Generation Redistribution or publication of this document by any means is strictly prohibited 7 3 a i y oa aria Pira i ve emit Ee on an Relay Solenoid Relay Resistor Ballast Splice ignition Coil Switch Start Stop Remote Swi
33. FLOAT LEVEL 5 Install float bowl and main mixture screw assembly Turn screw in until lightly seated and then turn out the number of turns specified tn Table 6 2 Forcing the mixture adjustment A CAUTION screws tight will damage the needle and seat Turn in only until light tension can be feit When carburetor is installed on set make final adjustments to mixture screws as described in Car buretor Mixture Screw Adjustments section Power Redistribution or publication of this document Generation 6 15 by any means is strictly prohibited Choke The choke consists of a bi metal spiral strip electric heating element and choke pulloff diaphragm The bi metal coil is connected to the choke shaft and holds the choke plate nearly closed when the engine is cold When the engine starts vacuum from the intake mani fold causes the pulloff diaphragm to pull in and partially open the choke As the engine continues to run electric current is supplied to the heating element Heat from the element causes the bi metal strip to coil The coiling action of the bi metal strip turns the choke shaft and gradually opens the choke plate Heat from the element keeps the choke open while the engine is running The choke gets very hot during nor AWARNING maj operation and can cause severe burns if touched Do not touch the choke assembly during and after set operation Allow the set to cool down before working on the choke assembly Ift
34. IC i PRIMING SOLENOID i j ff r 7 Z LOCK OFF ADJUSTMENT FS 1848 SCREW FIGURE 6 17 DEMAND REGULATOR WITH AUTOMATIC PRIMING SOLENOID NOTCH ON PLUNGER DISK ZERO MARK ON DIAL FS 1849 At this position there is no ivel fow when the Auto Prime is energized To start and increase fuel flow turn dial clockwise while manuaily depressing plunger FIGURE 6 18 AUTOMATIC PRIMING SOLENOID Power _ 6 18 Generation Redistribution or publication of this document by any means is strictly prohibited Regulator Lock off Adjustment The regulator lock off setting is used to set the valve opening pressure The lock off can be checked and adjusted as follows 1 Connect the regulator inlet Figure 2 to a source of air pressure regulated to 6 oz 11 inches of water column 2 Connecta T inthe balance line hose and connect one leg of the T to an incline monometer that reads from 0 to 2 inches of water column Connecta hose to the other side of the T 3 Put a soap bubble over the outlet opening of the regulator Lightly blow into the hose connected to the T in the balance line Slowly apply pressure until the soap bubble continues to grow because of air flowing through the regulator Approximately 0 25 to 0 35 inches of water column should cause air to flow through the regulator When air is first blown into the balance line the soap bubble may enlarge due to diaphragm movement this is not
35. ND VALVE GUIDE INSPECTION Power 7 ti 9 3 Redistribution or publication of this document Generation by any means is strictly prohibited Stems and Guides Always check 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 the valve or cylinder head which includes the valve guide or both Springs Check vaive springs for cracks worn ends and distortion if spring ends are worn check valve retainer for wear Check for spring distortion by placing spring on a flat surface next to a square Measure height of spring and rotate it against a square to measure distortion see Figure 9 7 Replace any valve spring that is weak cracked worn or distorted FIGURE 9 7 VALVE SPRING CHECKS Reconditioning Valves and Valve Seats Valves should not be hand lapped because the sharp contact made between the valve face and valve seat will be destoryed Valve faces must be finished in a machine at 44 5 to 45 degrees Each valve must have a minimum of 1 16 inch 1 6 mm margin Figure 9 8 Ifthe valve has less margin than this it will heat up during the compres sion stroke and pre ignite the mixture causing loss of power and economy This valve is also susceptible to warping and breakage Not all valves can be reconditioned A badly warped valve must be replaced because the excessive grinding required to make
36. PLATE INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN SEVERE PERSONAL INJURY DEATH AND OR EQUIPMENT DAMAGE SERVICE PER SONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND OR MECHAN ICAL SERVICE Power Redistribution or publication of this document by any means is strictly prohibited Generation Redistribution or publication of this document by any means is strictly prohibited Section 2 Specifications GENERAL ENGINE DOSI a arrera aR AIAN EAER 4 Cycle Single Cylinder Overhead Valve Generator Design easennsnnnsnesesasvoesevesercenano Onan Revolving Field 2 Pole Brushless AC Sarung 6 SOW ae cadawecsasdeciendeeseahes saps AE EE Ea bes 12 Volt Electric Starter ENGING SPEO sus iiedordrisrsrer tiyr anar ENERE ENA 60 Hertz 3600 r min 50 Hertz 3000 r min WV ONG ote stone E E T E E aos EEE AE E E T E A E E 110 Ib 50 kg ENGINE DETAILS DIS DAC OMG oaran a AREER EEEE EEVA ANE APENE ENE TINAASAN ERRAR EA 12 in 197 cm GOMMDNCSGION FAN O searre lee sataeiabecucysanedoudenercdseteeet rie tedwdbedeousstiesteucesises 8 5 1 DOE EEE EE E E E E E E etd EE E E E EE 2 64 in 67 mm Sa A A E N A teas E E E A E E A ead 2 2 in 56 mm B KOTE E P E A E A E eceeseseohiudseseuseneesseseseeiaeees 1 0 qt 0 95 L Ventilation Free Area ssnseseressnreressonrsossseseseenosossssosseseserresre gt 24 in 154 8 cm FUGl EEEE EE E E E E E EE Gasoline Gasohol LPG TUNE UP SPECS oj OY 1 ods RE 3 PEE OP E T
37. RTED WINDING TEST OHMMETER READING ACCEPTABLE RESISTANCE RANGE AT 77 F 25 C 60 HERTZ STATOR 0 191 to 0 233 0 191 to 0 233 0 024 to 0 030 0 024 to 9 030 0 615 to 0 751 0 615 to 0 751 50 HERTZ STATOR 1 013 to 1 238 1 013 to 1 238 0 090 to 0 110 0 090 to 0 110 0 738 to 0 902 0 738 to 0 902 TEST LEAD LOCATION Redistribution or publication of this document by any means is strictly prohibited ROTOR BEARING REPLACEMENT 3 Place the rotor shaft engine end down onto a 1 The rotor bearing is pressed onto the rotor shaft This 1 16 inch 27 mm O D steel shaft or use a plug mated to the engine end of the rotor shaft to protect bearing mustbe replaced very carefully to avoid damag ing the collector ring assembly and the rotor shaft Use the shaft taper from damage when pressing bearing the following procedures to replace the rotor bearing into place l 4 Refer to measurementtaken in step 1 Press bearing 1 Measure and record the distance between the bear onto rotor shaft press on inner race only until it ing and the collector ring assembly referenced rests at the same distance from the collector ring later for reassembling See Figure 8 13 assembly as the original bearing Do not place bear ing closer than 0 14 inches 3 5 mm to the collector The bearing casing is made of ring or arcing can result Check bearing seal for AWARNING hardened steel When struck it damage after installation will
38. Ry On a at gt ete a ab 0 sF D ake ot yn ore w RS a dae Nee ie em TS ee a apare ew r eae es me a v p Service Manual MicroLite 2800 Series Printed in U S A 981 0506 3 91 Spec A amp B Redistribution or publication of this document by any means is strictly prohibited Safety Precautions Before operating the generator set read the Operator s Manual and become familiar with it and the equipment Safe and efficient operation can be achieved only if the unit Is ofa operated and maintained Many accidents are caused by failure to follow fundamental rules and precautions The following symbols found throughout this manual alert you to steerer dangerous conditions to the operator service per sonnel or the equipment ew Ll This symbol warns of immediate haz ards which will result In severe personal Injury or death aWARNING This symbol refers to a hazard or unsafe practice which can result In severe personal injury or death 4 CAUTION This symbol refers to a hazard or unsafe practice which can result In personal injury or prod uct or property damage FUEL AND FUMES ARE FLAMMABLE Fire explosion and personal injury can result from improper practices e DO NOT fili fuel tanks while engine is running Fuel contact with hot engine or exhaust is a potential fire hazard DONOT SMOKE OR USE AN OPEN FLAME near the gen erator set or fuel thank e Fuel lines must be adeq
39. TCHING Never use gasoline or commer ACAUTION cial cleaners to clean cylinder bores after deglazing or honing These solvents will not remove abrasives from the wails Abra sives not removed from engine will rapidly wear CT 1090 1 rings cylinder walls and bearing surfaces of all lubricated parts BOTTOM OF RING TRAVEL 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 FIGURE 9 26 METHODS OF MEASURING THE DIAMETER OF A CYLINDER BORE Power er 9 17 Redistribution or publication of this document Generation by any means is strictly prohibited TIMING GEARS If replacement of either the crankshaft gear or the cam shaft gear becomes necessary it is recommended that both gears be replaced Each of these gears are pressed on The crankshaft gear requires a gear separa tor and puller to remove and the camshaft gear requires a press to remove Both gears can be installed using a press These gears use a Woodruff key to provide cor rect positioning on the shaft Each timing gear is stamped with an O near the edge The gear teeth must mesh so that these marks exactly coincide when the gears are installed in the engine See Figure 9 28 THESE MARKS MUST ALIGN WHEN INSTALLING TIMING GEARS VT 1042 FIGURE 9 28 TIMING GEAR ALIGNMENT BEARINGS One bearing is pressed into the engine block and the ot
40. ad and correct as required Replace fuse Control fuse F2 is open Faulty CR1 diode open Test CR1 diode and replace if defective Faulty fuel system due to sticking choke faulty fuel pump gasoline sets faulty priming solenoid fuel solenoid or regulator LPG sets or carburetor mixture screws incorrectly adjusted Refer to Fuel System section for test and service procedures Check oil ievel and add oil if low 5b Replace oil level switch Low oil level switch S2 is not open due to a low oil level b faulty low oil level switch Check normally closed contacts K5 30 K5 87A replace relay if defective 6 Defective K5 relay contacts 7 K3 relay not energizing due to a open circuit to K3 relay coil b faulty K3 relay Check for continuity and correct if circuit is open 7b Check K3 relay coil 85 5 ohms and contacts replace if defective 8 Governor linkage or K4 solenoid stuck or binding Check for free movement of governor arm and solenoid Repair as necessary Gasoline sets only Engine Starts 1 Output voitage from generator not But Stops When being supplied to control due to Switch is a open circuit in wiring between Check for continuity and correct if Released generator and control circuit is open b no output voltage from gene
41. ain fuel tank and refill with fresh fuel In cold weather place air preheater in winter position Replace magneto assembly Check for proper installation see Generator Service section Reset spark plug gap Replace magneto assembly Adjust carburetor main and idle adjusiment screws Adjust carburetor float level Disassemble carburetor and clean all internal passages Locate leak and correct as required See Engine Block Assembly section Power _ 6 1 Generation Redistribution or publication of this document by any means is strictly prohibited TROUBLESHOOTING ENGINE PRIMARY SYSTEMS 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 Engine Lacks 1 Faulty ignition due to Power a incorrect spark plug gap b incorrect ignition timing ta Reset spark plug gap 1b Replace magneto assembly Dirty air cleaner 2 Replace air cleaner Restricted fuel flow due to a Plugged fuel filter or b faulty fuel pump c LPG Regulator or fuel solenoid dirty or defective 3a Replace fuel filter 3b Test fuel pump and replace if faulty 3c Refer to LPG Fuel section Incorre
42. ainer using a 9 16 inch crows foot ona6inch extension and remove keeper See Figure 9 5 Remove spring retainer and spring then remove valve 9 16 INCH CROWS FOOT ee g FI VT 1038 FIGURE 9 5 VALVE REMOVAL KEEPERS Inspection Vaive Face Check the valve face for evidence of burn ing warping out of round and carbon deposits see Figure 9 6 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 warping and misalignment Warping occurs mainly due to exposure to intense heat Out of round wear follows when the seatis 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 quide admits air and oil into the combustion chamber affecting carburetion increasing oil consumption and making heavy carbon deposits Clean metal is a good heat conductor but carbon insulates and retains the heat This increases combustion chamber temperature which causes warp ing 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 FACE VALVE GUIDE VALVE STEM VT 1020 1 FIGURE 9 6 VALVE FACE VALVE STEM A
43. ame spark pilot light cigarette etc near the generator set Keep an ABC type fire extinguisher nearby 2 3 LP Gas Propane Purging Procedure To purge the LP gas from the set fuel system close the shut off vaive at the fuel tank and then start the genera tor set Allow the generator set to operate untilit 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 fire or flame 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 fuel tank for both the generator set fuel supply system and the appliance stove heater etc fuel supply system tn addition close the fuel shutoff valves at each appliance LP Gas Propane is extremely flam AWARNING mable pd pastes and aa ese in severe personal injury or death if accidentally ignited or inhaled Eliminate all possible sources of ignition such as open flame sparks pilot flights cigareties 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 where it connects to the
44. 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 service can create an unsafe installation that can result in damage to the vehicle and equipment and 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 Onan nameplate This information is necessary to identify the set when ordering replacement parts See Figure 1 Always use genuine Onan replacement paris obtained from an authorized Onan dealer or distributor Universal replacement type parts usually intended for automotive use often look similar but do not perform to Onan speci fications Only genuine Onan replacement parts are designed and tested for the application Model and Spec No Always give above no s important wher ordering parts ac vots Ph Time Rating Insul NEMA Class E Amb 40 C Onan Corp 1400 73rd Ave NE Minneapolis MN 55432 U S A wiace mn USA For Recreational Vehicle Use Only Pour Usage Dans Les Vehicules Recreatifs Type Fuel Gasoline 99 1360 FIGURE i ONAN NAME
45. ator SEVICE 60s 1080545654 e40 dinn Peed Renew des Gee aes 8 8 Brushes and Slip RIngS ccccccccccnevusvcceravennceue 8 10 Voltage Regulator VR1 Test 0 ccc cee ete e eens 8 11 Generator Testing eh arees E a ewe wow ee ae bee ee area cn 8 11 Rotor Bearing Replacement 00 cece ene cece ten enees 8 15 9 ENGINE BLOCK ASSEMBLY esssuseroonsossosoosrssesanuens 9 1 IUOOQUCHON v 25 lt n hw Ga onc eae habs oe ee eee cb aeen ean eens 9 1 Oil Pan and Oi Level Switch 0 ec ce eee cee tee aeee 9 1 Head COVE sescsasocosves E E EE ee ee 9 2 Cylinder Head CTCL Tee ee ee ee exe eas 9 2 Valve System eben ee ses PERETE neeo w 9 2 s Crankcase Cover 0 cc ceeeceee Pew ides steer E 9 5 Camshaft and Tappet Removal gk de Sas autos 2 erhuk ee aa 9 5 WOVEINO 5 6ic 000s E E E owece ee ee eee 9 6 Piston Assembly Removal and Service 05 jan bees 9 6 GRANMSNEN eccqces Cage sinr yesdenewwunaee eae bes ceaeem eins 9 10 CVUNGl HOCK cus ae iwc woes o05 K4 ee ee ee Se Od eee Na 9 10 TING GCOS oo c0eees c0ees cud rinni eka en ekaneheuew nee 9 12 BGAUINOS is s4 ete Veber ewe EA Se ee eee 9 12 Oil Seal ere ee ee ee e 9 12 Power i Redistribution or publication of this document Generation by any means is strictly prohibited Table of Contents SECTION TITLE PAGE l 10 SERVICE CHECKLIST 2 ccc ccc cece ccc ceeecseeaceeeeecerensnee 40 1 TOE leavers ck ory
