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MicroLite™ 4000 Series

1. gt MicroLite 4000 Series 981 0503 A lt i 2 S i s saq s S lt Printed U S A 2 97 Table of Contents SECTION QI fF GW N TITLE PAGE SAFETY PRECAUTIONS 2 ad lii INTRODUCTION EIU Ene x DS aa wana ER ZEN 1 1 SPECIFICATIONS idea So E dca xin d 2 1 DIMENSIONS AND CLEARANCES 3 1 TORQUE SPECIFICATIONS 4 1 PREPARING FOR SERVICE 5 1 Leu 5 1 Special TOOlS 2 2 2 2 wau Sr 1a Do Hie ubt mir yaa ab aqu 5 1 Safety Considerations 5 1 set hemoval GUIGEIINGS edie Ea e 5 2 TROUBLESHOOTING eR s 6 1 IHH OCHO uay ana TETTE 6 1 Generator Troubleshooting 6 28 Engine Primary Systems Troubleshooting 6 32 CONTROL a e be 7 1 M E PESE ERST D TRITT TEILTE 7 1 Control Description 7 1 Control ODOLatlQDl s ao datnr dede a PRESS Y 7 3 Control Component T6Sls RE EK P EATER CR 7 5 PRIMARY ENGINE SYSTEMS 8 1 ITE CIELO s
2. 0 01 285 185 9907 85 3311185 3NI1 282 163 9907 2985 9907 85 163 0 01 285 31 1 5 0907 85 3NI 1 Z82 JILLS 143 L 1185 3NI 1 L 83 0 01 285 9907 85 3NI1 282 162 GND 21 9 01 285 NY TVYLNAN n GVO T 82 3NI 1 7 L 1 3NI 1 Z L 3INI 1 L 1 a 12 19 G3SLV1OS WYLNSN WHYLNAN GSGNNOYD WYLNAN Q31V IOSI IWYLNSAN WYLNAN GALVIOS WYLNSN GSONNOYD WYLNAN AOLL QNO OL A0ZZ GND OL 7 044 38IM 4 7 02 OCC OIV ZH OG 009 3110431 LYVHI NOLLOSNNOO 3e FIGURE 12 18 VOLTAGE RECONNECTION DIAGRAM 611 1264 MICROLITE BEGI REGULATOR VOLTAGE COIL IGNITION SPLICE SPLITTER SWITCH LOW OIL LEVEL SWI TCH START STOP SOL REGULATOR LP ONLY RELAY STARTER MAGNETO I GNITION GENERATOR FUSE FUEL SHUTOFF SOL GAS ONLY FUEL PUMP FUEL SOL LP SPARK PLUG CIRCUIT BREAKER AC OUTPUT BATTERY 12 V MOTOR STARTER REMOTE CONTROL STANDARD REMOTE CONTROL DELUXE CONTROL ASSY j REMOTE RUN OUTPUT J2 F 1 IS USED ONLY ON GASOLINE SETS K2 IS USED ONLY ON LP SETS P1 9 AVR FIELD FLASH 1 6 STARTER SOL OUTPUT REMOTE RUN O
3. 1 Tv3dl1 n3N Q31V IOSI WYLNSAN WHYLNAN Q31V IOSI IWYLNAN OSONNOYD VSL OSN AOLL QND OL A0ZZ GND OL 7 0424 AUIM C AQ7Z OZL 066 01 4 ZH 06 009 SLI LYVHI FIGURE 12 10 VOLTAGE RECONNECTION DIAGRAM 612 1245 MICROLITE BEGIN SPEC F 50 HE S1 START STOP REGULATOR VOLTAGE COIL IGNITION SPLICE SPLITTER l SWITCH LOW OIL LEVEL SWITCH START STOP E i 5 b SOL REGULATOR LP ONLY 681 pe ees RELAY STARTER 508 Bee MAGNETO IGNITION 7 GENERATOR FUSE P1 5 BATTERY GND INPUT REMOTE START INPUT J2 C 5 8 FUEL SHUTOFF SOL GAS ONLY 5 i FUEL PUMP FUEL SOL LP PLUG 3 S85 g g CIRCUIT BREAKER AC OUTPUT EERE BATTERY 12 V MOTOR STARTER REMOTE CONTROL STANDARD REMOTE CONTROL DELUXE CONTROL ASSY NOTE 1 E3 IS USED ONLY ON GASOLINE SETS K2 IS USED ONLY ON LP SETS 2 S2 IS USED ON SPEC A F IF APPLICA BLE P5 4 amp 6 120V NEUTRAL L2 GND SCHEMATIC FIGURE 12 11 WIRING SCHEMATIC 612 1246 MICROLITE BEGIN SPEC F 60 HERTZ 12 12 NO lt gt M 2 6 a I GND NEUTRAL L2 CB1 LOAD I ie 4 Q 2 a m 22 Bi 2 CB1 LOAD 513 41
4. 12 20 12 1 P5 486 LOCAL START INPUT JI 11 B2 INPUT P6 2 LOCAL RETURN LOCAL STOP INPUT REMOTE RUN OUTPUT J2 5 REMOTE START INPUT J2 3 REMOTE STOP INPUT J2 2 BI INPUT AVR FIELD FLASH BATTERY GND INPUT OIL LEVEL INPUT STARTER SOL OUTPUT JI 6 IGN ENABLE OUTPUT 2 REMOTE RUN OUTPUT 42 6 41 12 FUEL PUMP OUTPUT 41 10 BATTERY INPUT CI ol J4 L2 NEUT GND SCHEMATIC e CBI LI LOAD PCB J6 PCB J8 1 4 20 KEE REGULATOR VOLTAGE COIL IGNITION SWITCH LOW OIL LEVEL SWITCH START STOP RESISTOR BATTERY CHARGE SOL REGULATOR LP RELAY STARTER MAGNE TO IGNITION GENERATOR FUSE FUEL PUMP FUEL SOLENOID SPARK PLUG RECT IF ILER BRIDGE CIRCUIT BREAKER AC OUTPUT BATTERY 12 MOTOR STARTER REMOTE CONTROL STANDARD REMOTE CONTROL DELUXE CONTROL ASSY FIGURE 12 1 WIRING SCHEMATIC 611 1194 MICROLITE SPEC 50 HERTZ 12 2 G2 PI 6 1 2 er EE P BEN H BTI Sus V CRI 2 CB I LOAD ij 4 11 79 WIRING DIAGRAM SEE FIGURE 12 1 FOR DESCRIPTIONS FIGURE 12 2 WIRING DIAGRAM 611 1194 MICROLITE SPEC 60 HERTZ 12 3 LI INPUT o 4 8 LOCAL START INPUT 5 2 d a 11 IGN ENABLE OUTPUT 0 BATTERY INPUT 5 486 FIGURE 12 3 VRI REG
5. 92 2 T1 IGN E3 mA 2 Fl K1 BAT 2 21 12 STOP 1 4 CB1 LOAD CB1 LOAD C1 PCB J6 PCB J8 NOTE WIRING DIAGRAM 1 S2 IS USED ON SPEC IF APPLICABLE SEE FIGURE 12 11 FOR DESCRIPTIONS FIGURE 12 12 WIRING DIAGRAM 612 1246 MICROLITE BEGIN SPEC F 60 HERTZ 12 13 TRANSFORMER CHARGER ASSY BATTERY REGULATOR VOLTAGE COIL IGNITION ONLY SWITCH LOW OIL LEVEL 2 SWITCH START STOP ee RESISTOR ASSEMBLY START STOP SOL REGULATOR LP ONLY RELAY STARTER MAGNETO IGNITION GENERATOR FUSE 5 AMP FUEL SHUTOFF SOL GAS ONLY FUEL PUMP FUEL SOL LP SPARK PLUG J2 F E L1 INPUT P1 4 LOCAL RETURN P1 7 LOCAL STOP INPUT 1 1 gt LOCAL START INPUT P1 13 REMOTE RETURN J2 A BATTERY 12 V MOTOR STARTER REMOTE CONTROL STANDARD REMOTE CONTROL DELUXE CONTROL ASSY J gt REMOTE RUN OUTPUT REMOTE STOP INPUT J2 B STARTER SOL OUTPUT REMOTE RUN OUTPUT J2 OUTPUT SOLENOID IGN ENABLE OUTPUT P1 10 BATTERY INPUT P1 9 AVR FIELD FLASH 12 OIL LEVEL INPUT P S BATTERY GND INPUT pin lt Pt P1 6 lt P1 2 FUEL PUMP OUTPUT REMOTE START INPUT J2 C lt P1 3 FUEL SHUTDOWN NOTE 1 THIS DRAWING ILLUSTRATES WIRING FOR 2 WIRE 220 240V OPERATION FOR ALL OTHER CONFIGURATIONS SEE FIGURE 12 15 a 2 E3 IS USED ONLY ON GASOLINE SETS
6. ZH OG 0097 dll H04 ev NOILO93NN0O33d4o FIGURE 12 7 VOLTAGE RECONNECTION DIAGRAM 612 1226 MICROLITE SPEC B THROUGH E FERRITE TRANSFORMER CHARGER ASSY BATTERY REGULATOR VOLTAGE 2 COIL IGNITION KOI OREN SPLICE SPLITTER START STOP SWI TCH LOW OIL LEVEL SWI TCH START STOP POTENT I SOL REGULATOR LP ONLY RELAY STARTER MAGNETO IGNITION GENERATOR FUSE 5 AMP FUEL SHUTOFF SOL GAS ONLY FUEL PUMP FUEL SOL LP SPARK PLUG LOCAL RETURN P1 7 REMOTE RETURN 2 LOCAL STOP INPUT P1 1 REMOTE STOP INPUT J2 B LOCAL START INPUT P1 13 J gt REMOTE RUN OUTPUT J2 F REMOTE START INPUT J2 C BATTERY 12 V MOTOR STARTER REMOTE CONTROL STANDARD REMOTE CONTROL DELUXE CONTROL ASSY P1 6 STARTER SOL OUTPUT REMOTE RUN OUTPUT J2 E P1 11 IGN ENABLE OUTPUT P1 2 FUEL PUMP OUTPUT P1 5 BATTERY GND INPUT P1 9 AVR FIELD FLASH P1 12 OIL LEVEL INPUT P1 3 FUEL SHUTDOWN P1 10 BATTERY INPUT NOTE 1 THIS DRAWING ILLUSTRATES WIRING FOR 2 WIRE 220 240V OPERATION FOR ALL OTHER CONFIGURATIONS SEE FIGURE 12 10 2 E3 IS USED ONLY ON GASOLINE SETS K2 IS USED ONLY ON LP SETS 3 FERRITE AND SHIELD ARE USED ONLY ON 50 HZ SETS 4 S2 IS USED ON SPEC A F IF APPLICA BLE FOR CONNECTIONS SEE FIGURE 12 10 FIGURE 12 8 WIRING SCHEMATIC 611 1245 MICROLITE BEGIN SPEC 50 HERTZ 12 9 3J1 11
7. Priming Solenoid Adjustment See Figure 8 19 If the genset does not start when it is hot rotate the dial counterclockwise the fuel mixture could be too rich If the genset does not start when it is at am bient temperature rotate the dial clockwise the fuel mixture could be too lean METAL DISK RED PLASTIC DIAL Adjust the primer solenoid by holding on to the metal disk and rotating the red dial Turn the dial clockwise to obtain a richer mixture and counterclockwise to obtain a leaner mixture FIGURE 8 19 AUTOMATIC PRIMING SOLENOID Fuel Shutoff Solenoid Valve Leak Test See Figure 8 20 If there is a smell of gas when the genset is not running or any other reason to suspect that the valve is leaking connect the inlet of the valve to a source of air pressure regu lated to not more than 14 inches WC 356 mm WC and disconnect the outlet hose Replace the sole noid if it leaks as checked by a soap bubble Operation Test If the genset cranks but does not Start first see Section 6 Troubleshooting deter mine whether or not the valve is opening With the source of air still connected energize the valve by connecting battery positive to the top terminal and battery negative to the grounded terminal Replace the solenoid valve if it does not open when it is energized LPG Carburetor Beginning Spec E See Figure 8 21 An LPG carburetor is not likely to cause problems and should be replaced only after a
8. BATTERY BT1 Cs Zs 22 lt CAE rusEF START STOP SWITCH 1 md FUEL PUMP E2 CONTROL ASSEMBLY A1 FUEL SHUTOFF LPG FUEL SHUTOFF E3 J1 CONNECTOR P1 CONNECTOR SPARK PLUG E1 gt IGNITION IGNITION G2 COIL T1 XZ 7 cum 59 FIGURE 6 14 SPEC B STOP MODE 6 26 Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only qualified service personnel with knowledge of fuels electricity and machinery haz ards should perform service procedures Review safety precautions on page iii TABLE 6 12 BEGIN SPEC B CONTROL TROUBLESHOOTING STOP MODE Possible Cause Corrective Action Page Genset 1 If set can be stopped from set control 1a Check wiring continuity between Does Not Stop but not from remote control panel control assembly A1 and remote When Switch fault is due to otart Stop switch Is Pushed To a Open circuit between control assy 1b Check remote Start Stop switch Stop A1 and remote Start Stop switch b Remote Start Stop switch faulty Always remove the load a few 2 If genset can be stopped from remote Check wiring continuity between minutes before control but not from genset fault due to control assembly A1 and Start stopping the a Open circuit between control assy Stop switch S1 genset to allow A1 and Start Stop switch S1 Check Start Stop switch S1 cool do
9. els Schematic for gasoline fueled model shown BATTERY BT1 7 k 2 rj I FUSE F4 START STOP SWITCH S1 L START Sage RELAY 1 VA STARTER MOTOR B1 _ Xo wa has CONTROL ASSEMBLY 1 PUMP 2 EL SHUTOFF LPG a n 2 i I T 5 EY a OIL LEVEL SWITCH S2 B F P1 CONNECTOR SPARK PLUG MAGNETO IGNITION L IGNITION G2 COIL T1 2 M L T ES2017 1s FIGURE 6 10 SPEC B START IGNITION MODE 6 18 Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only qualified service personnel with knowledge of fuels electricity and machinery haz ards should perform service procedures Review safety precautions on page iii But Does Not Start TABLE 6 8 BEGIN SPEC B CONTROL TROUBLESHOOTING IGNITION MODE Possible Cause Corrective Action Page Engine Cranks 1 Restricted fuel supply due to a Fuel level below pickup tube in tank b Fuel line supply valve closed C Fuel filter clogged Faulty ignition due to worn or fouled spark plug faulty plug wire faulty ignition coil or magneto Sticking choke or carburetor mixture screws incorrectly adjusted Fuel pump E2 not working due to a Fuel pump defective b Open circuit between fuel pump and control assembly A1 or control assembly is defective Fuel shutoff solenoid no
10. pair 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 arrester type muffler that is US Forest Service Approved and meets code re quirements Failure to provide and maintain a spark arrester muffler can be in violation of the law Con tact an Onan distributor for approved replacement exhaust parts Inhaling exhaust gases can cause severe personal injury or death Modifying the exhaust system may let poisonous exhaust gases enter the vehicle Use only Onan replace ment parts to service the exhaust system Un authorized modifications will void the Onan warranty Liability for injury or damages due to unauthorized modifications becomes the re sponsibility of the person making the modifica tion Muffler Disassembly 1 Allow the exhaust system to cool down before servicing 2 Loosen the exhaust pipe clamp securing the exhaust pipe to the genset 3 Remove exhaust pipe hanger s and lower ex haust pipe 4 Remove the genset from the vehicle and re move the outer housing See Set Removal Guideslines on Page 5 2 Spec A 5 Remove the bolts securing the muffler flange to the engine and the muffler outlet pipe to the base 6 Remove the hardware securing the muffler bracket to the engine bracket Remove the muffler and the exhaust gasket Begin Spec B 5 Remove the bolts securing the flexible exhaust manif
11. prove operation the problem may be within the gov ernor mechanism see Section 10 Engine Block Assembly GOVERNOR MOUNTING SHAFT BOLT SENSITIVITY ADJUSTMENT SCREW GOVERNOR SPEED GOVERNOR ADJUSTMENT LINKAGE SCREW FIGURE 8 7 GOVERNOR ADJUSTMENTS 8 10 GASOLINE FUEL SYSTEM The fuel system must be properly adjusted and in good condition for efficient genset operation The main components of the fuel system include Air filter Air preheater Choke Carburetor Intake manifold Fuel filter Fuel pump Air Filter and Preheater Assembly This assembly consists of the air filter housing air filter and preheat door assembly See Figure 8 8 Fuel presents the hazard of fire or explosion that can cause severe personal injury or death Eliminate all possible ignition sources such as open flame sparks cigarettes pilot lights arc producing equipment and electrical switches from the work area and rooms with common ventilation when performing the fol lowing procedures The air filter can be serviced without removing the genset from the vehicle Remove the service ac cess cover and the air filter housing cover Remove the air filter If the air filter is dirty replace it Spec A The preheat door assembly is located in side the air filter housing Inspection of the preheat er door operation can be made at this point Spec B The preheat door assembly is located in side the air housing assembly If a
12. 1 O P4 9 FOR CONNECTIONS SEE PAGE 2 LP ONLY z orem T1 H1 TRANSFORMER c T1 H2 TRANSFORMER P6 L1 G2 2 eh GASOLINE ONLY T1 IGN WIRING DIAGRAM SEE FIGURE 12 8 FOR DESCRIPTIONS FIGURE 12 9 WIRING DIAGRAM 611 1245 MICROLITE BEGIN SPEC 50 HERTZ 12 10 dO ASVAYONI WAWIXYN V SADVLIOA AHL 3SV3HONI TIIM NOILVLOY 3SIAMOO TO TANVd TOULNOD SHL JO LOd LNAWLSALOV AO ASN Ad aalsnfav NYO 39VLETOA 114110 ALON SWVYDVIG NOILISNNOI3SY 21 1 21 1 AOZ 022 N CTVY N CTVY N Z1 N b1 N Z1 Q3Sn LON 4341195 xog LV xog NOILINAL LV 21 01 L93NNOD G3SN LON YSLLNdSs SNOILINYLSNI 21 1 LISNNOD WwildadS N3dO 0 01 285 0707 2899 QVO 282 QVO 1 282 21 01 282 3111895 4311185 N IVS LO3N 0907 85 9907 85 9907 85 0907 85 0907 85 9907 85 9907 85 11 9907 85 RTZ 12 11 331 2989 4311185 3111185 3INI 1 83 3INI 1 Z82 3INI 1 83 I 1dS 183 3111185 3431 LI T1dS 1 28 33 L LI 1dS 832 QNNOWD 3INI 1 Z83 3INI 1 83 3NI 1 Z83 3111895 3INI 1 832 3INI 1 Z82 GN DO 39 3NI 1 832 G31V10SI WYLNAN
13. 2 Use a brush type deglazing tool with coated bristle tips to produce a crosshatch pattern in the cylinder bore 3 The deglazing tool should be driven by a slow speed drill Move the deglazing tool up and down in the cylinder rapidly enough to obtain a crosshatch pattern as shown in Figure 10 21 Never use gasoline or commer cial cleaners to clean cylinder bore after de glazing or honing These solvents will not remove abrasives from cylinder wall Abra sives that are not removed from the cylin der will rapidly wear rings cylinder wall and bearing surfaces of all lubricated parts 4 Clean the cylinder bore thoroughly with soap water and clean rags Continue cleaning until a clean white rag shows no discoloring when wiped through the cylinder bore Piston Rings and Connecting Rod The piston has two compression rings and one oil control ring Remove these rings from the piston us ing a piston ring expander as shown in Figure 10 22 10 12 PRODUCE CROSS HATCH SCRATCHES FOR FAST RING SEATING AVOID THIS FINISH C1091s FIGURE 10 21 CROSSHATCHING PISTON RING EXPANDER 1059 15 FIGURE 10 22 REMOVING PISTON RINGS Remove the piston pin retainer from each side heat the piston to 300 F 149 C and push the piston pin out Remove dirt and deposits from the piston sur faces with parts cleaning solvent Clean the piston ring grooves with a groove cleaner Figure 10 23 or the end of a piston ring
14. AC Output Voltage Too High Noisy Generator Generator Overheats TABLE 6 14 GENERATOR TROUBLESHOOTING Possible Cause Corrective Action Page 1 Engine governor out of adjustment If generator frequency is within specified limits but voltage is incorrect electronic voltage regulator is defective Loose brush holder Worn rotor bearing Rotor and stator rubbing together due to a Varnish lumps b Rotor misaligned with crankshaft Generator overloaded due to defective circuit breaker Airflow restricted due to dirt or debris covering vent openings in stator housing Stator windings covered with oil or dirt Defective rotor or stator windings Loose or missing service access cover or improper seal around the endbell assembly Improper installation due to a Insufficient air inlet size b Air inlet location allowing recirculation 6 31 Refer to Governor Adjustments Refer to Table 8 1 for voltage frequency specs Replace electronic voltage regulator Tighten brush holder Replace rotor bearing Check for varnish lumps between rotor and stator remove as required Follow specified assembly procedures to correct rotor to crankshaft alignment Replace circuit breaker Do not exceed specified load when operating genset Clear away all dirt or debris as required Clean stator windings Test each component for open grounded or shorted windings and