46. auses check good replace voltage regulator Refer to Governor section Check length of brushes and replace if worn excessively Clean or replace slip rings Check for jumper lead in regulator connector terminals 1 and 5 and correct if not attached 8 5 Redistribution or publication of this document by any means is strictly prohibited T Power Generation 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 POSSIBLE CAUSE CORRECTIVE ACTION AC Output Voltage 1 Engine governor incorrectly 1 Refer to Governor section Too High adjusted Faulty electronic voltage 2 Check output voltage if voltage regulator is over 135 on 120 voit units 242 on 220 volt units or 264 on 240 volt units and frequency is correct replace the electronic voltage regulator Noisy Generator Loose brush holder Tighten brush holder Worn generator end bearing Replace end bearing Rotor and stator rubbing Check for varnish lumps together due to between rotor and stator a varnish jumps and remove as required b rotor misaligned with Follow specified assembly 1 crankshaft procedures to correct rotor to crankshaft alignment Geneon
47. bolts and lift off the head Warping can occur if the head is ACAUTION removed while hot Wait until the engine has cooled before removing cylinder head 5 Clean out all carbon deposits Be careful not to damage outer sealing edge where gasket fits The head is made of aluminum and can be damaged by careless handling 6 Use new head gasket and clean both cylinder head and cylinder biock thoroughly where gasket rests 7 Place head in position and follow head torque tight ening sequence shown in Figure 9 3 Start out tightening all bolts to 11 ft lb 15 Nem then tighten to the specified torque see Torque Specification section VT 1036 FIGURE 9 3 CYLINDER HEAD TIGHTENING SEQUENCE VALVE SYSTEM The engine in the KV generator set uses an overhead valve design as shown in Figure 9 4 A properly func tioning valve system is essential for good engine per formance Access to the valve system can be gained by removing the head cover and the cylinder head Use the following procedures to inspect and service the valve system Redistribution or publication of this document by any means is strictly prohibited Ea Power Generation 9 2 CYLINDER RETAINERS EXHAUST VALVE RG wee INTAKE VALVE INTAKE VALVE SEAL SPRINGS VT 4037 FIGURE 9 4 OVERHEAD VALVE SYSTEM Valve Removal The valves can be removed from the cylinder head without the use of special tools Depress the valve spring ret
48. ch 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 Misfires 1 Faulty ignition due to a worn or fouled spark plug b faulty magneto assembly c faulty ignition coil d faulty plug wire e incorrect ignition timing 2 Lean fuel mixture due to a incorrectly adjusted fuel mixture Screws b incorrect float level c dirt in carburetor d vacuum leak 3 Contaminated fuel 4 Carburetor icing 5 Incorrect timing due to a defective magneto b incorrect flywheel or generator mounting Gasoline seis only 1 Faulty ignition due to a Incorrect spark plug gap b incorrect ignition timing Engine Backfires 2 Lean tuel mixture due to a incorrectly adjusted fuel mixture screws bh incorrect fioat level c dirt in carburetor d vacuum leak 3 Mechanical damage to engine Gasoline sets only CORRECTIVE ACTION Replace spark plug Replace magneto assembly Test coil and replace if necessary Check spark plug wire and replace coil assembly if necessary Rotor or fan hub improperly installed Adjust carburetor main and idie adjustment screws Adjust carburetor float level Disassemble carburetor and clean all passages Locate leak and correct as required Dr
49. circuit description Always refer to the specific wiring diagram that corresponds to the model and spec number of the generator set when trouble shooting Gasoline sets only F2 is the fuel pump on gasoline sets and the fuel solenoid on LPG sets 7 1 Redistribution or publication of this document by any means is strictly prohibited JF ca ca 26s Generation a C Starting Placing the start stop switch 1 in the start position connects battery negative B to the start relay coil K1 This energizes the start relay which closes the K1 K1 2 relay contacts that connect battery positive B to the starter motor B1 It also connects B to the fuel pump E2 and the K3 relay through fuse F2 and diode CRt The fuel pump is energized through diode CR3 used to bypass ballast resistor R2 on initial production sets CR3 and R2 may not be used on later production sets Battery positive B is also supplied to the voltage regulator pin 7 for the generator field winding through the start disconnect relay K2 normally closed contacts K2 2 K2 6 Connecting battery positive B as described produces the following control responses Flashes the generator field winding to ensure that there is adequate residual magnetism to induce vol tage buildup Energizes the starter motor B1 Energizes the fuel pump E2 which begins pumping fuel to the carburetor Energizes relay K3 Closing the start
50. ct fuel mixture due to a incorrectly adjusted fuel mixture screws b incorrect float level or c dirtin carburetor d vacuum leak 4a Adjust carburetor main and idle adjustment screws 4b Adjust carburetor float level 4c Disassemble carburetor and clean all internal passages 4d Repair vacuum leak Exhaust system blocked or Locate and remove cause of blockage restricted remove and clean spark arresting screen Incorrect valve lifter 6 Adjust valve lifters inspect valves clearance or defective valve s see Engine Block Assembly section No ioad speed set too low Adjust governor setting Excessive engine wear or See Engine Block Assembly section damage to engine Carburetor air preheater set incorrectly 9 In hot weather place air preheater in summer position Gasoline sets only Engine Overheats Restricted air flow due to Clear away any debris that may dirt or debris blocking air restrict airflow to set and do not inlet or outlet use compartment for storage area 2 Dirt or oil covering engine 2 Clean away all dirt and oi from cooling fins engine cooling fins 3 Incorrect ignition timing 3 Replace magneto assembly 4 Cooling fan plugged or broken 4 Inspect cooling fan see Generator Service section 5 Lean fuel mixture due to Sa Adjust carburetor main a incorrectly adjusted and idle adjustment screws fuel mixture screws 5b Adjust ca
51. e Recheck the valve clearance after adjustment has been made and also check the rocker arm bolts to see that they have not loosened as a result of adjust ing the valve lash Reinstall the head cover and torque head cover bolts to specified torque FIGURE 9 11 VALVE LASH ADJUSTMENT CRANKCASE COVER Remove the crankcase cover mounting bolts and lightly tap cover with plastic faced hammer to loosen Be care ful not to lose crankshaft and camshaft shims When installing the cover make sure the governor shaft is properly positioned Use a new gasket and clean the crankcase cover and the engine block where the gasket rests Place crankcase cover in position and torque until all bolts are tightened to the specified torque see Torque Specifications section CRANKCASE COVER GASKET C 1913 FIGURE 9 12 CRANKCASE COVER CAMSHAFT AND TAPPET REMOVAL The camshaft gear is pressed onto the camshaft and shouid be removed from the engine as a set Check for matching mark with crankshaft before removing cam shaft The tappets can be removed after camshaft removal See Figure 9 13 CAMSHAFT GEAR TAPPETS CAMSHAFT C 1114 FIGURE 9 13 CAMSHAFT AND TAPPETS Power Generation 9 5 Redistribution or publication of this document by any means is strictly prohibited GOVERNOR With the crankcase cover removed the governor can be inspected or disassembled for service The governor assembly must spin freel
52. e following procedure to adjust 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 Verify that the frequency is within 60 0 5 Hz 50 1 on 50 Hz units and adjust the governor speed adjustment nut if necessary to obtain required frequency 3 Turn the main adjustment screw inward until vol tage or frequency drops and then outward until voltage or frequency drops again Set the main adjustment screw at the point where the voltage and frequency are highest 4 Remove the load and verify that frequency is within 62 5 0 5 Hz 62 0 5 on 50 Hz units Adjust governor speed adjustment nut if necessary to obtain required frequency THROTTLE STOP SCREW a IDLE MAIN Er ADJUSTMENT ADJUSTMENT 7 U SCREW SCREW M 1878 FIGURE 6 20 LPG CARBURETOR ADJUSTMENTS 5 Turn the idle adjustment screw inward until voltage and frequency drops and engine begins to run rough or starts hunting Back out idle adjustment screw until engine runs smoothly without hunting 6 Pull the governor linkage toward the front of the set so that the throttle lever on the carburetor is resting against the throttle stop screw Adjust the stop screw to obtain a setting of 55 1 Hz 45 1Hzon 50 Hz units 7 Release the governor linkage and observe the sta bility of the set Set the voltage and frequency and adjust the sensitivity of the gover
53. e that exhaust manifolds are secure and not warped Do not use exhaust gases to heat a compartment Bea sure the unit is well vantilated MOVING PARTS CAN CAUSE SEVERE PERSONAL IN JURY OR DEATH e Before starting work on the generator set disconnect batter Dawn ies This will prevent accidental arcing m7 afat da h i Se el BET e Keep your hands away from moving parts e Make sure that fasteners on the generator set are secure Tighten supports and clamps keep guards in position over fans drive balts etc Do not wear loose clothing or jeweiry while working on gen erator sets Loose clothing and jewelry can become caught in moving parts Jeweiry can short out electrical contacts and cause shock or burning e if adjustment must be made while the unit is running use ex treme caution around hot manifolds moving parts etc _ ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH e Disconnect starting battery before removing protective shields or touching electrical equipment Use rubber insula tive mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment Do not wear damp clothing particularly wet shoes or allow skin sur faces to be damp when handling electrical equipment e Use extreme caution when working on electrical compo nents High voltages can cause injury or death e Follow all state and local electrical codes Have ali electrical installati
54. e the blade to vibrate and be attracted to the core Replace a shorted armature with a new part K HACK SAW BLADE J an A GROWLER ES 1615 FIGURE 6 24 TESTING ARMATURE FOR SHORTS Power Generation a Pap A E na k Ny 8 mm WEAR LIMIT 6 23 Testing for Opens Touch one ohmmeter lead to a commutator bar and then systematically touch the other lead to each of the remaining commutator bars A high resistance reading indicates an open circuit between the commutator bars and armature windings Replace an open armature with a new part Brush inspection Measure brushes Figure 6 25 and replace if worn less than 0 425 11 mm 0 315 INCH A NEW 0 472 INCH 12 mm ES 1768 FIGURE 6 25 BRUSH INSPECTION Redistribution or publication of this document by any means is strictly prohibited METAL SPRING RETAINER CLUTCH amp amp SPLINE WASHER ROLLPIN ASSEMBLY 1 1 16 INCH GEAR WASHER SPRING i RETURN COVER r7 I RETURN SPRING i WASHER SPRING WASHER FLAT WASHER ARMATURE o BRUSH ENDCAP THROUGH BOLT MAGNETIC HOUSING ES 1813 1 FIGURE 6 26 STARTER ASSEMBLY 12 it Return Spring is Unassembled A Place 1 1 16 inch O D washer over end of shaft See Figure 6 26 B With chamfered side of shaft hole up place plas tic retainer on shaft and line up hole with hole in shaft Support the plastic retainer with a vise
55. ear before replacing Remove the carbon from the top of the cylinder bore and check for a ridge Remove ridge witha i ridge reamer see Figure 9 15 before attempting piston removal Remove the piston as follows improper use of a ridge reamer can oe ACAUTION damage the cylinder bore Follow tool manufacturer s instructions and be careful when using a ridge reamer FIGURE 9 16 REMOVING PISTON RINGS Powe r 9 6 Redistribution or publication of this document Generation by any means is strictly prohibited Remove the piston pin retainer from each side and push the piston pin out Remove dirt and deposits from the piston surfaces with an approved cleaning solvent Clean the piston ring grooves with a groove cleaner Figure 9 17 or the end of a piston ring filed to a sharp point Care must be taken not to remove metal from the groove sides Using caustic cleaning solvent or ACAUTION wire brush for cleaning pistons will damage piston Use only parts cleaning solvent When cleaning the connecting rod in solvent include the rod bore Blow out all passages with low pressure com pressed air Most parts cleaning solvents are AWARNING flammable and can result in severe personal injury tf used improperly Follow the manu facturer s recommendations when cleaning parts CT 1660 FIGURE 9 17 CLEANING RING GROOVES Inspection The following covers inspection procedures for piston and connecting rod Piston Inspection nsp
56. eater assembly consists of the air filter cover air filter scroll assembly preheat door pre heat linkage preheat hose and intake air stove portion of the muffler assembly See Figure 6 7 The air filter preheat linkage preheat door and preheat air hose can be checked without removing the genera tor set from the vehicle Remove the access cover and the air filter cover Remove the air filter retainer and pul out the air filter Inspection of the air filter and preheater operation can be made at this point If a problem exists with operation of the preheat door remove the generator set see Set Removal section 5 and remove the enclosure assembly Check preheater linkage and adjust as required If the problem is within the scroll assembly follow the Generator Removal procedures Section 8 through the scroll removal step and repair or replace as required PRE HEATER AIR HOSE FILTER PRE HEATER CONTROL LEVER z4 SPEED ati ADJUSTMENT SENSITIVITY SCREW ADJUSTMENT SCREW oo ts g N i FS t75 3 ae pe jo COVER M 1877 15 Ta of AJS GASOLINE MODEL p i f FIGURE 6 7 AIR FILTER AND PREHEATER ASSEMBLY SPEED ADJUSTMENT SCREW SENSITIVITY ADJUSTMENT SCREW _ M 1877 a LPG MODEL FIGURE 6 6 GOVERNOR ADJUSTMENTS Power 6 11 Redistribution or publication of this document by any means is strictly prohibited Generation Carburetor and Intake Manifold Assembly Fuel presents
57. ect the piston for fractures atthe ring lands skirt and pin bosses Check for wear at the ring lands using a new ring and feeler gauge as shown in Figure 9 18 Replace the piston when the side clear ance of the top compression ring reaches 0 0039 inch 0 1 mm CT 1061 FIGURE 9 78 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 good cylinder wall contact Figure 9 19 QS PISTON N CYLINDER WALL LL IMPROPER Y RING CONTACT j CT 1062 FIGURE 9 19 NEW RING IN WORN RING GROOVE Replace piston showing signs of scuffing scoring worn ring lands fractures or damage from pre ignition Connecting Rod Inspection Replace connecting rod bolts and nuts with damaged threads Replace connect ing rod with deep nicks signs of fractures scored bores or bores out of round more than 0 002 inch 0 05 mm Power mp Redistribution or publication of this document Generation 9 7 by any means is strictly prohibited 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 pin that is cracked scored or out of round more than 0 002 inch 0 05 mm Piston Clearance Proper pi
58. ection Remove the spark plug boot and inspect the engine cooling fins by viewing the area around the spark plug if the engine is clean in this area and the air inlet area is clean disasembly for cleaning the engine will not be necessary If debris is visible in the area of the Spark plug or at the air inlet area proceed to the Disas sembly section CS 1341 2 FIGURE 6 3 COOLING AIRFLOW Disassembly Remove the generator set as described in the Set Removal section 1 Follow the generator set disassembly procedures section 8 through the scroll assembly removal Inspect and clean the fan hub assembly using a brush or low pressure less than 30 psi compressed air lf the fan blades are damaged remove the fan hub assembly as described in section 8 and replace the fan Remove the top and bottom air guide housings cowling for access tothe engine cooling fins for cleaning Use a brush or low pressure compressed air to remove any dirt or debris that may be lodged on the engine cooling fins 2 Assembly Cooling system assembly is in reverse order of disassembly Follow the generator assembly instruc tions section 8 for installing the fan hub assembly if removed for cleaning or replacement Overheating can result in engine ACAUTION damage To avoid overheating never operate the generator set with the access cover or any of the cooling system parts removed IGNITION SYSTEM The ignition system consists of
59. ed to remove light wear and for surface finishing If the slip rings are in bad condition and there is no power build up refinish using a fine sandpaper Use the following procedure to service 1 Follow Generator Disassembly this section to remove generator endbell and rotor 2 Place rotor in machine lathe and center Turn rotor and use fine sandpaper against rotating slip rings to clean and true slip rings Turn rotor until all grooves or roughness are smoothed out Power Contact with rotating machinery AWARNING can result in severe personal injury Keep hands clothing jewelry and fingers clear while servicing slip rings Careless handling of rotor can A CAUTION damage the insulation on the windings 3 Clean rotor and prepare for reinstallation Follow Generator Assembly procedures this section to reinstall rotor and remaining generator components VOLTAGE REGULATOR VR1 TEST Confirm that voltage regulator VR1 is faulty before replacing it Use a meter with a diode checking function Fluke Model 73 or equivalent Multimeter to perform the following tests 1 Disengage the wiring connector and remove the voltage regulator Figure 8 9 2 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 9 Itis important that the positive lead of the meter be connected to the first terminal of each pair 3 Replace the voltage regulator if
60. emain in while vacuum is applied Apply finger pressure lightly against the choke lever to take up the free play in the pulloff linkage see Figure 6 16 Check linkage alignment as viewed from the top of diaphragm stem pullofi linkage and choke linkage Correct alignment as required to obtain one half travel at choke lever Move the choke lever back and forth to check for free movement Verify that choke does not bind or stick Remove vacuum supply and reconnect the diaph ragm hose to rear side of intake manifold DIAPHRAGM HOSE CHOKE PULLOFF DIAPHRAGM DIAPHRAGM STEM PULLOFF LINKAGE Fuel Pump An electric fuel pump is used to supply fuel to the car buretor ff the pump malfunctions or insufficient fuel delivery is suspected use the following procedures to test the fuel pump Do not substitute automotive type A WARNING electric fuel pumps for standard Onan supplied electric fuel pumps The output pres sure is much higher and can cause carburetor flooding or fuel leakage creating a fire hazard Fuel Pump Test Test the fuel pump by checking the pump outlet pressure as follows 1 Remove fuel line from carburetor inlet and install a pressure gauge Press start switch and hold it for several seconds until pressure reading is constant The pressure reading for a good pump should fall within 3 1 2 to 5 psi 17 2 to 34 4 kPa The pressure should stay constant or drop off very slowly If pre
61. erminals specified in Table 8 1 A reading of less than one megohm indicates a ground Replace a grounded stator with a new stator xa x5 Q1 x2 T 61 B2 T2 Xt X6 x4 02 ES 1766 FIGURE 8 12 STATOR ASSEMBLY Power _ Generation 8 14 TABLE 8 1 STATOR GROUND TEST OHMMETER TEST LEAD LOCATION READING T1 to Ground infinity T2 to Ground Infinity B1 to Ground Infinity B2 to Ground Infinity Qt to Ground Infinity Q2 to Ground Infinity Open or Shorted Stator Windings Test To test for open windings set the onmmeter for the highest resistance scale and then connect the test prods see Figure 8 12 to the terminals specified in Table 8 2 The ohmmeter should indicate continuity between terminals A high resistance reading indicates an open winding If an open circuit is measured replace the stator To test for shorted windings use a digital type ohmmeter that reads to within 0 01 ohms Connect the test prods to the terminals specified in Table 8 2 A reading of less than the value shown in Table 8 2 at 77 F 25 C indi cates a shorted winding f stator tests indicate a shorted winding replace the stator If stator tests good check jumper leads X1 X2 X3 X4 and X5 X6 for continuity and for good electrical con nection with the stator terminals Also check remaining stator wire connections for continuity and good electri cal contact with stator See Figures 8 1 and 8 2 for wire locations TABLE 8 2 STATOR OPEN AND SHO
62. ets FIGURE 8 1 Power _ Generation ii HL alll L t Fi GENERATOR SET WIRING DIAGRAM 60 HERTZ 8 3 Redistribution or publication of this document by any means is strictly prohibited mya ar FI K3 RELAY IGNITION STOP K4 SOLENOID PRIMING Fa Splice Tt Ignition Cail Switch Start Stop Remote Switch Low Oil Level Switch Start Stop Resistor Charging Plug Remote Plug Voltage Regulator Meter Total Run Time Meter Battery Condition Start Disconnect Relay Start Solenoid Magneto Ignition Generator Fuse FUEL SOLENOID Spark Plug Lamp Remote Diode Diode Circuit Breaker Capacitor Battery Starter Motor Deluxe Remote Control Standard Remote Control S3 S2 Mt K2 K1 G2 G1 F1 F2 E2 E1 DSi CR2 CR1 CB1 Ci BT1 Bi A2 Al FIGURE 8 2 LPG GENERATOR SET WIRING DIAGRAM 60 HERTZ Power _ Generation OD K 39 tf Je tu a P t A pd Pe 4 gt i EE C5 Pi 2 LA ek x ol Tl a ae Pie ai i Kz le ae E ease SE co ee LHS t o Mie 8 4 e NIA GHD a g Ci 9 ma i Ct 14 GI Fi t G1 O2 G2 2 ee I l 1 _ J JRNL Tl Les y a ee EI Redistribution or publication of this document by any means is strictly prohibited TROUBLESHOOTING THE GENERATOR AWARNING Many troubleshooting procedures presen
63. fied to DC by diode CR2 and supplied to the battery through the charge resistor R1 This charges the battery at a variable rate 1 ampere maximum during set operation The charge rate varies with the generator load and battery condition Stopping Placing the start stop switch S1 in the stop position energizes the K5 relay which opens K5 30 K5 87A relay contacts This removes B from the fuel pump E2 stopping fuel flow to the carburetor B is also removed from relay K3 which causes the K3 30 K3 87A con tacts to close and ground the output from the magneto assembly G2 Placing the start stop switch in the stop position also energizes solenoid K4 which pushes against the governor arm causing itto close the throttle Each of these actions work together to shut down the generator set As the generator output voltage drops the start discon nect relay K2 de energizes opening contacts K2 3 K2 5 Diode CR2 prevents the battery from discharging through the generator windings when the set is not running Redistribution or publication of this document by any means is strictly prohibited 7 2 CONTROL OPERATION LPG FUELED Starting Placing the start stop switch S1 in the start position connects battery negative B to the start relay coil K1 This energizes the start relay which closes the K1 1 K1 2 relay contacts that connect battery positive B to the starter motor B1 It also connects B to the K4 p
64. g Q1 Q2 is an excitation winding that provides power to the voltage requlator The stator mounts inside the generator Rotor The rotor consists of a number of laminations stacked together a field winding wrapped around the lamina tions a shaft through the laminations molded stip rings on the shaft and a bearing pressed on the shaft The entire assembly is connected directly to the tapered engine crankshaft by means of a throughbolt The rotor is supported on the other end by the endbell which is placed over the bearing and secured to the housing The rotor field winding provides the rotating magnetic fieid which in turn generates the voltage and current in the stator windings to power the connected loads The magnetic field is established by a DC current flowing from the brushes through the slip rings and the field winding Power Generator Cooling Cooling airflow for the generator is provided by a cen trifugal fan mounted on the shaft behind the bearing A portion of the airflow from the fan is directed into the generator Part of this air flows down the rotor cooling the rotor winding and the rest flows over the stator windings cooling them Electronic Voltage Reguiator The electronic voltage regulator controls the output of the generator so that the voltage remains constant under any load condition The electronic voltage regula tor takes power from the excitation winding rectifies it and feeds it into the field windi
65. g squarely in the cylinder ata position corresponding to the bottom of its travel Figure 9 21 The gap between the ends of the ring is given in Dimensions and Clearances section The practice of filing ring ends to increase the end gap is not recommended Hf the ring end gap does not meet specifications check for the correctness of ring and bore sizes Rings of the tapered type are usually marked TOP on one side or identified in some other manner Install these rings with the identification mark toward the CONNECTING p closed end of the piston ROD MARK a FIGURE 9 22 ROD CAP ASSEMBLY one ni 9 8 Redistribution or publication of this document Generation by any means is strictly prohibited installing Piston in Cylinder When installing the pis 3 Tap piston down into bore with handle end of ton assembly observe markings on the connecting rod hammer until connecting rod is seated on crankpin cap and splasher and assemble in correct position See Check crankpin clearance before proceeding to 4 Figure 9 22 step see Crankpin Clearance section 4 Lubricate the rod crankpin and install the connect 1 Turn crankshaft to position crankpin at bottom ofits ing rod cap Tighten connecting rod bolts to speci stroke fied torque 2 Lubricate piston assembly and inside of cylinder Compress rings with a ring Compressor as shown in The bearing cap must be tapped several times to Figure 9 23 properly align it with the co
66. he engine starts but runs roughly and blows out black smoke after a minute or two of operation the choke is set too rich If the engine starts but sputters or stops before it warms up the choke is set too lean Choke Adjustment An adjustment screw is mounted on the bottom of the choke assembly see Figure 6 14 for making choke setting adjustments Turn the adjustment screw clockwise to lean the system and counterclock wise to increase richness it the choke has been replaced or is way out of adjust ment use the following procedures to establish an initial choke setting 1 Allow the generator set to cool down an ambient temperature of approximately 75 F 24 C is required before making initial setting Move the choke lever back and forth to check for free movement Verify that choke does not bind or stick Slowly rotate the adjustment screw on the bottom of the choke assembly so that the choke lever is held in the center of its travel Move the choke lever back and forth to check for smooth operation Choke lever should return auto matically to the center position when released from the open position without sticking or binding FS 1762 FIGURE 6 14 CHOKE ASSEMBLY Choke Replacement If the choke fails to open check to see if the heating element is working The heating element cover should become hot after a few minutes of operation If the element cover does not get hot start the set and then use an AC vol
67. he starter to the endbell Remove the choke the engine end Place a wooden block under the assembly from the generator endbel and discon muffler to Hold the set level Support the set to pre nect the leads attached to the resistor at the top of vent it from falling during service the endbell Remove endbell mounting screws and Th j remove the endbell Secure springs for rein AWARNING fe generator set is heavy and stallation can result in severe personal injury if dropped during service Support the Sharp edges can cause severe generator set during service to prevent it from AWARNING personal injury Wear gloves falling hen handling com nts with sharp edges j g atiii p eag 2 Check to see that Woodruff key is installed properly AC AU TIO IN J Careless handling of rotor or on engine crankshaft stator can damage the insulation l i l on the windings Do not allow windings to be 3 Check the generator housing for burrs in the alumi brushed or scraped during removal num slots that the stator slides into Remove burrs and clean housing if required inspect stator housing for stator holding pins 2 used on some early production units produced before serial number 126644 4 Position the stator so the output connector termi Figure 8 2 Remove holding pins by gripping pin head with a nals face outward from generator housing and locking pliers and pull outward with a slight counterclockwise orient stator lamination alignment tabs with mount twi
68. head 2 VALVE SEAL INSTALLATION TOOL FIGURE 9 10 VALVE SEAL INSTALLATION Power _ Generation Redistribution or publication of this document by any means is strictly prohibited Valve Seat and Valve Guide Replacement Worn valve stem guides or valve seats that are loose cracked or severely pitted should be replaced by replacing the cylinder head assembly Both the valve stem guides and the valve seats are available only as part of the cylinder head assembly Valve Lash Adjustment The engine is equipped with adjustable valve tappets Adjust the valve clearance when the engine is at ambient temperature Proceed as follows 1 Follow head cover removal instructions this sec tion inspect valve stems for proper alignment with tappets Advance the engine until both of the valves are closed and there is no pressure on the valve lifters piston at top dead center Clearances are shown in the Specifications section For each valve the gauge should just pass between the top of the valve stem and the rocker arm see Figure 9 11 Check the cylinder head mounting boit torque see Cylinder Head this section before performing valve lash adjustment To correct the valve clearance place a 14 mm wrench on the adjusting nutand a 10mm wrench on the outer locking nut Loosen the auter locking nut and turn the adjusting nut as needed to obtain the correct clearance Tighten locking nut after adjust ment is mad
69. her bearing is pressed into the crankcase cover The bearing in the engine block can be pressed out after the oil seal is removed following section The bearing in the crankcase cover can be pulled out using a puller Clean the bearing mounting surfaces and press new bearings back in OIL SEAL Use an oil seal remover to pry the oil seal out of the engine block Clean the oil seal resting surface and lubricate surface before installing new oil seal Press new oil seal into the engine block until oil seal is flush with cylinder block boss see Figure 9 29 Lubricate the lips of the oil seal with a light coating of grease This provides initial lubrication until engine oil reaches the seal OIL SEAL CT 1093 FIGURE 9 29 OIL SEAL Power _ Generation 9 12 Redistribution or publication of this document by any means is strictly prohibited Section 10 Service Checklist EXHAUST GAS IS DEADLY Exhaust gases contain carbon monoxide an odorless and colorless gas Carbon monoxide is poisonous and can cause unconsciousness and death Symptoms of carbon monoxide poisoning can include Throbbing in Temples Muscular Twiitching Vomiting Inability to Think Coherently Dizziness Nausea Headache Weakness and Sleepiness IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS GET OUT INTO THE FRESH AIR IMMEDIATELY tt symptoms persist seek medical atten tion Shut down the unit and do not ope