15. Engine Lean fuel mixture due to Backfires a Incorrectly adjusted fuel Through adjustment screws Carburetor b Dirt in carburetor c Vacuum leak Mechanical engine defect intake valve defect Faulty ignition due to incorrect spark plug gap 2 Drain fuel tank clean the fuel system and refill with fresh fuel 3a Adjust carburetor main and idle adjustment screws 36 Disassemble carburetor and clean all internal passages Replace filter 3c Locate and correct leak 3d Replace gasket 4a Replace spark plug 4b Check magneto and coil connections 4c Perform Ignition Spark Check 4d Check spark plug wire and boot Rotor or fan hub improperly installed Adjust carburetor main and idle mixture screws Disassemble carburetor and clean all internal passages Locate and correct leak Perform Leak Down Test Reset spark plug gap 6 32 Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only qualified service personnel with knowledge of fuels electricity and machinery haz ards should perform service procedures Review safety precautions on page iii Engine Backfires Through Muffler When Running Engine Lacks Power TABLE 6 16 TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Possible Cause Corrective Action Page 1 Rich fuel mixture due to a Incorrectly adjusted fuel adjustment screws b Choke sticking or out of adjustment c Restricted
16. FIGURE 8 10 CARBURETOR ADJUSTMENTS BEGINNING SPEC D Carburetor Mixture Screw Adjustments Does Not Apply to Spec D and Later The most common causes of poor carburetion are the idle and main mixture screws being out of ad justment and contamination in the carburetor Vari ation from the correct mixture settings can cause serious engine problems Too rich a mixture wastes fuel and increases engine wear by washing the lu bricant from the cylinder walls and diluting the crankcase oil Too lean a mixture causes power loss flat spots in acceleration and a tendency to burn valves and spark plugs Unless a carburetion problem is indicated the mix ture screw settings should not be changed This does not include problems due to high altitude which can usually be corrected with a small adjust ment of the main mixture screw within the range provided by the limiter cap The limiter cap on the main mixture screw should not be removed unless the carburetor has been overhauled or is way out of adjustment Before making adjustments make sure the ignition system is working properly Forcing the mixture adjustment screws tight will damage the needle and seat Turn in ONLY until light resistance can be felt To make preliminary mixture screw settings Remove the limiter cap from the main adjustment screw Turn both of the mixture screws in until lightly seated Figure 8 11 then turn the main screw out 2 turns and the idle screw out 2 1 2
17. This provides a current in the field winding to provide magnetism for voltage buildup As the engine starts and speed increases the rotating field induces an AC voltage in the stator windings AC voltage from the excitation winding Q1 Q2 is fed to the voltage regulator where it is rectified into DC voltage and fed back into the rotor to cause further voltage build up This process continues as the engine picks up speed Voltage buildup is controlled by an electron Ic voltage regulator that is connected to the power output leads L1 L2 The regulator continually measures the output voltage 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 volt age Is obtained During operation the regulator is continually moni toring 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 volt age and the output voltage match Similarly when the load is decreased the output voltage begins to increase and the voltage regulator senses this in crease In this case the regulator decreases the amount of current to the field until the output voltage again matches the reference voltage By continual ly measuring the output voltage and compensating for load changes the electronic voltage regulator
18. keeps the voltage of the generator constant with varying load conditions GENERATOR SERVICE This section covers generator disassembly and as sembly procedures Refer to Figure 9 1 on Page 9 2 9 3 and Figure 9 2 on Page 9 4 to identify the var ious generator components described in each sec tion Raising the generator and engine assembly above the base assembly is necessary to disas semble the generator Lifting eyes are provided on the starter bracket and endbell assembly on the Spec A models A lifting hoist will be required for this step Generator Disassembly Base Removal 1 Drain the engine oil while the genset is still mounted in the vehicle 2 Remove the genset from the vehicle and place it on a sturdy work bench Refer to Set Removal Guidelines on Page 5 2 for the recommended genset removal procedures The genset is heavy and can re sult in severe personal injury if dropped during removal or service Use the recom mended removal techniques and keep hands and feet clear while removing mounting bolts 3 Remove the side mounting screws from the en closure cover and lift cover off genset Begin Spec B 50 Hz models Remove the leads from the battery charger assembly mounted to the left side of the housing Spec A Instructions 4 Remove the engine mounting bolt and two gen erator mounting bolts T 55 driver from under the base assembly Apply antiseize lubricant to the treads of these bolts before
19. least three locations Use a hole gauge to measure the valve guide at several depths 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 the valve springs for cracks worn ends and distortion If the spring ends are worn check valve retainer for wear Check for spring dis tortion by placing the spring on a flat surface next to a square Measure the height of spring A and ro tate it against a square to measure distortion B see Figure 10 9 Replace any valve spring that is weak cracked worn or distorted VALVE STEM VT 1012 1s FIGURE 10 8 VALVE FACE STEM AND GUIDE FIGURE 10 9 VALVE SPRING CHECKS 10 5 Valve Seat Surface Width Clean the valve seat surface Use a vernier caliper to measure the valve seat width Figure 10 10 See Section 3 Dimen sions and Clearances for seat width allowable limit Apply red lead to the valve surface to check for scratches or unevenness When the measurement is within the allowable limit check the seating ratio If the ratio is less than 70 the valve seat needs to be reground If the measurement exceeds the allowable lim it replace the valve and regrind the valve seat see Regrinding Seat Surface on Page 10 6 Regrinding Seat Surface Grind the valve seat surface with 45 cutter Use a cutter appropriate for the valv
20. ments Voltage frequency sensitive equip ment such as VCRs televisions computers etc may be damaged by power line frequency variations Some solid state devices are pow ered whenever connected to an AC outlet even if the device is not in actual operation For this reason disconnect all devices which are volt age or frequency sensitive before attempting any carburetor governor adjustments If dis connecting the devices is not possible open the circuit breaker s at the distribution panel or at the genset if so equipped Adjustments to the governor should be made in the following sequence 1 Run the genset at least 10 minutes at 50 to 75 of its rated load Check that the choke is completely open If the governor is completely out of adjustment make a preliminary adjust ment at no load to attain a safe voltage and speed operating range 2 Check the governor linkage for binding or ex cessive looseness Check the motion spring for bending or damage and straighten or replace as needed 3 With unit operating at no load adjust the speed adjustment screw see Figure 8 7 on Page 8 10 on the governor linkage to obtain 62 Hz and 127 5 4 5 volts Set 50 hertz units to ob tain 52 0 0 5 Hz at between 220 and 231 volts for 220 volt units and 240 to 252 volts for 240 units To increase the engine speed turn the adjustment screw clockwise To decrease the engine speed turn the adjustment counter clockwise 4 Check t