70. high tension connection indicated by carbon tracking Replace a coil with any defects Measure the primary winding resistance Connect one ohmmeter lead to the primary terminal and the other lead to the ground lead ring terminal The resistance should be approximately 0 5 ohms at 75 F 24 C Replace the coil if a high or low read ing is measured Measure the secondary winding resistance Con nect one ohmmeter lead to the spark plug connec tor inside the boot and the other lead to the ground lead ring terminal The resistance should be approx imately 1 400 ohms at 75 F 24 C Replace the coil if a high or low reading is measured lf no spark is seen and the coil windings check good proceed to the ignition Wiring check ignition Wiring It will be necessary to remove the genset from the vehi cle and remove the housing to inspect some of the wiring The ignition wiring consists of one ground wire connected to the coil and one ground wire connected to the magneto assembly One wire from the magneto to the ignition coil primary One wire from the shut down circuit connected to K3 30 to the magneto One high tension lead from the ignition coil secondary to the spark plug Refer to Figure 7 1 Do notdisassemble the set to check the wiring at the magneto at this time Thoroughly inspect the ignition wiring for loose connec tions and cuts or breaks in the insulation Test suspect leads for continuity with an ohmmeter Use
71. holding the brushes off piece of wire modified as shown in Figure 8 7 to check the slip rings Connect the F lead wire to the out for excessive brush wear Insert the painted end of the board brush terminal and the F lead wire to the wire through the hole above each brush Make sure the inboard brush terminal wire is resting on the brush and not on the spring If the ainted part of the wire is not visible The brush is 9 Install fan hub onto rotor shaft and align key slot on scenic wom and must be replaced Always replace lan hub with key slot in end of rotor shaft Install the brush springs when installing new brushes to main alignment key Insert washer on rotor through bolt tain proper tension on the brushes Clean carbon dep and install into rotor shaft Verity alignment of rotor osits from brushes and slip rings see Slip Ring Service shaft and fan hub Use special tool to secure fan hub section Use the following procedure to replace the assembly Figure 8 4 and tighten the rotor through brushes bolt to the specified torque 10 Lower the generator end of the set and allow set to rest on base A 11 Attach choke assembly to endbell Install two starter A mounting bolts through endbell and attach starter at 1 IN 25 mm specified torque Attach connectors to resistor on endbel Figure 8 1 12 Attach fan to fan hub with three bolts and instal scroll housing Install air filter retainer and filter cover 13 Install air inlet batf
72. ibution or publication of this document by any means is strictly prohibited 5 Check the frequency and voltage first with a load applied and then with no load applied The fre quency and voltage should stay within the limits shown in table 6 1 6 Adjust the governor sensitivity screw to give the closest regulation least speed and voltage difference between no toad and full load without causing a hunting condition To increase the sensitivity turn the adjustment screw counterclockwise one to two turns only To decrease sensitivity turn the adjust ment screw clockwise 7 Recheck the speed setting made in step 3 and read just if necessary TABLE 6 1 CHECKING VOLTAGE AND SPEED FREQUENCY Voltage Maximum No Load Typical No Load Minimum Full Load Typical Full Load Speed Frequency Maximum No Load Speed r min Frequency Hz Typical Frequency Minimum Full Load Speed r min Frequency Hz Typi 50 HERTZ SPRING LOCATION a a 60 HERTZ SPRING we Pi LOCATION p au RETAINER GASOLINE FUEL SYSTEM The fuel system must be in good condition and be prop eriy adjusted for efficient generator set operation The main components of the fuel system are the air filter assembly carburetor choke intake manifold fuel filter fuel pump and air preheater When servicing use the procedures in the following sections Air Filter and Preheater Assembly The air filter and preh
73. ied number of turns TABLE 6 2 CARBURETOR ADJUSTMENT SPECIFICATIONS MIXTURE SETTING FLOAT 1 1 2 1 4 1 3 4 1 4 9 16 1 16 in 14 2 mm THROTTLE STOP SCREW IDLE ADJUSTMENT SCREW MAIN ADJUSTMENT SCREW FS 1759 FIGURE 6 9 MIXTURE SCREW ADJUSTMENT Power Forcing the mixture adjustment ACAUTION screws tight will damage the needle and seat Turn in only until light tension can be felt Contact with moving parts can cause AWARNING severe personal injury Keep clothing jewelry hands and fingers clear while adjusting the governor A hot generator set can cause severe AWARNING burns Always allow the generator set to cool before touching any components or remov ing any parts Start the engine and allow it to run for about 10 minutes The location of the adjustment screws is shown in Fig ure 6 9 Use the following procedure to adjust 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 Verify that the frequency is within 60 5 t hertz 50 0 1 hz on 50 hertz units and adjust the governor speed adjustment screw if necessary to obtain required frequency 3 Turn the main adjustment screw inward until volt age or frequency drop and then outward until volt age or frequency drop again Locate the point where the voltage and frequency are highest From this setting turn the main
74. ignited by a spark ff leaks are detected shut generator set down and correct leak 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 compartment and verify there are no breaks or openings in the vapor proof wall that separates the compartment from the coach interior Seai openings as required Gru Power amp Generation 10 2 Redistribution or publication of this document by any means is strictly prohibited Power Redistribution or publication of this document Generation by any means is strictly prohibited Onon Onan Corporation 1400 73rd Avenue N E Minneapolis MN 55432 1 800 888 ONAN 612 574 5000 International Use Telex 275477 Fax 612 574 8087 ey Gnan is a registered trademark of Onan Corporation l i Redistribution or publication of this document a Generation by any means is strictly prohibited
75. il from the unit Accu mulated grease and oil can cause overheating and engine damage which presents a potential fire hazard e DO NOT store anything in the generator compartment such as oil or gas cans oily rags chains wooden blocks portable propane cylinders etc A fire could result or the generato set operation cooling noise and vibration may be ad versely affected Keep the compartment floor clean and dry a Do not work on this equipment when mentally or physically fatigued or after consuming any alcohoi or drug that makes the operation of equipment unsafe Redistribution or publication of RW8ocument by any means is strictly prohibited Table of Contents SECTION TITLE PAGE SAFETY PRECAUTIONS 22000 pias eas Inside Front Cover 1 INTRODUCTION eee anes err ee ee re eee ee 1 1 i About this Manual esssssssorssssaesssesnsesese E E a Model identification ccc cece ee ten e cee e ee ten nee nae 1 1 2 SFECIFIGATONS 6 6008 04 ie008 adda de SENS Oaweeteeaeeen anes 2 1 3 DIMENSIONS AND CLEARANCES 2c ccc cece eee ee eee 3 1 4 TORQUE SPECIFICATIONS 0 ce ccc cc ec eee ete e ee eaes 4 4 5 PREPARING TO SERVICE 1 ec cc ce te cee eee teeter ance 5 1 TPOUDIGSNGOUNG 66 68 ct Hence cake sesi Erino eee RASANE 5 1 SPECA OCIS 6 0 dcsre seca dade ene Goae tab eee eeeae eee aes 5 1 Safety Considerations 0 cence cen erence acne cnet se renene 5 1 DEL MOMOVGl ccnau 400
76. il it clears ail procedure obstructions and can be safely moved out from under the vehicle AWARNING 2 opping the generator E pail 6 When reinstalling the generator set be sure that all het U DATE ESSENER pole bolts brackets and electrical exhaust and fuel sys or death Make sure no one moves the vehicle during this procedure and that the procedure is tem components are connected exactly as they A were before removal performed very carefully and only as instructed FORKLIFT M 1725 FIGURE 5 3 COMPLETE SET REMOVAL Power np Redistribution or publication of this document Generation 5 5 by any means is strictly prohibited Power Redistribution or publication of this document Ge ion by any means is strictly prohibited section 6 Engine Primary Systems INTRODUCTION The engine primary systems include the following The engine primary systems can often be serviced with out removing the generator set from the recreational vehicie 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 for problems Exhaust System e Cooling System ignition System Crankcase Ventilation System Governor Fuel System Electric Starter related to starting the generator set TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Many troubleshooting procedures present hazards whi
77. ill cause erratic governor action or alternate increase and decrease in the engine speed hunting A rich or lean carburetor adjustment can cause hunting and a fouled spark plug can cause miss ing and hunting Springs tend to lose their calibrated tension through fatigue and after long usage and may require replacement lf the governor action is erratic after adjustments are made replace the spring If this does not improve opera tion the problem may be within the governor mecha nism see Engine Block Assembly section 9 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 lf the carburetor needs adjusting refer to the Mixture Screw Adjustments in this section before making any adjustments to the governor 2 Setthe carburetor throttle stop screw as specified in Carburetor Mixture Screw Adjustments step 5 3 Check the governor linkage for binding or exces sive looseness Check the motion spring for bend ing or damage and straighten or replace as needed 4 With unit operating at no load adjust the speed adjustment screw See Figure 6 6 on the governor linkage to abtain 62 5 0 5 Hz at between 120 and 126 volts on 60 hertz units Set 50 hertz units to obtain 52 0 0 5 Hz at between 220 and 231 volts for 220 volt units and 240 to 252 volts for 240 volt units Power _ Generation 6 10 Redistr
78. is defective 2 Open circuit between ground 2 Check for continuity and correct if Generator Set 1 Faulty set control start stop 1 Check start stop switch and replace Does Not Stop switch S1 if defective After Start Stop Switch Is Pushed 2 K5 relay not energizing due to 2a Check for continuity and correct if to Off Position a open circuit to K5 relay coil circuit is open b faulty K5 relay 2b Check K5 relay coil 85 5onms and contacts replace if defective Note Always remove load 3 K4 solenoid not energizing due a few minutes to 3a Check for continuity and correct if before stapping a Open circuit to K4 solenoid circuit is open to allow set to a faulty K4 solenoid 3b Replace K4 solenoid cool down 4 K4 solenoid out of adjustment 4 Adjust K4 solenoid mounting bracket so solenoid causes governor arm to i completely close throttle when energized 5 Defective K3 relay contacts 5 Gasoline fueled sets Check normally closed contacts K3 30 K3 87A replace relay if defective LPG fueled sets Check K3 relay coil and K3 normally open contacts K3 30 K3 87 Gasoiine sets only replace relay if defective Note A ballast resistor R2 is used inline with the fuel pump to reduce the voltage to approximately 9 volts ta increase pump tite During cranking the ballast resistor is bypassed through diode CR3 for low voltage operation of the pump Resistor R2 and diode CR3 are not used in later uctionse
79. jacent brush boxes Place magnetic housing over armature Use a nut driver over the end of shaft to hold down armature and endcap Place spring washer and flat washer on shaft as shown in Figure 6 26 Place mounting bracket on motor with through bolt lead ins to the inside of motor The flat near one mounting hole should line up with the positive stud on end cap so through bolt wilt line up Insert the through bolts and torque to 35 45 in Ib 3 4 5 Nem Wipe dust from helix and gear and apply a light coat of GE Versilube 322 L on outside diameter of helix inside diameter of gear and unchamfered end of gear Place clutch and helix assembly on motor shaft with flats engaged in clutch hole Redistribution or publication of this document by any means is strictly prohibited da Power ti Generation 6 22 Testing Armature for Grounds Touch one ohmmeter lead to a commutator bar and then touch the other lead to armature shaftand core laminations A low resistance reading indicates a grounded armature Replace grounded armature with a new part See Figure 6 23 ES 1614 FIGURE 6 23 TESTING ARMATURE FOR GROUNDS Testing for Shorts Use a growler Figure 6 24 for locat ing shorts in the armature Place armature in growler and hold a thin steel blade e g hacksaw blade parallel to the core and just above the armature while slowly rotating armature in growler A shorted armature will caus
80. le assembly and tighten mounting nuts to specified torque 14 Connect fuel line to fuel pump and inspect the fue supply line for cuts cracks and abrasions Make M 1729 sure fuel supply line does not rub against anything that could cause breakage FIGURE 8 7 BRUSH WEAR CHECK Grud Power n 8 10 Redistribution or publication of this document i Generation by any means is strictly prohibited 1 Remove the brush block mounting screws and lift out the brush block 2 Remove brushes and springs from holder and replace with new parts see Figure 8 8 SPRING BRUSH G 1179 FIGURE 8 8 BRUSH REPLACEMENT 3 Pull each brush outward from brush holder and insert a stiff wire through the small hole in the base of the hoider See Figure 8 6 The wire holds the brushes off the slip rings during assembly Inspect slip rings before installing brush block See Slip Ring Service this section 4 Install brush block in endbell but do not tighten mounting screws 5 Remove the wire holding the brushes off the slip rings Adjust the brush biock so that the brushes are centered on the slip rings then tighten mounting screws 6 Follow Generator Assembly procedures this sec tion to reinstall fan hub and remaining generator components Slip Ring Service Foliow Generator Disassembly procedures this sec tion through fan hub assembly removal Inspect the slip rings for grooves pits or other damage A Scotch Brite pad can be us
81. ml wecwene near eeus telus badauasnseeess 5 2 6 ENGINE PRIMARY SYSTEMS 0cccccanccaucsevsceene 6 1 WOGUGCUON ts so0s65545cse ee cance h i oceeene age eaeee beens 6 1 Troubleshooting Engine Primary Systems c cece c ec ee eer eens 6 1 Exhaust System 1 0 0 0 ccc ecw caer ewe cet eee ra eneeresacas 6 5 COOlNG SYSIGNY ccc btsuenaedecane ee bee saweauendacedateeeaees 6 8 HANOI Systemi 4 005400 4a sate Nae es bee e 60 o aware 4 eed sees 6 8 Crankcase Ventilation System Leuguenwacese eens eye es 6 10 Governor Terre cree Tere Tee eee cawet 0710 Gasoline Fuel System 2 2 cece eee eee Teter ee ee ee 6 11 LPG Fuel System cee ccc nue e renee NEO EEEE 6 18 BIGCWIC SIQNG 60 5 65866 4444054 lt 000 ens 0s ou oes OEE EET 6 21 7 CONTROL Sie Aaa Gee Pa eee ee ee E saree 7 1 Introduction 0 eee ee ET TT EEE EE EA PE E75 Control Description OCCT E CC Tee Ce ere ee ee 7 1 Control Operation Gasoline Fueled 6 ccc cece ee tence 7 1 Control Operation LPG Fueled cc cece eee e eee c ce eees 7 3 Control Troubleshooting ove Te E Te ee ee eee ee 7 6 8 GENERATOR i ccvnee Uso oxce lt n cues bonnes yaaa bene sueeneenan ae 8 1 igel Ieo a E E E E EEE E we a0 8 1 Generator Description ssssssrssusorsssesseseesnrenuu 8 1 Generator Operation 20 eee cece eet e reece nent etenee 8 2 Generator Troubleshooting 0 ce ccc ce eee eee tance rc enaees 8 2 Gener
82. nd recharge or replace Clean and tighten all connections at start solenoid K1 starter motor B1 and ground connections Increase cable size Contro fuse F1 is open 4 Locate cause of overload and correct as required Replace fuse Start disconnect relay K2 5 Check for continuity at normally defective closed contacts K2 1 K2 5 and replace if defective Start solenoid K1 not energizing due to a Open circuit between K1 6a Check for continuity and correct if and K2 or K1 and ground circuit is open b defective K1 relay 6b Replace K1 relay c defective start stop switch 6c Check start stop switch and replace if defective Defective starter B1 7 Refer to electric starter section for test and service procedures Redistribution or publication of this document by any means is strictly prohibited TROUBLESHOOTING THE CONTROL 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 Engine Cranks Faulty ignition due to worn or fouled Refer to Ignition System section for But Does Not spark plug or faulty plug wire test and service procedures Start Faulty magneto or ignition coil Locate cause of overlo
83. nd know how to use it safely Use the correct tool for the job and check its condition before starting Observe the warnings and cautions in this manual and take special precautions when working around electrical equipment Do not work alone if possible and do not take risks Be prepared if an accident does occur Numerous agencies such as the Red Cross and your local police and fire departments offer basic courses in first aid mouth to mouth resuscitation and fire control Take advantage of these offerings so you are ready to respond when an accident happens Learn to be safety conscious and make safe practices a part of your work routine Do not work when tired or after consuming any alcohol or drug that makes the operation of equipment unsafe SET REMOVAL Some service procedures will require removing the generator set from the coach While there are many variations generator set installations are generally classified as either conventional compartment mountor under 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 ofthe 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 With
84. ng through the brushes and slip rings The regulator reads the output of the power winding and its circuitry decides how much cur rent should be fed into the field winding to maintain the proper output at various load levels Brushes and Brush Block The brush block is a one piece molded part that mounts inside the endbell There are two carbon brushes in the brush block which ride on the slip rings and provide the means by which the controlled DC current from the regulator is conducted into and out of the rotor Each brush is kept in contact with its slip ring by a spring mounted inside the brush block behind the brush The spring exerts just the right amount of pressure to pro vide good contact and long brush life Wiring Harness 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 which must be provided by the RV manufacturer or generator set installer A 1 2 inch conduit elbow is provided to facilitate installation The load wire conduc tor is black the neutral conductor is white and the ground conductor is green Redistribution or publication of this document by any means is strictly prohibited Generation 8 1 GENERATOR OPERATION The schematic shown in Figure 8 1 is provided to heip follow the generator operating description Always refer to the specific
85. nkcase cover and check to see that the crankshaft turns freely Checking Endplay With the crankcase cover installed check the crank shaft endplay at the point shown in Figure 9 25 Refer to the Dimensions and Clearances section for the recom mended crankshaft endplay If necessary add or remove shims as required and recheck endplay Verify that the crankshaft turns freely without binding FIGURE 9 25 CHECKING ENDPLAY CYLINDER BLOCK Cleaning After removing the piston crankshaft cylinder head etc inspect the block for cracks and extreme wear If block ts still serviceable prepare it for cleaning as follows 1 Scrape ali old gasket material from block Power _ Generation 2 Remove grease and scale from cylinder block by agitating in a bath of commercial cleaning solution or hot soapy washing solution 3 Rinse block in clean hot water to remove cleaning solution Inspection r 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 using any stand ard method of crack detection One method of crack detection follows 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
86. nnecting rod Clearance varies on the crankpin if this is not done Crank the engine by hand to see that the crankshaft turns freely without binding Crankpin Clearance 1 Mark parts so they can be installed in their original positions and wipe all parts clean of any oil or grease 2 Placea piece of the correct size Plasti gage across the full width of the rod cap about 1 4 inch 6 mm off center 3 Install the rod cap and tighten to the specified torque Do not rotate the crankshaft after the cap is in place 4 Remove the rod cap and leave the flattened Plasti NS Gy a gage on the part to which it adheres Compare the My CT 1066 1 widest point of the flattened Plasti gage with the graduations on the envelope see Figure 9 24 to determine the crankpin clearance ENVELOPE GRADUATION SCALE CT 1092 FIGURE 9 24 MEASURING CRANKPIN CLEARANCE P we Power np 9 9 Redistribution or publication of this document ai Generation E by any means is strictly prohibited CRANKSHAFT Remove the crankshaft after the connecting rod and piston have been removed carefully pulf the crankshaft out of the oil seal and bearing inspection Check the crankpin O D and finish If itis worn or scored and cannot be smoothed out by polishing or if it exceeds the allowable size limit the crankshaft should be replaced installation Lubricate the bearings with engine oil Slide the crank shaft into the bearing Install the cra
87. nor as specified in Governorinthis section Add and remove a half load several times to make certain the set does not bog down or hunt Carburetor problems not corrected by mixture adjust ments may be caused by dirt in fuel passages or worn internal parts Under normal conditions the carburetor should seldom require cleaning since LP gas vaporizes completely before reaching the carburetor and leaves no residue However a bad fuel supply may allow dirt or oil to collect in the carburetor This may require that the carburetor be cleaned to restore satisfactory operation Cleaning the carburetor includes complete disassem bly thorough cleaning and replacement of worn parts and gaskets Power Generation 6 20 Redistribution or publication of this document by any means is strictly prohibited ELECTRIC STARTER A 12 volt electric starter with negative ground is used for cranking the generator set When the starter is ener gized an inertial engagement system causes the starter pinion gear to engage the ring gear on the fan hub j assembly As the starter spins the starter pinion gear drives the ring gear causing the generator set to crank Because the starter is an integral part of the set control system check the complete control before servicing the starter Use the following procedures to disassemble inspect and assemble the starter lt is necessary to remove the generator set from the vehicle before the starter can be
88. nt Power Control Fuses Provide protection ior the control box wiring and remote wiring from short circuit or other overload The cranking fuse provides protection during Start up and the run ning fuse provides protection while the generator set is running The control fuses are mounted on the front of the control panel and are removable for service replacement Battery Charge Resistor The battery charge resistor limits the battery charge rate to no more than 1 ampere The resistor mounts on top of the generator and is removable for service replacement Shutdown Circuit The shutdown circuit consists of two relays K3 K5 and a solenoid K4 These components work together to prevent the generator set from running once the start stop switch is placed in the stop position Both relays are mounted to the back side of the set on the generator end The solenoid is mounted on top the engine These components are removable for service replacement Optional Remote Start Stop Control The remote start stop control is an optional accessory that allows the generator set to be started monitored and stopped from a remote location The deluxe control includes a running time meter and a battery condition meter Remote control panels are usually mounted inside the vehicie CONTROL OPERATION GASOLINE FUELED The following section covers the control operation The schematic diagram shown in Figure 7 1 can be used to heip follow the
89. nt by any means is strictly prohibited 9 10 C Measure and record as C cylinder bore Deglazing Cylinder Bores diameter perpendicular to crankshaft near the Deglaze the cylinder bores if there are no scuff marks top of cylinder bore where greatest amount of and no wear or out of round beyond specifications wear occurs before installing new rings Deglazing gives a fine finish D Also measure and record as D cylinder bore but does not enlarge cylinder diameter so the original diameter perpendicular to crankshaft at the pistons with new rings may still be used pone ee ci es The reason for deglazing a cylinder is to provide cavities E Reading A subtracted from reading B and to hold oil during piston ring break in reading C subtracted from reading D indi cates cylinder taper 1 Wipe cylinder bores with a clean cloth which has F Reading A compared to reading C and read been dipped in clean light engine oil ing B compared to reading D indicates tips to produce a crosshatch pattern in the cylinder If out of round exceeds 0 0039 inch 0 10 mm bore the cylinder block must be replaced 3 The deglazing tool should be driven by a slow speed drill Move deglazing tool up and down in cylinder rapidly enough to obtain a a crosshatch pattern as shown in Figure 9 27 PRODUCE CROSS HATCH SCRATCHES AVOID THIS FINISH FOR FAST RING SEATING C 1091 FIGURE 9 27 CROSSHA
90. o not soak non metal floats or other non metal parts Follow the cleaner manufacturer s recommendations 2 Clean all carbon from the carburetor bore espe cially where the throttle and choke plates seat Be careful not to plug the idle or main fuel ports 3 Blow out all passages with compressed air Avoid using wire or other objects for cleaning that might increase the size of critical passages 4 Check the condition of any needle valve and replace if damaged Figure 6 11 Replace float if loaded with fuel or damaged 5 Check the choke and throttle shafts for excessive piay in their bore and replace if necessary 6 Replace old components with new parts included in repair kit THROTTLE IDLE SHAFT ADJUSTMENT SCREW THROTTLE PLATE N THROTTLE STOP SCREW SCREW FUEL BOWL GASKET O RINGS MAIN i 7 ONSTMENT SCREW AP FS 1760 SPRING C PLATE FIGURE 6 10 CARBURETOR OVERHAUL Ed Power _ Generation Redistribution or publication of this document by any means is strictly prohibited 6 14 s b in ott ee hee J Reassembly and Installation When the carburetor parts are clean and dry reassemble using the following procedure 1 Ifremoved during overhaul slide in the throttle shaft and install the throttle plate using new screws if necessary Beiore tightening the screws the throttle plate must be centered in the bore To do so remove the throttle stop screw and c
91. oad shock and vibration Install exhaust taiipipe at jeast 3 inches 76 mm away from any combustible material wood felt cotton organic fibers etc or be so located insulated shielded that it does not raise the temperature of any combustible material more than 117 F 65 C above the ambient air inlet temperature The exhaust system must extend a minimum of 1 inch 25 mm beyond the perimeter of the vehicle If the generator set tailpipe is on the same side of the vehicle as the air intake terminate the tailpipe downward and aft of the generator set air intake to reduce the possibility of recirculating exhaust gases EXHAUST GAS IS DEADLY Exhaust gases contain carbon monoxide an odorless and colorless gas Carbon monoxide is poisonous and can cause unconsciousness and death Symptoms of carbon monoxide poisoning can include Dizziness Nausea Headache Weakness and Sleepiness Throbbing in Temples Muscular Twitching Vomiting 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 operaling carbon monoxide detector Protection against carbon monoxide inhalation also includes proper exhaust system in
92. ompletely close the throtile lever Seat the plate by gently pressing with fingers into place then tighten screws Install the choke shaft and plate in the same manor DAMAGE AND WEAR OCCUR HERE FS 1483 2 FIGURE 6 11 MIXTURE NEEDLE INSPECTION 2 Install idle mixture screw assembly Turn in screw until lightly seated and then out the number of turns specified in Table 6 2 Forcing the mixture adjustment ACAUTION screws tight will damage the need e and seat Turn in only until fight tension is felt 3 Install needie valve and seat fuel bowl gasket and float assembly Make sure all clips and springs are properly placed and the float moves freely without binding See Figure 6 12 PIN i a l i lt n NEEDLE VALVE Eh POSITION HOOK FS 1761 UNDER TAB ON FLOAT FIGURE 6 12 FLOAT INSTALLATION 4 Invert the float and needle vaive assembly and check float level by measuring between the float and carburetor at the point shown in Figure 6 13 The full weight of the float should be resting on the needle valve and spring The correct distance is specified in Table 6 2 If the setting is incorrect remove float and bend tab to adjust Bend the float only at the point indicated Attempting adjustments with the ACAUTION lloat assembly installed can dam age the inlet needie and seat Remove float assembly before making adjusiments BEND TAB TO ADJUST MEASURE THIS DISTANCE FS 1745 2 FIGURE 6 13
93. on of this document by any means is strictly prohibited Generation the voltage regulator and test prods should be secured so that they are not being held during testing See Figure 8 9 Contact with rotating machinery can AWARNING result in severe personal injury Keep hands clothing jewelry and fingers clear while servic ing slip rings AWARNING a shock can cause severe ersonal 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 ACCESS COVER VOLTAGE REGULATOR Start 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 18 to 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 replace the volt age regulator and retest If battery voltage is not supp gt lied to the voltage regulator during starting refer to Control section 7 for troubleshooting procedures CONNECTOR PLUG ES 1763 FIGURE 8 9 VOLTAGE REGULATOR CONNECTOR PLUG P14 Power Generation 8 12 Redi
94. ons performed by a qualified licensed electrician Tag open switches to avoid accidental closure a DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM Hazardous volt ages can flow from the generator set into the utility line This creates a potential for electrocution or property damage Connect only through an approved device and after building main switch is open Consult an electrician in regard to emergency power use GENERAL SAFETY PRECAUTIONS e Have a fire extinguisher nearby Maintain extinguisher prop erty and become familiar with its use Extinguishers rated ABC by the NFPA are appropriate for ail applications Con suit the local fire department for the correct type of extin gutsher for various applications e Hot coolants under pressure can cause severe personal in jury DO NOT open a radiator pressure cap while the engine is running Stop the engine and carefully bleed the system pressure Benzene and lead found in some gasoline have been iden tified by some state and federal agencies as causing cancer or reproductive toxicity When checking draining or adding gasoline take care not to ingest breathe the fumes or con tact gasoline Used engine oiis have been identified by some state or fed eral agencies as causing cancer or reproductive toxicity When checking or changing engine oil take care not to in gest breathe the fumes or contact used oil Remove ali unnecessary grease and o
95. ooting guide is divided into six sections After identifying the problem refer to the guide for the possible cause and the recommended corrective location of most of the control components Refer to the nenon wiring diagram in Figures 8 1 or 8 2 for location of wiring terminals i TROUBLESHOOTING THE CONTROL 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 Engine Does Not Crank Power _ Generation 1 If engine cranks at set but not at remote control panel fault is due to a open circuit in remote control wiring b faulty remote start stop switch If engine cranks at remote control panel but no at set fault is due to a open circuit in set control panel wiring b faulty set contro start stop switch S1 Insufficient voltage for cranking due to a battery not charged or b terminal connections loose or dirty c insufficient battery cable size 7 6 1a tb 2a 2b 3a 3b 3C Check for continuity and correct if circuit is open Replace remote control start stop switch 53 Check for continuity and correct if circuit is open Replace set control start stop switch Check condition of battery a