21. replace if defective Check for proper fit of service access cover and check seal around endbell Make sure air inlet is not blocked and that it is properly sized refer to Installation Manual Make sure that air outlet is not blocked and check for recirculation of outlet air ENGINE PRIMARY SYSTEMS Poor engine performance is often caused by a dirty TROUBLESHOOTING carburetor Make certain that the carburetor is clean before troubleshooting for performance prob Use the following troubleshooting guide to locate lee problems with the engine primary systems Many of the primary systems can be serviced without re moving the genset from the vehicle Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only qualified service personnel with knowledge of fuels electricity and machinery haz ards should perform service procedures Review safety precautions on page iil TABLE 6 15 TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Possible Cause Corrective Action Page 1 Check and replace if necessary Engine Runs 1 Dirty air or fuel filter Rough 2 Contaminated fuel Lean fuel mixture due to a Incorrectly adjusted Fuel mixture screws b Dirt in carburetor c Vacuum leak d Gasket failure Faulty ignition due to a Worn or fouled spark plug b Poor magneto or coil connections c Faulty ignition components d Faulty plug wire e Incorrect ignition timing
22. this screw is neither visible nor accessible for adjustment FIGURE 8 18 TOP VIEW OF DEMAND REGULATOR WITH AUTOMATIC PRIMING SOLENOID Checking and Adjusting Regulator Lock off Pressure Lock off pressure is determined as fol lows by pressurizing the back vent side of the reg ulator diaphragm to simulate carburetor venturi vacuum 1 Connect the regulator inlet Figure 8 18 on Page 8 22 to a source of air pressure regu lated to 11 inches WC 280 mm WC 2 Disconnect from the carburetor the LPG supply hose which comes from the regulator 3 T in two hoses to the end of the hose con nected to the regulator vent fitting 3 8 inch D Use one hose to measure pressure by connecting it to an inclined manometer that reads 0 to 2 inches WC 0 to 50 mm WC and the other to provide the test pressure 4 Attach a soap bubble to the end of the LPG supply hose which was disconnected from the carburetor While reading the pressure indi cated by the manometer and watching the soap bubble blow lightly into the hose being used to pressurize the regulator Regulator lock off pressure is the minimum pressure that will cause air to flow through the regulator as indicated by the expanding soap bubble At first the soap bubble may expand due to dia phragm movement but will stop expanding if air is not flowing through the regulator If this is a bench test of the reg ulator make sure the diaphragm is in a ver tical plane
23. 2 Insufficient cranking voltage due to Also see Table 6 5 on page 6 13 a Battery not charged b Battery connections loose or dirty c Battery cable size too small Start solenoid K1 not energized due to a Open circuit to start solenoid coil b Defective start solenoid coil c Defective Start Stop switch d Defective control assembly A1 Starter B1 not energized due to a Open circuit to starter B1 b Open circuit between battery B and the start solenoid contact BAT c Defective start solenoid K1 d Defective starter B1 If engine cranks from set but not from remote control panel fault is due to a Open circuit between control assy A1 and remote Start Stop switch b Remote Start Stop switch faulty Check fuse If open locate and correct cause of overload Replace fuse Check condition of battery and recharge or replace Clean and tighten all connections at battery K1 start solenoid and starter motor Increase starting battery cable size Check wiring continuity to the start solenoid K1 coil from control assy A1 and from ground to start solenoid Test start solenoid K1 Test Start Stop switch 51 Measure voltage between start solenoid terminal I and ground with switch 51 held in the Start position If voltage is not present and continuity and battery check OK Cont assy A1 is defective Check continuity between start
24. 50 HERTZ ONLY L 15 Circuit Breaker CONTROL PANEL START RELAY 1 CONTROL ASSEMBLY 1 1899 35 FIGURE 7 2 BEGIN SPEC CONTROL COMPONENT LOCATIONS Optional Remote Control A2 A3 The remote control is an optional accessory that al lows the genset to be started monitored and stopped from a remote location The deluxe control A3 includes a running time meter and a battery condition meter Remote control panels are mounted inside the vehicle Rectifier Bridge CR1 Spec A Only The rectifier bridge consists of four diodes con nected in a bridge circuit to form a full wave voltage rectifier The bridge circuit rectifies the AC voltage from the generator battery winding B1 B2 to sup ply DC voltage for battery charging Battery Charge Resistor R1 Spec A Only The battery charge resistor limits the battery charge rate to a maximum of one ampere Battery Charger Assembly VR2 Begin Spec B 50 Hz Only The battery charger assembly rectifies the AC age from the generator battery winding B1 B2 to supply DC voltage for battery charging Transformer T1 Begin Spec B 50 Hz Only The transformer provides isolation required for some 50 Hz reconnection applications See Figure 6 2 on Page 6 3 for transformer location 7 3 CONTROL OPERATION The schematic diagrams in Section 12 Wiring Schematic Diagram can be used to help follow the circuit description A
25. B terminal and ground Figure 7 7 with the genset off should read the starting battery voltage approximately 12 VDC With the genset running a reading between the B terminal and ground should be slightly more than the first reading 12 5 to 14 VDC If the same or less voltage is measured connect the voltmeter between the two AC terminals to measure the input voltage from the B1 B2 battery charge winding During set operation voltage from the B1 B2 battery charge winding should be approxi mately 17 to 19 VAC If this reading is obtained and charger output voltage does increase when the genset is started replace the battery charger If low or no voltage is measured between the AC termi nals check the wiring harness connections and re fer to the generator test section 7 9 GROUND CONNECTION FIGURE 7 7 BATTERY CHARGER ASSEMBLY VR2 Transformer T1 Begin Spec B 50 Hz Only The transformer see Figure 7 8 is located on the backside of the genset see Figure 6 2 on Page 6 3 The transformer can be checked with an ohm meter Isolate the transformer leads from the circuit and measure the resistance between H1 H2 pri mary winding The primary should measure 440 to 540 ohms Measure the resistance between 1 X2 secondary winding The secondary should mea sure 225 to 275 ohms If an abnormal reading is measured replace the transformer 7 10 TRANSFORMER 1 PRIMARY 7 SECONDARY TRANSFO
26. Em K2 IS USED ONLY ON LP SETS PCB J6 adio VR 4 3 FERRITE AND SHIELD ARE USED ONLY ON 50 HZ SETS 3799 J4 4 S2 IS USED ON SPEC IF APPLICABLE FOR CONNECTIONS SEE FIGURE 12 15 FIGURE 12 13 WIRING SCHEMATIC 612 1255 MICROLITE BEGIN SPEC F 69 HZ 100 V 12 14 SEE PAGE 2 GND G2 4 amp B1 J L O des 2 FOR CONNECTIONS 2 pe CIEE LP ONLY PS u NOTE 1 S2 IS USED ON SPEC A F IF APPLICABLE 4 E2 nner gt J1 2 E i qe P G2 2 J1 3 E3 ELT GASOLINE ONLY T1 IGN 4 4 52 4 5 1 12 oo 1 K1 BAT 6 2 K1 BAT 5 1 ac 2 LINE BAB GND CB1 LOAD Jt 4 Jt 7 1 13 ur J4 SEE FIGURE 12 13 FOR DESCRIPTIONS FIGURE 12 14 WIRING DIAGRAM 612 1255 MICROLITE BEGIN SPEC F 60 HZ 100 V 12 15 ASVAYONI INOIWIXVIN V Ad 3SV1TOA 3H L 3SVddONI TIIM NOILV LOH ASIMMOOTO IOHLNOO AHL dO JO LNO amp H AHL NO LOd LN3IWISRfP Qv AHL dO ASN aarsnfrav NYO 39VETOA LAdLNO 31ON SWVYDVIG 0 HZ 100 V SPEC Fo NOILISNNOI3SY 21 1 N CTVY N CTVY N Z1 N b1 N Z1 Q3Ssn LON 4341195 xog LV xog NOILINAL LV 21 01 LIANNOD G3SN LON 1 SNOILINYLSNI 21 1 LISNNOD 79153 090