96. or other solid surface Using a 5 32 to 1 8 inch nail set and hammer drive in a new roll pin The pin should be driven in about 1 10th of an inch 2 5 mm from the edge of the plastic retainer or so it is evenly spaced from each side D Place spring cover over top of plastic retainer then the return spring on top of the retainer Power _ Generation 6 24 E With washer placed over point of plastic retainer push metal retainer into hole of plastic retainer as far as it will go Carefully mount the starter on the end bell and tighten the mounting bolts and rear support bracket mounting bolt and nut to the specified torque Connect the positive cable to the starter lug terminal Mount outer housing on the generator set and install set into vehicle Reconnect generator set starting battery negative cable last Redistribution or publication of this document by any means is strictly prohibited Section 7 Control INTRODUCTION The contro system includes all functions that relate to starting monitoring for fault conditions instrumentation battery charging and 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 following components Panel mounted Start Stop Switch S1 Start Solenoid K1 e Start Disconnect Relay K2 Control Fuses F1
97. or set Refer to Figures 5 1 and 5 2 for component locations in typical generator set installations Some installations may require partial removal of the set to gain access to the battery cable fuel line and other connections Read this section before starting set removal 1 Disconnect the vehicle negative battery cable at the battery terminal Disconnect the generator set negative battery cable at the battery terminai Disconnect the generator set positive battery cable from the wire harness Disconnect the remote control wire plug from the generator set housing Disconnect the generator load wires atthe RV elec trical system junction box Tag the RV circuit wires for positive identification when reconnecting Loosen the conduit connector and pull the load wires and flexible conduit free of the junction box Disconnect the tailpipe from the muffler or discon nect any support brackets or hangers attached to the tailpipe to allow set removal Disconnect the fuel line at the generator set hous ing Securely plug the end of the fuel line to prevent fuel leakage or an accumulation of explosive gaso line vapor Gasoline vapor is 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 Before disconnecting the fuel line be certain there are no ignition sources such as fl
98. ot bend or Carefully guide the wire through the brush block flex stator wire terminals or damage can occur and then release each brush Verify that each brush is held off the slip rings by the wire A The brushes will be damaged ACAUTION ee or eure te stator CAUTION terminals can cause breakage of oh the sip ninge re fi pene as A paren the terminals Use caution when removing the sta before removing the generator endbell for wires and when handling the stator 14 Place a wooden shim between the bottom of the stator housing and the base assembly to prevent movement between the generator and the base Carefully tap on the rotor shaft with a lead hammer to free tapered rotor shaft from the crankshaft Be careful to avoid striking the collector rings Pull the rotor straight out and locate the Woodruff key used to align the rotor shaft with the crankshaft The collector rings will be dam ACAUTION aged if struck during rotor re moval Use caution to avoid hitting collector rings when using lead hammer on rotor shaft Generator Assembly Use the following procedures to assemble the generator 1 Prepare the set for stator and rotor installation The N stator and rotor must be installed while the set is i standing vertically on the engine end for correct PARE anes AASE NGE alignment of the rotor shaft to the crankshatt Raise 12 Remove the two starter mounting bolts that secure the generator end of the set and allow it to rest on t
99. own incorrect choke adjustment open circuit in wiring between choke heater and generator or defective choke heater 3 Vapor lock due to 3a Remove any objects or debris that a high ambient air temperature may restrict airflow b faulty fuel pump 3b Refer to Fuel System section for testing and service procedures 4 Contaminated or incorrect fuel 4 Refill tank with fresh fuel Gasoline sets only Low Battery 1 Weak or discharged battery Generator set charger will not recharge a battery that is in a very low state of charge Connect a separate battery charger to bring battery up to full charge 2 Load connected to battery Turn off load while set is turned off Refer to Generator section for testing and service 3b Test CR2 diode and replace if defective 3c Test resistor Rt and replace if defective 3 Disconnect the negative battery cable at the battery and remove lead marked F1 1 to CR2 C from control fuse F1 terminal 1 Connect a DC ammeter and a 5 ampere fuse in series between control fuse Fi terminal 1 and the disconnected lead marked F1 1 to CR2 C Reconnect battery negative cable With set running the ammeter should read between 0 to 1 ampere If meter shows battery is discharging fault is due to a defective generator charge winding b defective diode CR2 c defective resistor R1 Power _ 7 8 Generation Redistribution or
100. partment mount generator set The following section covers the service procedures for the exhaust system The generator must be shut down and the exhaust system serviced immedialely if inspection reveals leaking joints or connections toose fasteners or broken corroded or damaged components Always replace worn components with new original equipment replacement parts Do not attemptto repair a broken exhaust pipe or manifold by welding and do not replace worn out components with parts that do not meet factory specifications The muffler is a spark arres ter type muffler that is Forest Service Approved and meets code requirements Failure to provide and main tain a spark arrester muffler can be in violation of the law Contact an Onan distributor for approved replace ment exhaust parts inhalation of exhaust gases can AWARNING result in severe personal injury or death Modifying the exhaust system can allow poi sonous exhaust gases to enter the coach Use only original equipment replacement parts when servicing the exhaust system Unauthorized modifications will also void the warranty and cancel the UL Listing CSA Certification Liability for injury or damages due to unauthorized modifications becomes the responsibil ity of the person making the change Disassembly 1 Allow the exhaust system to cool down before servicing 2 Loosen the exhaust pipe clamp securing the exhaust pipe to the muffler 3 Remove exhaust pipe hanger
101. plash Fouled Check for accumulated combus tion chamber deposits See Cylinder Head section Light Tan or Gray Deposits Normal plug color If the spark plug Is in good condition proceed to the Ignition Cail section ES 1462 FIGURE 6 4 MEASURING PLUG GAP Ignition Coil T1 The ignition coil is a transformer that steps up the mag neto output voltage to about 20 000 volts for spark piug firing The coil consists of a primary and a secondary winding Perform the following checks Ignition Spark Check 1 Make sure the engine oil level is adequate and that the genset is level Remove the spark plug reconnect the spark plug lead and ground the plug side electrode to bare metal on the engine Do not touch the plug or plug wire during testing Crank the engine and observe the plug A good spark should be observed If no spark is observed proceed to the coil winding check 2 Coil Winding Check The ignition coil is located below the lower right corner of the access cover Disconnect the coil ground lead primary lead and spark plug lead from the spark plug The coil can be removed from the set for testing See Figure 6 5 SPARK PLUG BOOT SECONDARY GROUND LEAD TERMINAL PRIMARY ES 1767 FIGURE 6 5 IGNITION COIL Power 1 Inspectthe terminal and leads for signs of corrosion or looseness and look for cracks dents or other damage Look for evidence of electrical leakage around the
102. rate 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 GENERAL 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 If 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 tight and hooked up properly Check each of the following Load Wires Contro Wires Ground Strap Battery Cables Power 1 RV INITIAL START ADJUSTMENTS Adjust the carburetor idle adjustment screw and main adjustment screw as specified in the Fuel System sec tion to allow starting Start the set and immediately adjustthe
103. rator 1b Refer to Generator section for test and service procedures 2 Start disconnect relay K2 not Check for continuity and correct if energizing due to circuit is open a open circuit to K2 relay coil 2b Test K2 relay and replace if b faulty K2 relay defective 1 i i 3 Fuel pump not energized due to Check resistance of ballast resistor faulty ballast resistor R2 if used R2 for approximately 1 2 ohms and replace if defective R2 is not used in later production sets 4 Corroded slip rings Refer to Generator section for slip ring service 5 Defective voltage regulator Refer to Generator section for voltage Gasoline sets only b T Power ep 7 7 Redistribution or publication of this document _ Generation by any means is strictly prohibited TROUBLESHOOTING THE CONTROL 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 Engine Starts and 1 Fuel level is low or oil level i 1 Check fuel and oil level and refill Runs Then Stops is low as necessary Set Restarts immediately or Set 2 Faulty choke operation due to 2 Refer to Fuel System section for Restarts After sticking choke linkage testing and service procedures Cooling D
104. rburetor float level b incorrect float level 5c Disassemble carburetor and clean c dirtin carburetor all internal passages Gasaline sets only Power m 6 2 Redistribution or publication of this document Generation by any means is strictly prohibited TROUBLESHOOTING ENGINE PRIMARY SYSTEMS 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 Black Exhaust 1 Rich fuel mixture due to i Smoke a dirty air cleaner 1a Replace air cleaner b choke sticking 1b Clean choke and adjust or replace c incorrectly adjusted fue linkage mixture screws ic Adjust carburetor idle and d dirt in carburetor main adjustment screws 1d Disassemble carburetor and clean all internal passages Gasoline sets only White or Blue 1 Lean fuel mixture due to a incorrect float level b incorrectly adjusted fuel mixture screws c dirt in the carburetor Exhaust Smoke 1a Adjust carburetor float level 1b Adjust carburetor idie and main adjustment screws 1c Disassemble carburetor and clean all internal passages 2 Contaminated fuel Drain and replace fuel 3 Excessive engine wear See Engine Block Assembly section Gasoline
105. riming solenoid and E2 fuel solenoid through fuse F2 and diode CR1 Battery positive B is also supplied to the voltage regulator pin 7 for the generator field wind ing through the start disconnect relay K2 normally closed contacts K2 2 K2 6 Connecting battery positive B as described produces the following control responses Flashes the generator fieid winding to ensure that there is adequate residua magnetism to induce vol tage buildup Energizes the starter motor B1 Energizes the priming solenoid E4 and the fuel solenoid E2 allowing fuel to flow to the carburetor Closing the start solenoid K1 contacts connects the battery positive B to the starter motor which begins to crank the engine to initiate starting Starter Lockout Run As the engine comes up to speed the power output from the generator is applied to the start disconnect relay K2 and causes it to energize Engergizing the K2 relay opens the K2 1 K2 5 and K2 2 K2 6 contacts and closes the K2 3 K2 5 contacts This produces the fol lowing control responses Opening the K2 1 K2 5 contacts disconnects B from the start solenoid K1 de energizing it and causing the K1 1 K1 2 contacts to open This dis connects B from the start motor B1 and the K4 priming solenoid e Opening the K2 2 K2 6 contacts disconnects B from the voltage regulator Closing the K2 3 K2 5 contacts applies B to the fuel solenoid E2 through fuse
106. rm service procedures Review safety precautions on inside cover page TROUBLE POSSIBLE CAUSE CORRECTIVE ACTION High Oil Oil viscosity is too light Drain oil and refill with correct Consumption or oil is diluted viscosity oil Crankcase breather valve is Clean crankcase breather and replace dirty or defective if defective Note New engines sometimes Oil leaks Locate source of leak and repair as have high oil required consumption during Excessive engine wear See Engine Block Assembly section break in intake valve seal worn or defective See Engine Block Assembly section Light loading Do not run set at no load for long periods of time Engine Shuts Low oil level Add oil as required Down and Will Not Restart Low oil tevel switch defective Replace oil level switch see Engine Block Assembly section Worn spark plug Clean or replace spark plug Faulty fuel system Refer to Fuel System section for test and service procedures Power A Redistribution or publication of this document Generation by any means is strictly prohibited EXHAUST SYSTEM The condition of the exhaust system is critical on RV generator sets because of the possibility of exhaust gases entering the vehicle The exhaust system consists of the muffler and muffler support brackets exhaust pipe clamps and hangers needed for installation of the exhaust pipe Figure 6 1 shows a typical exhaust system for a com
107. s manner the electronic voltage regulator keeps the voltage of the generator constant with varying load conditions GENERATOR TROUBLESHOOTING Use the following troubleshooting guide to help tocate problems related to the generator Figure 8 3 shows the location of most of the generator components Refer to the wiring diagram in Figures 8 1 and 8 2 for reference to the generator wiring Always refer to the specific wiring diagram that corresponds to the model and spec number of the generator set when troubleshooting The troubleshooting guide is divided into five sections After identifying the problem refer to the guide for the possi ble cause and the recommended corrective action Ed Power _ ori Generation Redistribution or publication of this document by any means is strictly prohibited Gia Denn ene pe Diy aa gt m Ee ee ee ae P aad alas Dan Solenoid Relay Resistor Ballast Splice Ignition Coil Switch Start Stop Remote Switch Low Oil Level Switch Start Stop Resistor Charging Plug Remote Plug Voltage Regulator Meter Total Run Time Meter Battery Condition Start Disconnect Relay Start Solenoid Choke Magneto Ignition Generator Fuse 5A Fue Pump Spark Piug Lamp Remote Diode Diode Diode Circuit Breaker Capacitor Battery Starter Motor Deluxe Remote Control Standard Remote Control R2 and CR3 may not be used in fater production s
108. sche matic that corresponds to the model and spec number of the genera tor set when troubleshooting probiems When the start stop switch is placed in the start posi tion the rotor begins to turn and is momentarily con nected to the battery This provides a current inthe rotor field winding which induces a voltage in the stator wind ings in particular the excitation winding Q1 Q2 The regulator takes this voltage and rectifies it and feeds it back into the rotor which causes the voltage to increase further This process continues as the engine picks up speed The voltage does not increase uncontrollably because the regulator is connected to the power output leads L1 L2 and constantly measures the output volt age and compares it to an internal reference voltage When the output voltage exceeds the reference the regulator causes the current in the rotor to decrease until the proper voitage is obtained During operation the regulator is constantly monitoring the output voltage When additional load is applied to the generator the output voltage starts to decrease The regulator senses this decrease and increases the field current until the reference voltage and the output volt age match Similarly when the load is decreased the output voltage begins to increase but is noticed by the regulator In this case the regulator decreases the amount of current to the field until the output voltage again matches the reference voltage In thi