27. Install the float valve into the slot in the float and install the float with the float pin Figure 8 14 Make sure that the float moves freely without binding Install the main mixture screw assembly and the idle mixture screw assembly 8 16 Forcing the mixture adjustment screws tight will damage the needle and seat Turn them in until only light tension can be felt 4 Adjust the idle and main mixture screws as de scribed in this section DAMAGE AND WEAR OCCUR HERE FS1483 4s FIGURE 8 13 MIXTURE NEEDLE INSPECTION FIGURE 8 14 FLOAT INSTALLATION Choke Assembly The genset has an automatic choke assembly that consists of a bimetal choke coil coil housing heater tube from the exhaust tube and choke linkage The choke linkage connects to the choke shaft lever on the carburetor When the engine is cold the choke coil position causes the linkage to hold the choke nearly closed When the engine starts hot air from the exhaust manifold enters the coil housing The choke coil ex pands pulling the linkage to partially open the choke As the engine warms up the coil continues to expand and gradually opens the choke and holds it open while the engine is operating This action varies the fuel air mixture as the engine warms up to provide smooth engine operation If the engine starts but runs rough and exhausts black smoke after a minute or two of operation the choke setting is too rich If the engin
28. Page 5 2 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 follows Oil pan and oil level switch Head cover and breather Rocker arms and push rods Cylinder head valve springs and valves Crankcase cover camshaft and balancer Connecting rod and piston Crankshaft and governor lever shaft Jo ci cnm LEAK DOWN TEST Perform the leak down test if performance problems or high oil consumption occur and poor compres sion is suspected Follow each of these steps and refer to the test equipment manufacturer s instruc tions A typical tester is shown in Figure 10 1 1 Start the engine and allow it to warm up for ten minutes If the engine will not start continue to the next step 2 Disconnect the battery negative cable to prevent accidental starting and remove the spark plug 3 Manually rotate the the engine in the direction of normal operation by turning the fan hub as sembly Stop turning the engine when it reach es top dead center T D C on the compression stroke T D C can be determined by A Removing the head cover and observing the valve overlap on the compression stroke 10 1 B Feeling compression air escaping the spark plug hole C Using a tester with a T D C indicator fea ture Connect the tes
29. Possible Cause Corrective Action Page Fuel level is below genset fuel Eo tube or oil level is low Faulty choke operation Vapor lock from high ambient temperature Contaminated or incorrect fuel Open circuit in remote control wiring If battery condition meter and run lamp 2 work but time meter does not time meter is defective If time meter works but battery condition 3a meter does not operate a Defective battery condition meter b Defective zener diode inside remote control Meters and switch function properly but run lamp does not illuminate Lamp internal to switch is burned out If remote switch functions properly for starting and stopping genset but meters and run lamp do not operate and step 1 checks OK control assy A1 defective Too much DC load over 2 amps connected to the remote output Check fuel and oil level and refill if low Refer to choke section for adjustments Remove any objects or debris that may restrict airflow Make sure fuel system is installed correctly Refill tank with fresh fuel 8 17 Check continuity between remote control and control assembly A1 Replace time meter Connect a voltmeter between the positive terminal on battery charge meter and ground Use the following to determine fault If reading equals battery voltage minus 10 volts battery condition meter is defective If reading does not equal battery volt
30. SHOWN 10 2 Remove the oil level switch mounting bolts and switch assembly Spec A F only if applicable Clean the oil pan and use a new gasket when rein Stalling Torque all mounting bolts to the specified torque see Section 4 Torque Specifications BREATHER HEAD COVER Remove the head cover to gain access to the cylin BREATHE der head breather assembly and valve system NME DD ASSEMBL 1 Remove the head cover mounting bolts and pull off the head cover Figure 10 3 2 Clean the head cover Be careful not to dam age the surface of the cover where the gasket mounts 3 Clean the cylinder head and cover thoroughly In the cover gasket mating area Make sure the breather assembly is correctly seated in the cylinder head cavity 4 Install a new head cover gasket HEAD 5 Place the head cover in position and install the mounting bolts Torque all of the bolts star pattern until they are tightened to the specified torque FIGURE 10 3 HEAD COVER REMOVAL 10 2 ROCKER ARMS PUSH RODS AND CYLINDER HEAD Remove the cylinder head for cleaning when poor engine performance is noticed or to inspect the valves 1 Remove the rocker arm mounting nuts Re move the rocker arms and push rods Figure 10 4 Remove the spark plug Remove the cylinder head mounting bolts and pull off the cylinder head Warping can occur if the head is removed while it is hot Wait until the en gine has cooled b
31. a setting of 55 1 Hz 45 1 Hz on 50 Hz units Readjust the governor speed screw to within 62 5 0 5 Hz on 60 Hz models or 52 0 5 Hz on 50 Hz models at no load Observe the sen sitivity of the genset If necessary adjust the governor sensitivity as specified in Governor on Page 8 9 THROTTLE STOP SCREW ADJUSTMENT SCREW FS1807 2s FIGURE 8 11 MIXTURE SCREW ADJUSTMENT PRICK TO SPEC D Carburetor Overhaul Does Not Apply to Spec D and Later Carburetion problems that cannot be corrected by mixture screw adjustments are usually a result of gummed up fuel passages or worn internal parts The most effective remedy is a complete carburetor overhaul Overhauling a carburetor consists of complete dis assembly a thorough cleaning and replacement of worn parts The carburetor repair kit includes new gaskets and replacements for the parts that are most subject to wear Carefully note the location of carburetor parts for correct reassembly Review these instructions be fore starting The carburetor components are illus trated in Figure 8 12 Gasoline fuels deteriorate over time causing fuel system corrosion and the formation of gum and var nish like deposits If the genset will not be operated for more than 120 days a fuel preservative and sta bilizer such as OnaFresh should be used to pro tect the fuel system Follow the label instructions for using a fuel additive Gasoline is extremely flammable
32. and cause flooding A negative fuel supply line pressure more than minus 1 3 psi or three feet of lift will pre vent the pump from delivering enough fuel Mea sure the pressure at the pump inlet Inlet pump pressure must be between a minus 1 3 psi and a positive 1 5 psi minus 8 3 kPa and positive 10 3 kPa If an abnormally high or low inlet pressure is measured the fuel line installation is improper Re fer to the Fuel System section of the Installation Manual FIGURE 8 17 FUEL PUMP TEST LPG FUEL SYSTEM LPG is flammable and explosive and can cause asphyxiation NFPA 58 Section 1 6 requires all persons handling LPG to be trained in proper handling and operating proce dures Do not smoke if you smell gas or are near LPG containers or LPG burning equipment or are in an area sharing ventilation with such equip ment Keep flames sparks pilot lights electri cal arcs arc producing equipment electrical switches and all other sources of ignition well away Have an ABC fire extinguisher handy L PG models are designed for a low pressure vapor withdrawal type of LPG supply system LPG supply pressure at the inlet to the demand regulator must be 9 to 13 inches 229 to 330 mm water column WC when the genset is running under full load The components of the genset LPG system include e A fuel shutoff solenoid valve e A demand regulator with a built in automatic priming solenoid which allows fuel to pass through duri
33. as in the genset otherwise the weight of the diaphragm will cause erro neous readings of lock off pressure e For Gensets Beginning Spec E Replace the demand regulator assembly if the lock off pres sure does not fall between 0 10 and 0 30 inch es WC 2 5 and 7 6 mm WC e For Gensets Prior to Spec E Adjust lock off pressure as follows e f the lock off pressure is greater than 0 30 inches 7 6 mm WC loosen the lock nut on the lock off adjusting screw and back out the screw counterclockwise until the lock off pressure falls between 0 10 and 0 30 inches WC 2 5 and 7 6 mm WC Set the adjusting screw locknut and test lock off pressure again Repeat the procedure if necessary e f the lock off pressure is less than 0 10 inches WC 2 5 mm WC loosen the lock nut on the lock off adjusting screw and turn in the screw clockwise until the lock off pressure falls between 0 10 and 0 30 inch es WC 2 5 and 7 6 mm WC Set the ad justing screw locknut and test lock off pressure again Repeat the procedure if necessary e Replace the demand regulator if it contin ues to leak after lock off pressure adjust ments have been attempted Priming Solenoid Test Upon completing the lock off pressure test energize the priming solenoid by connecting battery positive to the orange lead and battery negative to the green lead Replace the regulator assembly if the priming solenoid does not cause the regulator to open
34. 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 Procedure Oil leaks at the seals may indicate that the crank case 15 pressurized Use the following procedure to eliminate this condition 1 Remove the breather tube from the valve cover see Figure 8 6 2 Remove the head cover and breather assem bly 3 Inspect the reed valve It must be flat with no signs of creases or other damage Replace a defective reed valve If the breather is dirty clean it in parts cleaning solvent 4 Check the breather tube and air passages for clogging and clean as required Most parts cleaning solvents are flammable and can result in severe personal in jury if used improperly Follow the solvent manufacturer s recommendations when clean ing parts BREATHER HOSE 151173 18 FIGURE 8 6 CRANKCASE BREATHER SYSTEM GOVERNOR The governor controls engine speed which directly affects the frequency and voltage output of the gen erator The governor reacts to the speed frequency differential between no load and full load condi tions known as droop Good overall governor op eration requires a proper amount of governor droop Too large a droop and genset voltage fre quency control may be adversely affected Too small a droop may cause erratic governor action or alternately increase and decrease engine speed hu
35. feeler gauge to measure the amount of distortion 3 If the measurement exceeds the specified limit replace the cylinder head see Section 3 Di mensions and Clearances Cylinder Block Cleaning After removing the piston crankshaft cylinder head etc inspect the block for cracks and extreme wear If the block is still serviceable pre pare it for cleaning as follows 1 Scrape all of the old gasket material from the block 2 Remove grease and scale from the cylinder block by agitating in a bath of commercial cleaning solution or hot soapy washing solu tion 3 Hinse block in clean hot water to remove clean ing solution 10 10 ROD CAP 1134 15 FIGURE 10 18 PISTON REMOVAL C105F079 FIGURE 10 19 CYLINDER HEAD SURFACE FLATNESS Inspection When rebuilding the engine thorough ly inspect the block for any condition that would make it unfit for further use his inspection must be made after all parts have been removed and the block has been thoroughly cleaned and dried 1 Make a thorough check for cracks using any standard 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 oxide white lead dissolved in wood alco hol If cracks are present the white coating will become discolored at the
36. from the genset and plug the end of the hose to prevent fuel from escaping if someone inadvertently opens the shutoff valve s at the LPG container s Gasoline and LPG liqui fied petroleum gas are flammable and explosive and can cause severe per sonal injury or death Do not smoke Keep flames sparks pilot lights arc producing and switching equipment and all other sources of ignition away from fuel tank and system and areas sharing ventilation Have an ABC fire extinguisher handy LPG is flammable and ex plosive and can cause asphyxiation NFPA 58 Section 1 6 requires all per sons handling LPG to be trained in proper handling and operating proce dures LPG sinks and can accumulate in ex plosive concentrations Before discon necting the LPG fuel line close the fuel shutoff valve s at the LPG container s and move the vehicle outside and away from pits basements and other below grade spaces where LPG could accu mulate Set Removal After the genset is disconnected from electrical ex haust 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 housing will be mounted to the coach framework Depending on the installation the set may be removable from the side back or bottom Verify that the genset is adequately supported be fore loosening any of the mounting bolts or support members Use a forklift t
37. is excessively worn and must be replaced Always re place the brush springs when installing new brushes to maintain proper tension on the brushes Clean carbon deposits from brushes and slip rings see Slip Ring Service section on Page 9 13 Use the following procedures to replace the brushes HOLDER lt tran i ia 2 z Z SSS SSS SSS FIGURE 9 11 BRUSH REPLACEMENT G1179 2s Remove the brush block mounting screws and lift out the brush block Remove the brushes and springs from the holder and replace with new parts see Figure 9 11 on Page 9 12 Push each brush into the brush holder and in sert a stiff wire through the small hole in the base of the holder See Figure 9 4 on Page 9 6 The wire holds the brushes off the slip rings during assembly NOTE Inspect slip rings before installing brush block See Slip Ring Service following Install the brush block in endbell but do not tighten the mounting screws Remove the wire holding the brushes off the slip rings Adjust the brush block so that the brushes are centered on the slip rings then tighten the mounting screws Follow Generator Assembly procedures on Page 9 7 to reinstall the fan hub and remain Ing generator components Slip Ring Service Follow Generator Assembly procedures on Page 9 7 through fan hub assembly removal Inspect the slip rings for grooves pits or other damage A Scotch Brite pad can be used to remove
38. light arc producing equipment or other ignition sources e Burns Hot exhaust pipes Hot engine and generator surfaces Hot engine oil Electrical short in DC wiring system e Poisonous gases Carbon monoxide from faulty exhaust Operating genset where exhaust gases can accumulate Develop safe work habits Unsafe practices are the cause of most accidents involving tools or ma chinery Be familiar with your tools and machines and learn how to use them safely Use the right tool for the job and check its condition before starting Follow all warnings and cautions in this manual and take extra precautions when working around elec trical equipment Avoid working alone and do not take risks Do not work when tired or after consum ing any alcohol or drug that makes the operation of equipment unsafe Be prepared for a potential accident The Red Cross and public safety departments offer courses in first aid CPR and fire control Use this informa tion to be ready for an accident Be safety con scious and make safety procedures part of the work routine SET REMOVAL GUIDELINES Some service procedures will require removing the genset from the coach While there are many varia tions genset installations are generally classified as either conventional compartment mount or un der the floor mount 5 2 e Electrical shock AC Improper genset load connections Faulty RV wiring Faulty electrical appliance Faulty genset wiring