109. scroll housing together Figure 8 3 9 Attach a special tool to the fan hub to keep it from rotating Figure 8 4 Remove the rotor through bolt Be careful not to lose the alignment key behind the rotor through bolt washer Figure 8 3 gt So e weneration 8 8 aia f te a FAN HUB ROTOR Wy NS Meat THROUGH OM EE BOLT eo SPECIAL TOOL M 1726 1 FIGURE 8 4 SECURING FAN HUB ASSEMBLY FOR REMOVAL 10 Install a puller on the end of the fan hub as shown in Figure 8 5 Use two 1 4 inch thread cutting cap screws to secure the puller to the fan hub Place a washer on the end of the rotor shaftto protect it from the puller center screws Tighten puller center screw against washer until fan hub pulls free of rotor shaft Remove puller when complete PULLER FAN HUB ASSEMBLY M 1727 1 FIGURE 8 5 PULLING THE FAN HUB ASSEMBLY Redistribution or publication of this document by any means is strictly prohibited 11 Prepare the brushes for endbell removal Discon stator laminations next to the alignmenttabs Figure nect wire harness leads from brush block and pull 8 3 Squeeze screw driver handles together and each brush outward from the holder and atthe same carefully pull stator straight out of the endbell If time insert a piece of wire into the small hole in the stator will not slide out tap on generator housing endbell at bottom of brush block See Figure 8 6 while pulling on stator to remove Do n
110. se order of disassembly Use new gaskets between the intake manifold and engine and between the carburetor and the intake manifold Tighten mounting screws to specified torque INTAKE ELBOW MOUNTING BOLTS FS 1758 FIGURE 6 8 CARBURETOR AND INTAKE MANIFOLD ASSEMBLY Ga Power a Generation Redistribution or publication of this document 6 1 2 by any means is strictly prohibited Carburetor Mixture Screw Adjustments The most common cause of poor carburetion is unsatis factory adjustment of the idle or main mixture adjust ment screws Significant variation from the correct set tings 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 screw adjustment should be checked with every engine tune up and whenever a carburetion prob lem is suspected Before adjusting be sure the ignition system is working properly and the governor is correctly set The limiter cap on the main mixture screw should not be removed unless the carburetor is totally out of adjustment or has been overhauled With the limiter cap removed use the mixture settings in Table 6 2 for preli minary adjustments Turn the mixture screws in until lightly seated then turn out the specif
111. shatter into small pieces and can cause severe personal injury Use protective eye wear and cloth ing when replacing the rotor bearing Heating the rotor bearing for m COLD CHISEL ACAUTION removal or installation can cause damage to the bearing and the collector ring housing Do not heat the rotor bearing CUT BEARING RACE 2A If available use a smal puller with grips that will fit P between the bearing and the collector ring assem bly Cover the end ofthe rotor shaft with a steel plate ROTOR SHAFT to prevent deformation of the shaft during removal 2B ifa suitable puller is not available wrap the collector ring with a cloth for protection and cut off the outer A race of the bearing using a small hand grinder with a ert cutting wheel Be careful to avoid cutting the collec tor ring assembly Remove the bearings and make two cuts approximately halfway through the inner race 180 apart See Figure 8 14 Place rotor with ibe one cut face down on a hard surface and center a cold chisel on the other cut and strike to split apart FIGURE 8 14 ROTOR BEARING REMOVAL Be careful not to damage the rotor shaft The bear ing casing is made of hardened steel that can shat ter into small pieces Use protective eye wear and clothing to protect yourself from injury when striking the bearing casing inspect the rotor shaft for dirt or corrosion If necessary clean with emery cloth before before installing new bearing MEASURE SPACE
112. sion and it is poisonous These hazards can result in 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 fine is shared with any appliance do not continue with any further Service procedures Correct as necessary to comply with applicable codes before cantinuing service work Demand Regulator with Automatic Priming Solenoid The demand regulator is designed for low pressure vaporized fuel An automatic priming solenoid allows tue to pass through the regulator during cranking Ser vice is limited to replacing the complete assembly if it malfunctions The regulator assembly is usually not the cause of engine performance problems All other possi ble causes should be checked before replacing the regulator assembly Refer to Figure 6 17 The regulator should be periodically inspected for fuel leakage past the valve seat and to make sure that the vent is clean The priming solenoid can be bench tested by connect ing battery positive B to the orange lead and battery negative B to the green lead The solenoid shouid energize and press in on the regulator diaphragm The priming solenoid can be adjusted by manually hold ing in the plunger disk and then rotating the adjustment dia clockwise to increase fuel flow or counterclockwise to decrease fuel flow Refer to Figure 6 18 INLET OUTLET A AUTOMAT
113. solenoid K1 contacts connects the battery positive B to the starter motor which begins to crank the engine to initiate starting Starter Lockout Run As the engine comes up to speed the power output from the generator is applied to the start disconnect relay K2 and causes it to energize Engergizing the K2 relay opens the K2 1 K2 5 and K2 2 K2 6 contacts and closes the K2 3 K2 5 contacts This produces the fol lowing control responses e Opening the K2 1 K2 5 contacts disconnects B from the start solenoid K1 de energizing it and causing the K1 1 K1 2 contacts to open This dis connects B from the start motor B1 Opening the K2 2 K2 6 contacts disconnects Bt from the voltage regulator Closing the K2 3 K2 5 contacts applies B to the fuel pump E2 and to the K3 relay through fuse F1 providing fuel flow to the carburetor and ignition voltage from the magneto assembly G2 to the spark plug E1 As the engine begins to run the start stop switch should be released The switch will automatically return to the center Run position and the engine will continue to run The start disconnect relay K2 will remain ener gized and the start solenoid K1 remains de energized Charging Circuit The charging circuit supplies voltage to the choke heater element H1 which activates the heating ele ment and opens the choke The charging circuit also supplies generator battery charge voltage 20 2 volts thatis recti
114. ssure reading is below 3 1 2 psi 17 2 kPa replace fuel pump lf pressure reading is at zero stop engine cranking and check electricai connections Press the Start switch and recheck pressure reading There are no serviceable components in the fuel pump Replace complete fuel pump assembly if defective 2 CHOKE LINKAGE CHOKE LEVER FS 1763 FIGURE 6 16 CHOKE PULLOFF DIAPHRAGM Power nes 6 4 Redistribution or publication of this document Generation 17 by any means is strictly prohibited LPG FUEL SYSTEM The LPG fueled models use a low pressure vapor withdrawai system that must be properly adjusted and be in good working condition Components unique to the fuel system are Demand Regulator with Automatic Priming Solenoid e LPG Carburetor Fuel Sclenoid Speciai precautions must be taken to avoid releasing large quantities of highly flammable LP gas when servic ing the fuel system Use the LP gas purging procedure described in the Preparing to Service section to purge the fuel system of LP gas before servicing any fuel system components The fuel supply line pressure to the demand regulator must be in the range of 6 to 8 ounces per square inch 10 to 14 inches of water column The fuel supply line from the primary regulator to the generator set fuel system components must be dedi cated to the generator set only and not shared with any appliances AWARNING LP gas presents the hazard of fire or explo
115. st Stator holding pins are not required to reassemble the ing grooves in housing as shown in Figure 8 3 Carefully lower stator into generator housing If 13 Remove each ofthe wire connectors from the stator necessary the stator can be lightly tapped on the assembly Wear gloves when handling the stator for lamination mounting tabs until the stator seats into protection from sharp edges Insert two 6 inch the housing screw drivers into the holes on opposite sides of the Power as 8 Redistribution or publication of this document Generation 9 by any means is strictly prohibited Careless handling ofthe stator can A CAUTION damage the insulation on the stator windings Do Not brush windings against the hous ing or strike windings during installation Leaking fuel will create a fire AWARNING hazard which can result in severe personal injury or death If leaks are detected correct immediately Replace worn fuel line components before leaks occur 5 Align slotin rotor shaft with Woodruff key on crank shaft and lower rotor onto crankshaft Make sure 15 Connect the B lead to the start solenoid Attach K3 that the rotor is seated relay to the inlet baffle assembly Figure 7 3 ACAUTION Misalignment of the rotor shaft 16 Install the control panel inspect assembly check all and the crankshaft can cause electrical and mechanica connections for correct damage to the rotor and stator assembly Use care fit and location Place enclosure
116. stallation and visual and audible inspection of the complete exhaust system at the start of each generator set operation 1 RY Power Generation 6 6 Redistribution or publication of this document by any means is strictly prohibited Do not terminate the exhaust tailpipe under the fuel tank fill spout to prevent spitled fuel from being ignited by a hot tailpipe Do not terminate the exhaust tailpipe under any door or operable window No part of the exhaust system shall intrude into the departure angle or approach angle unless it is ade quately protected by a skid bar or other protection device See Figure 6 2 Use a sufficient number of hangers to prevent damage or dislocation of the system Exhaust gases present the hazard of A WARNING of severe personal injury or death Do not terminate tailpipe under the vehicle Direct exhaust gases away from any vent window door or any open ing which can be opened and is not permanently sealed from the vehicle living space Do not mount any protion of the exhaust system into the departure angle or approach angle unless it is adequately protected Use sufficient number of hangers to prevent damage or dislocation of the exhaust system Excessive exhaust back pressure A CAUTION can cause engine damage if tailpipe deflector is used make sure it is large enough to pre vent back pressure SKID BARS TAILPIPE DEPARTURE ANGLE CLEARANCE APPROACH REAR VIEW LINE ANGLE M 1689 4 FIGURE
117. ston tolerances must be maintained for satis factory operation Use a micrometer to measure the piston diameter at the point shown in Figure 9 20 When the cylinder bore is measured see Cylinder Block sec tion subtract the piston diameter from the cylinder bore diameter to obtain the piston pin to cylinder wall clear ance Refer to the Dimensions and Clearances section for the recommended piston clearance FIGURE 9 21 CHECKING RING GAP Piston Assembly Installation Lubricate all parts with clean engine oil Position the piston on the connecting rod install the piston pin The piston pin is a full floating type and must be kept in place in the piston with two lock rings one at each side Install the tock rings and see that they are properly in A MEASURE CX DIAMETER HERE place before installing the piston and connecting rod in 7 O the engine Install the rings on the piston beginning with the oil control ring Use a piston ring spreader to prevent twist ing or excessive expansion of the ring Compression rings are marked with a dot or 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 CT 1063 Stagger ring gaps 120 degrees apart Do not position ring gaps on thrust face of cylinder FIGURE 9 20 PISTON CLEARANCE MEASUREMENT Fitting Piston Rings Before installing new rings on the piston check the ring gap by placing each rin
118. stribution or publication of this document by any means is strictly prohibited Rotor Test The rotor can be tested for grounded open or shorted windings using an ohmmeter Figures 8 10 and 8 11 show the rotor removed from the generator set for test ing The rotor can be tested without removing it from the generator To gain access to the slip rings follow the Generator Disassembly procedures this section through the fan hub assembly removal procedure Usea stiff wire to hold the brushes off the slip rings during testing Refer to the Brushes and Slip Ring section for the procedures to use for inserting the wire liavailable itis recommended that a megger or insulation resistance meter be used for ground tests Ground Test To test for grounds set the onmmeter for the highest resistance scale Touch one test prod to the rotor shaft and hold it there Touch the other test prod to one of the slip rings as shown in Figure 8 10 A reading of less than one megohm indicates the rotor is grounded Replacea grounded rotor with a new rotor Open or Shorted Test To test for open windings setthe ohmmeter on the highest resistance scale Place test prods on the slip rings as shown in Figure 8 11 The ohmmeter should indicate continuity between the 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 rotor winding is open
119. systems the set may be removed for major service work The generator set is mounted on support brackets that are bolted to the underside of the floor on the vehicle or trailer and to the generator set housing The generator set is completely suspended underneath the floor of the RV by the support brackets To avoid dropping the set during removai follow the recom mended set removal procedures Power _ Generation 5 4 Redistribution or publication of this document by any means is strictly prohibited AWARNING He generator set is heavy and can 2 Use a forklift truck to support the weight of the gener result in severe personal injury if ator set at the points shown in Figure 5 3 dropped during removal Use the recommended remo 3 Raise the forklift just so it makes contact with the val techniques and keep hands and feet clear while bottom of the generator set housing then put a little removing mounting bolts upward pressure under the set Verify that the weight of the generator set is supported by the forks before Park the recreational vehicle on as level a surface as proceeding possible Then follow these steps very carefully 4 Remove the bolts that secure the generator set to 5 1 Put the vehicle in its park position tock the brakes the side mounting brackets and rear mounting and remove the keys if applicable Make sure no braces one moves the vehicle while performing this 5 Slowly lower the generator set uni
120. t 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 No AC Output 1 Open circuit breaker Locate cause of overload voltage Note This condition may cause the generator set to stop when the start switch is released AC Output Voltage Too Low Open circuit between brush block and regulator or start disconnect relay contacts K2 2 K2 6 and the regulator Brushes stuck in holder or not making good contact with slip rings Capacitor C1 shorted Faulty start disconnect relay K2 Open grounded or shorted rotor or stator Faulty electronic voltage regulator Engine governor incorrectly adjusted Brushes worn or not making good contact with slip rings Jumper lead not making contact on voltage regulator terminals 1 and 5 and correct as required Reset breaker Check for continuity and correct if circuit is open Release brushes if jammed in holder Clean slip rings if dirty Check capacitor and replace if defective Check start disconnect relay K2 normally closed contacts K2 2 K2 6 Replace if defective Test each component for open grounded or shorted windings and replace if defective If other possible c