39. light wear and for surface finishing If the slip rings are rough pitted or out of round by more than 0 002 inches recondition them in a lathe with a commutator stone Use the following procedure to service 1 Follow Generator Disassembly on Page 9 2 to remove the generator endbell and rotor Place the rotor in the machine lathe and center Turn the rotor and use a commutator stone Onan tool 420 0259 against the rotating slip rings to clean and true the slip rings Turn the rotor until all grooves or roughness are smoothed out Rub out must be less than 0 0001 inch and surface finish must be less than 32 micro inch Contact with rotating machin ery can result in severe personal injury Keep hands and fingers clear while servic ing slip rings 2 9 13 Careless handling of rotor can damage the insulation on the windings Place rotor on protected surface when set ting down Clean the rotor and prepare for reinstallation Follow Generator Assembly procedures on Page 9 7 to reinstall the rotor and remaining generator components ROTOR BEARING REPLACEMENT The rotor bearing is pressed onto the rotor shaft This bearing must be replaced very carefully to avoid damaging the collector ring assembly and the rotor shaft Use the following procedures to replace the rotor bearing 1 Measure and record the distance between the bearing and the collector ring assembly See Figure 9 12 Heating the rotor bearing f
40. this reason disconnect all devices that are voltage or frequency sensitive before attempting any carburetor governor adjustments If discon necting the devices is not possible open the circuit breaker s at the distribution panel or at the genset If the fuel system was worked on check that the idle and main adjustment screws are adjusted as de scribed in the fuel system sections of Section 8 Pri mary Engine Systems before starting the genset Reinstall adjustment screw limiter caps Start the genset then immediately adjust the gover nor speed for a safe no load operating speed With no load applied listen for unusual sounds or vibra tions Warm up the genset for at least 15 minutes at 50 to 75 of rated load and check that the choke Is completely open Adjust the carburetor and gov ernor as specified in the governor and fuel system sections of Section 8 Primary Engine Systems EXHAUST SYSTEM With the genset operating inspect the entire ex haust system including the muffler and exhaust pipe Make certain that the exhaust pipe terminates beyond the perimeter of the coach Visually and au dibly check for leaks at all connections welds gas kets and joints Also make sure that exhaust pipes do not heat surrounding areas excessively If leaks are detected correct immediately Inhalation of exhaust gases can re sult in severe personal injury or death Inspect exhaust system audibly and visually for leaks Shut off t
41. turns A hot genset can cause severe burns Always allow the genset to cool before touching any components or removing any parts Start the engine and allow it to run for ten minutes Use the following procedure to adjust the mixture Screws 1 Stop the genset and connect a voltmeter fre quency meter and load bank to the generator output leads 2 Start the genset and apply the rated load Verify that the frequency is within 60 5 1 Hz Adjust the governor speed adjustment screw if neces sary to obtain the required frequency 8 14 Turn the main adjustment screw inward until voltage or frequency drop and then outward until voltage or frequency drop again Locate the point where voltage and frequency are the highest From this point turn the main adjust ment screw out an additional 1 4 turn Install the limiter cap so it is vertical Remove the load and verify that the frequency is within 62 5 0 5 Hz on 60 Hz models or 52 0 5 Hz on 50 Hz models Adjust the governor Speed adjustment screw if necessary to obtain required frequency Turn the idle adjust screw inward until voltage and frequency drop and the engine begins to run rough or hunt Back the idle screw out until the engine runs smooth without hunting Pull the governor linkage toward the front of the genset so that the throttle lever on the carbure tor is resting against the throttle stop screw Figure 8 11 Adjust the stop screw to obtain
42. with a feeler gauge CONNECTING ROD ON CRANK PIN Figure 10 31 3 If the clearance exceeds the allowable limits replace them Cam Heights for Intake and Exhaust 1 Measure the height of the cam at its highest point with an outside micrometer Figure 10 32 2 f the measurement is less than the allowable limit replace the camshaft FIGURE 10 32 INTAKE AND EXHAUST CAM HEIGHTS C105F090 FIGURE 10 30 CRANK PIN AND CONNECTING ROD CLEARANCE 10 16 PISTON AND CRANKSHAFT INSTALLATION Lubricate the bearings with engine oil Slide the crankshatt into the bearing and add shim s Install the crankcase cover and check to see that the crankshaft turns freely Measure the side clearance of the crankshaft as follows Side Clearance of Crankshaft 1 Set a dial gauge as shown in Figure 10 33 push the shaft in and measure the clearance 2 If the side clearance exceeds the allowable lim its adjust with shims Remove the crankcase cover and assemble the piston to the connecting rod Heat the piston to 300 F 149 C Position the piston on the connect ing rod Install the piston pin Install the lock rings on each side of the piston pin Installing the Piston in Cylinder When installing the piston assembly observe the markings on the connecting rod cap and splasher See Figure 10 34 1 Turn the crankshaft to position the crankpin at the bottom of its stroke 2 Lubricate the piston assembly and inside o
43. 1 or voltage regulator VR1 6 21 Check oil level and add oil if low Disconnect low oil level switch and check set operation Replace if defective Check wiring continuity to the brush block F1 F2 voltage regulator VR1 control assembly A1 and generator B1 B2 50 Hz and Q1 Q2 windings Check connections of P5 and P6 connectors on the generator housing Check brushes for wear and for contact with the slip rings Check the slip rings Perform field voltage test Begin Spec B Run Mode When the engine starts release the Start Stop switch and it will return to the center Run position The following events occur e Control assembly A1 opens the circuit to the start solenoid K1 which opens the circuit to the starter motor M1 to stop cranking Control assembly A1 also opens the field flash circuit to AVR pin 7 e 50 Hz models only Voltage from the battery used to power the control assembly A1 and the fuel pump E2 is replaced with output voltage from the generator charge winding B1 B2 Refer to Battery Charge Mode on page 6 24 e The control assembly senses output voltage from L1 X1 50 Hertz for the start disconnect function e Remote run output is energized through the control assembly A1 to power the time meter battery condition meter and run lamp in the optional remote control e Voltage from the generator Q1 Q2 winding provides power to the voltage regulator VR1 to use for supplying field
44. 11 2 Mechanical x det bed AREE RR RU RR Rc bos 11 2 12 WIRING SCHEMATIC DIAGRAM 12 1 Safety Precautions Thoroughly read the SERVICE MANUAL before servic ing the genset Reliable service can be obtained only with close adherance to the procedures in this manu al The following symbols in this Manual alert you to potential hazards to the operator service person and equipment Alerts you to an immediate hazard which will result in severe personal injury or death AWARNING Alerts you to a hazard or unsafe practice which can result in severe personal injury or death CAUTION Alerts you to a hazard or unsafe practice which can result in personal injury or equipment dam age Electricity fuel exhaust moving parts and batteries pres ent hazards which can result in severe personal injury or death GENERAL PRECAUTIONS e Keep ABC fire extinguishers handy e Make sure all fasteners are secure and torqued prop erly e Keep the genset and its compartment clean Excess oil and oily rags can catch fire Dirt and gear stowed in the compartment can restrict cooling air e Before working on the genset disconnect the nega tive battery cable at the battery to prevent starting e Use caution when making adjustments while the gen set is running hot moving or electrically live parts can cause severe personal injury or death e Used engine oil has been identifie