121. tch Low Oil Level Switch Start Stop Resistor Charging Plug Remote Plug Voltage Requlator Meter Total Run Time Meter Battery Condition Start Disconnect Relay Start Solenoid Choke Magneto Ignition Generator Fuse 5A Fuel Pump Spark Plug Lamp Remote Diode Diode Diode Circuit Breaker Capacitor Battery Starter Motor Deluxe Remote Control Standard Remote Control R2 and CA3 may not be used in later production sets FIGURE 7 1 SCHEMATIC 60 HERTZ Power i 7 4 Redistribution or publication of this document Generation by any means is strictly prohibited om RELAY IGNITION STOP SOLENOID PRIMING Splice Ignition Coil Switch Stanl Stop Remote Switch Low Oii Level Switch Stari Stop Resistor Charging Plug Remote Plug Voltage Regulator Meter Total Run Time Meter Battery Condition Start Disconnect Relay Start Solenoid Magneto Ignition Generator Fuse FUEL SOLENOID Spark Plug Lamp Remote Diode Diode Circuit Breaker Capacitor Battery Starter Motor Deluxe Remote Control Standard Remote Control K3 K4 Z T1 FIGURE 7 2 LPG GENERATOR SET SCHEMATIC 60 HERTZ Power Generation Se 7 5 Redistribution or publication of this document by any means is strictly prohibited CONTROL TROUBLESHOOTING Use the following troubleshooting guide to help locate problems related to the control Figure 7 2 shows the The troublesh
122. the hazard of fire or AWARNING explosion which can cause severe personal injury or death Piug fuel lines when servicing the fuel system to prevent fuel leakage Do not permit any flame spark pilot light cigarette or other ignition source near the fuel system Keep an ABC type fire extinguisher nearby The carburetor and intake manifold assembly consists of the intake manifold carburetor choke pulloff and governor control linkages See Figure 6 8 Disassembly Use the following procedures to remove and disassemble the carburetor and intake manifold assembly 1 Remove the generator set from the vehicle see Set Removal section 5 and remove the set enclosure 2 Remove the choke assembly mounting bolts and disconnect the choke linkage from the carburetor Remove the vacuum hose from the intake manifold 3 Remove the governor control linkage and spring attached to the carburetor CARBURETOR ASSEMBLY 4 Disconnect the fuel line and plug to prevent fuel leakage 5 Remove the two bottom intake manifold mounting bolts that connect the intake manifold to the cylinder head 6 Remove the carburetor and intake manifold as an assembly 7 Remove the intake manifold gaskets and plug the intake port to prevent loose parts from accidentally entering the engine 8 Remove the two screws that secure the carburetor to the intake manifold and carefully separate the carburetor from the intake manifold Assembly Rever
123. the magneto assembly ignition coil spark plug and ignition wiring If a problem with the ignition system is suspected the spark plug can be inspected and an ignition spark check can be made without removing the genset from the vehicle Perform the spark plug ignition coil and ignition wiring checks before proceeding to the Magneto Assembly section Electrical shock can cause severe AWARNING personal injury or death Do not touch electrical wiring or components during testing Disconnect elecirical power by removing the starting battery negative cable before handling electrical wiring or components Do not connect meters while circuit is energized Spark Plug E2 Remove the spark plug and inspect the electrode If the spark plug has carbon deposits use a wire brush to clean it lf the spark plug is badly fouled or deformed replace it Measure and reset the spark plug gap to 0 025 inches 0 64 mm An examination of the spark plug can often help diagnose an engine problem Refer to the following spark plug conditions Carbon Fouled Check for a poor high tension lead connection faulty choke operation rich fuel mixture or dirty air filter Oi Fouled Check for low compression Burned or Overheated Check for leaking intake manifold gasket lean fuel mixture or incorrectspark plug type Power _ Generation Redistribution or publication of this document by any means is strictly prohibited 6 8 S
124. the under the floor mount installation see Figure 5 2 special brackets are used to suspend the genera tor set under the floor of the vehicle The mounting Power _ Generation Electrical Shock AC Improper generator set load connections Faulty RV wiring Faulty electrical appliance Faulty generator set wiring Working in damp conditions Jewelry touching electrical components Rotating Machinery Jewelry or loose clothing catching in moving parts Slippery Surfaces Leaking or spilled oil Heavy Objects Removing generator set from RV Removing heavy components brackets bolt to special support members that are built into the vehicle framework The generator setis mounted near the exterior of the vehicle Access is provided through a door located in the exterior of the vehicle Because of the wide variety of generator set installa tions it js not possibile 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 AWARNING Generator sets are heavy and can 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
125. ting Crank the engine and observe the plug A good spark should be observed If no spark is observed the magneto or wires connected to the magneto are the most likely cause Refer to the Generatorsection for generator disassembly to access the magneto assembly CRANKCASE VENTILATION SYSTEM The crankcase breather prevents pressure from build ing up in the crankcase it also prevents oil contamina tion by removing moisture or gasoline vapors and other harmful blow by materiais from the crankcase These vapors are routed to the carburetor where they are mixed with the incoming air and burned in the combus tion chamber A sticky breather valve can cause oil leaks high oil consumption rough idle reduced engine power and a rapid formation of sludge and varnish within the engine Crankcase Breather Service If the crankcase becomes pressurized as evidenced by oil leaks at the seals use the following procedures to service Remove the breather tube and the head cover see Engine Block Assembly Section 9 then remove the breather from the cylinder head and inspect it The reed valve must be flat with no sign of creases or other damage if the breather is defective replace it If the breather is dirty clean it in parts cleaning solvent Most parts cleaning solvents are AWARNING flammable and can result in severe personal injury it used improperly Follow the manu facturer s recommendations when cleaning parts Check breather
126. tme ter to check for voltage approximately 20 VAC at the element cover terminals lf voltage is not pres ent check for opens or shorts in the control wiring lf the voltage is present at the heating element cover terminals stop the set and remove the heating ele ment cover Inspect the heating element and replace if burned out or broken Also inspect the bi metal spiral strip and replace if damaged deteri orated or dragging in the housing When installing a new bi metal strip maintain the origina direction of spiral see Figure 6 15 The outer tab must point in a clockwise direction Make sure the coil rests squarely in the housing and the inner end of the coil engages the slot in the choke shaft When installing the element cover make sure the slotted tang on the cover engages the bi metal strip CLOCKWISE FS 1606 1 FIGURE 6 15 BI METAL SPIRAL STRIP Power _ Generation Redistribution or publication of this document by any means is strictly prohibited 6 16 Choke Pulloft Diaphragm Adjustments The choke pull off diaphragm partially opens the choke plate following engine startup This helps prevent flooding and pro vides for smoother engine operation as the set is warm ing up Use the following procedure to adjust 1 Disconnect the diaphragm hose from the rear side of the intake manifold and apply 1 to 2 inches 25 4 to 50 8 mm Hg vacuum to the diaphragm Diaph ragm stem should pull in and r
127. ts Power ni 7 9 Redistribution or publication of this document Generation by any means is strictly prohibited 7K SOLENOID K5 RELAY ne fee ee mm mo ee K3 RELAY Q nes G CONTROL Z PANEL START SOLENOID K1 CONTROL STAAT STOP FUSES SWITCH AC CIRCUIT BREAKER START DISCONNECT RELAY K2 STOP START O l CO a 8C 1608 1 FIGURE 7 3 CONTROL COMPONENT LOCATIONS Gra Power 0 al oe j n Redistribution or publication of this document a Generation 7 1 by any means is strictly prohibited Section 8 Generator INTRODUCTION The KV generator set uses a 2 pole revolving field generator design and an electronic voltage regulator All AC load connections are made through generator lead wires that connect directly to a customer supplied junction box A circuit breaker provides overcurrent protection for the generator and also functions as an on off switch in the load circuit GENERATOR DESCRIPTION The generator consists of the following major components Stator and housing Rotor Electronic Voltage Regulator Brushes Wiring Harness The stator consists of a number of steel laminations stacked together with three separate windings wound onto it in a torroidal fashion Winding T1 T2 is the main power winding that provides the voltage and current to operate the connected loads Winding B1 B2 is for bat tery charging and internal low voltage loads Windin
128. tube and air passages for clogging and clean as required 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 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 maintains a constant engine speed under chang ing load conditions so that generator voltage and fre quency do not vary Governor Adjustments Contact with moving parts can cause AWARNING severe personal injury Keep clothing jewelry hands and fingers clear while adjusting the governor A hot generator set can cause severe AWARNING burns Always allow the generator set to cool before touching any components or remov ing any parts Before making governor adjustments run the unit about 15 minutes under 50 percent load to reach normal oper ating 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 An accurate voltmeter and frequency meter should be connected to the generator in order to correctly adjust the governor accuracy of 0 3 on frequency and 0 5 on voltage A small speed drop not noticeable without instruments will cause an objectionable voltage drop A binding in the governor shaft governor linkage or carburetor throttle w
129. uately secured and free of leaks Fuel connection at the engine should be made with an ap roved flexible non conductive line Do not use copper pip de a flexible lines as copper will work harden and become o Be sure ail fuel supplies have a positive shutoff vaive GASOLINE AND LPG FUEL MAY BE ACCIDENTALLY IG NITED BY ELECTRICAL SPARKS Pena e hazard of fire or explosion which can resuit in severe personal in jury or death When installing the generator set Do not tie electrical wiring to fuel lines Do not run electrical lines and fuel lines through the same compartmert openings Keep electrical and fuel lines as far apart as possible Place a physical barrier between fuel lines and electrical lines wherever possible if electrical and fuel lines must pass through the same com partment opening make certain that they are physically separated by running them through individual channels or by passing each line through a separate piece of tubing e DO NOT SMOKE while servicing batteries Lead acid bat teries emit a highly explosive hydrogen gas that can be ig nited by electrical arcing or by smoking EXHAUST GASES ARE DEADLY e Never sleep in the vehicle with the generator set running un less vehicle is equipped with an operating carbon monoxide detector e Provide an adequate exhaust system to properly expel dis charged gases Inspect exhaust system daily for leaks per the maintenance schedule Ensur
130. utside suppliers A complete listing of the tools availa ble fram Onan is contained in the Tool Catalog 900 0019 which is available from Onan Dealers or Distributors Engine Tools Torque wrench 0 50 Ft Lbs or 0 70 Nem Feeler gauge Pressure gauge Spark plug gap gauge Flywheel puller Gear separator Cylinder ridge reamer Piston ring compressor Piston ring spreader Cylinder hone Valve seat cutter Wire brush 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 Valve Seal Replacement Too Power _ Generation Generator and Control Tools Lead or dead blow hammer Battery hydrometer VOM multi tester Frequency meter Armature growler Load test panel Jumper wires Fan hub assembly holding tool SAFETY CONSIDERATIONS Always consider the safety aspects of any service procedure Generator sets present several hazards that the serviceperson must be aware of to safely complete the job Read through the safety precautions listed on the inside cover and familiarize yourself with the various hazards shown in Table 5 1 Once the hazards are known approach the job with a safety conscious atti tude Being safety conscious is the most effective way to avoid injury to yourself or others Reduce the chance that an accident will occur by adopting the following safeguards Safequards to Avoid Hazards Use Personal Protection Protect your
131. ver Nut 6 8 7 11 Speed Adjust Lever Nut 8 15 11 20 Vibration Isolators 4 6 5 5 8 0 Power 4 Redistribution or publication of this document Generation 1 by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited section 5 Preparing to Service TROUBLESHOOTING Before starting to service the generator set follow a systematic troubleshooting procedure to locate and iso late the problem For servicing purposes the generator set can be divided into the following Engine Primary Systems Control Generator Engine Block Assembly This manual contains separate sections that cover each area Several troubleshooting guides are included in this manual to help the serviceperson locate the cause of various malfunctions Note that some malfunctions might have several possible causes For this reason the serviceperson may have to investigate several likely problem areas in order to isolate the source of the mal function Because of the complexity of the product a troubleshooting chart cannot list every malfunction and the cause In some Situations the serviceperson will have to rely on experience and a knowledge of the product to locate the problem and service as required SPECIAL TOOLS The following special tools may be required to service the generator set Some of these tools may be pur chased from Onan while others may be purchased from o
132. y on the center pin without excessive looseness or wobble Sleeve tip wear is the most common cause of governor failure If governor sleeve gear or flyweights are worn or otherwise dam aged replace them To disassemble remove the snap ring from the governor center pin and slide governor gear assembly off mounting shaft being careful not to lose outer washer See Figure 9 14 To install governor assembie in reverse order of removal see inset draw ing Figure 9 14 for position of flyweight and sleeve CT 1090 To remove the governor shaft remove the retainer clip outside the block then lower the governor shaft into the FIGURE 9 15 REMOVING WEAR RIDGE crankcase SNAP RING s qa N 1 Remove two bolts from connecting rod Mark direc tion of assembly for connecting rod cap and splasher 2 Lift the rod cap from the rod and push the piston assembly out of the top of the cylinder with the handle of a hammer Be carefu not to scratch the crankpin or the cylinder wall when removing FLYWEIGHTS The piston is fitted with two compression rings and one oil contro ring Remove these rings from the piston using a piston ring expander as shown in Figure 9 16 ieee M 2 k CA a Pi CT 1089 FIGURE 9 14 GOVERNOR PISTON ASSEMBLY REMOVAL AND SERVICE The piston assembly consists of the piston piston pin and connecting rod assembly After piston removal ail parts must be carefully inspected for damage and w

981-0506 Onan KV

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