45. 6 35 a Check fuel pump and replace if defective Drain and refill fuel supply Let genset cool down Check for blockage air inlet or outlet or improper fuel system installation Replace fuel filter Clean passages or replace pilot jet Adjust carburetor main and idle adjustment screws Disassemble carburetor and clean all internal passages Check linkage alignment Make sure it does not touch other parts Clean and lubricate linkage Adjust speed and sensitivity settings Replace governor spring See Governor in Section 10 Engine Block Assembly Drain oil and refill with correct viscosity oil Clean crankcase breather and replace if defective Locate source of leak and repair as required See Section 10 Engine Block Assembl Do not run genset at no load for long periods of time Replace intake valve seal Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only qualified service personnel with knowledge of fuels electricity and machinery haz ards should perform service procedures Review safety precautions on page iii TABLE 6 19 TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Possible Cause Corrective Action Page Engine Shuts 1 Low oil level 1 Add oil as required Down and Will Not Restart 2 Low oil level switch is defective 2 Check low oil level switch Spec A F if applicable Also see 3 Worn spark plug 3 Clean or repla
46. 611 1255 611 1255 611 1255 611 1264 611 1264 611 1264 611 1265 611 1265 DESCRIPTION FIG NO Wiring Schematic MicroLite Spec A 60 Hertz 12 1 Wiring Diagram MicroLite Spec 60 Hertz 12 2 Wiring Schematic MicroLite Spec B through E 60 Hertz 12 3 Wiring Diagram MicroLite Spec B through E 60 Hertz 12 4 Wiring Schematic MicroLite Spec B through E 50 Hertz 12 5 Wiring Diagram MicroLite Spec B through E 50 Hertz 12 6 Voltage Reconnection MicroLite Spec B through E 50 Hertz 12 7 Wiring Schematic MicroLite Begin Spec F 50 Hertz 12 8 Wiring Diagram MicroLite Begin Spec F 50 Hertz 12 9 Voltage Reconnection MicroLite Begin Spec F 50 Hertz 12 10 Wiring Schematic MicroLite Begin Spec F 60 Hertz 12 11 Wiring Diagram MicroLite Begin Spec F 60 Hertz 12 12 Wiring Schematic MicroLite Begin Spec F 60 Hz 100 V 12 13 Wiring Diagram MicroLite Begin Spec F 60 Hz 100 V 12 14 Voltage Reconnection MicroLite Begin Spec F 60 Hz 100 V 12 15 Wiring Schematic MicroLite Begin Spec G 50 Hertz 12 16 Wiring Diagram MicroLite Begin Spec G 50 Hertz 12 17 Voltage Reconnection MicroLite Begin Spec G 50 Hz 100 V 12 18 Wiring Schematic MicroLite Begin Spec G 60 Hz 12 19 Wiring Diagram MicroLite Begin Spec G 60 Hz
47. 7 1 49 1 45 Top Compression Ring to Ring 0 0016 0 0032 0 0047 Groove Clearancce 0 04 0 08 0 12 Second Compression Ring to 0 0008 0 0012 0 0039 Ring Groove Clearance 0 02 0 06 0 10 Top Compression Ring End Gap 0 0120 0 0140 0 0197 0 305 0 356 0 50 Second Compression Ring End 0 0120 0 0140 0 0197 Gap 0 305 0 356 0 50 Oil Ring Side Rail Gap 0 0120 0 0140 0 0197 0 5 Intake Valve Valve Stem O D 0 2740 0 2746 6 960 6 975 Valve Guide 1 0 0 2756 0 2762 7 000 7 015 Valve Stem to Guide Clearance 0 0010 0 0022 0 0002 0 0035 0 025 0 055 0 005 0 09 Valve Stem to Rocker Arm 0 0008 0 0032 0 0008 0 0032 Clearance Valve Lash 0 02 0 08 0 02 0 08 Face Angle 45 N A 3 2 All clearances are at 70 F 21 C room temperature All measurements are listed in inches with millimeter measurements in parentheses Measurements are for standard size parts ALLOWABLE DESCRIPTION LIMIT Intake Valve Seat Seat Width Exhaust Valve Valve Stem O D 0 2732 0 2740 0 2732 6 940 6 960 6 940 Valve Guide 1 0 0 2756 0 2762 0 2748 0 2768 7 000 7 015 6 98 7 03 Valve Stem to Guide Clearance 0 0016 0 0030 0 0002 0 0035 0 04 0 075 0 005 0 090 Valve Stem to Rocker Arm 0 0008 Yes 0 0008 0 0032 Clearance Valve Lash 0 02 0 02 0 08 Exhaust Valve Seat Seat Width Seat Angle Valve Springs Free Length 1 8228 46 3 Distortion Square Ignition System Gasoline
48. 7 85 331 2989 4311185 3111185 331 89 9907 85 3INI 1 Z82 3NI 1 83 N3dO 9907 85 I 1dS 183 3111185 QVO 1 282 333 L LI 1dS 0907 85 331 I 1dS 331 2995 3111895 832 QVO 1 282 0907 85 3NI 1 282 3INI 1 83 0 1 285 4311185 0 01 185 331 2995 3111895 82 QVO 1 282 0 01 185 3NI 1 282 3NI 1 832 QND GNNOYD 21 01 282 NY IVS LO3N 1 9907 85 12 16 031 105 WYLNAN 1 WHYLNAN Q31V IOSI WYLNSN WYLNAN Q31V IOSI IWYLNAN OSONNOYD IVSL OSN AOOL OND OL A00Z GND OL 3MIM 4 00 000 00 AOOL ZH 09 0007 3110491 LAVH2 NOLLOS3NNOO2 38 FIGURE 12 15 VOLTAGE RECONNECTION DIAGRAM 9612 1255 MICROLITE FERRITE TRANSFORMER CHARGER ASSY BATTERY REGULATOR VOLTAGE COIL IGNITION SPLICE SPLITTER SWITCH LOW OIL LEVEL SWITCH START STOP SOL REGULATOR LP ONLY RELAY STARTER MAGNETO IGNITION GENERATOR FUSE 5 AMP FUEL SHUTOFF SOL GAS ONLY FUEL PUMP FUEL SOL LP SPARK PLUG BATTERY 12 V MOTOR STARTER REMOTE CONTROL STANDARD REMOTE CONTROL DELUXE CONTROL ASSY LOCAL ST
49. 9 10 5 5 11 5 12 and 5 3 The posi tive meter lead must be connected to the first terminal of each pair 3 Replace the voltage regulator if any reading in dicates a short or open except for pair 10 5 which should indicate an open NOTE Short is indicated by zero or a number very near zero Meters of different make indicate open differently read the meter instruction manual If in doubt compare with readings of a regulator of the same part number that is known to be good 4 f the regulator checks good there is a chance that the regulator could still be bad Verify that the connector pins are making good contact If voltage regulation problems contin ue replace the voltage regulator with a known good regulator and recheck operation BRUSHES AND SLIP RINGS This section covers brush replacement and slip ring service Brush Replacement Follow Generator Disassembly Base Removal procedures on Page 9 2 through fan hub assem bly removal Inspect the brushes and brush block for burn marks or other damage If the brushes ap pear to be in good condition use a piece of wire modified as shown in Figure 9 10 to check for ex cessive brush wear minimum brush length is 0 375 inches 9 5 mm Insert the painted end of the wire through the hole above each brush Make sure the wire is resting on the brush and not on the spring If the painted part of the wire is not visible the brush
50. ART INPUT P1 13 LOCAL RETURN P1 7 LOCAL STOP INPUT 1 1 REMOTE STOP INPUT J2 B REMOTE RETURN J2 A NOTE 1 THIS DRAWING ILLUSTRATES WIRING FOR 2 WIRE 220 240V OPERATION FOR ALL OTHER CONFIGURATIONS SEE SHEET 2 1 9 AVR FIELD FLASH 1 6 STARTER SOL OUTPUT REMOTE RUN OUTPUT J2 E P1 2 FUEL PUMP OUTPUT REMOTE START INPUT J2 C 1 5 BATTERY GND INPUT 1 IGN ENABLE OUTPUT P1 3 FUEL SHUTDOWN P1 10 BATTERY INPUT 2 E3 IS USED ONLY ON GASOLINE SETS K2 IS USED ONLY ON LP SETS 3 FERRITE AND SHIELD ARE USED ONLY ON 50 HZ SETS FOR CONNECTIONS SEE PAGE 2 FIGURE 12 16 WIRING SCHEMATIC 611 1264 MICROLITE BIGIN SPEC G 50 HERTZ 12 17 FOR CONNECTIONS SEE PAGE 2 ETSI SEE FIGURE 12 16 FOR DESCRIPTIONS FIGURE 12 17 WIRING DIAGRAM 611 1264 MICROLITE BEGIN SPEC G 50 HERTZ 12 18 s Wan i 1 SWVYDVIG NOILISNNOI34Y N A N CTV N CTV N721 N72 N b1 072 YO 022 AOZL G3S LON 3 11185 LV LV LISNNOD SNOILINYLSNI G3asn LON 4341185 lt LON 4341185 27 17 L23NNO2 vi23dS 0907 2985 N3dO 99071 85 3NI 1 282 4311185 4311185 3NI1 L82 0 01 285 N3dO 9907 85 3NI 1 Z82 163 N3dO 9907 85 31 1 5 3NI 1 83
51. CONNECTOR voltage regulator for field flashing and voltage build up Electrical shock can cause severe personal injury or death Use extreme caution when working on electrical circuitry Attach and remove meter leads only when genset is not op erating Do Not touch meter or meter leads dur ing tests The voltage regulator plug J4 remains connected to wire harness plug P4 for Test A and B The voltme ter leads should be secured so that they are not be ing held during testing Use long pointed test leads or paper clips connected with alligator clips to the test leads Refer to Figure 9 6 VOLTAGE REGULATOR VR1 ES2018s FIGURE 9 6 VOLTAGE REGULATOR CONNECTOR P1 Test A Connect a DC voltmeter into the back side of the voltage regulator connector J4 as follows At tach the positive meter lead to J4 pin 7 and the negative meter lead to J4 pin 3 Push the start switch and observe the voltmeter reading If approximately 12 VDC is measured field flash voltage is available proceed to Test B If no voltage is measured check for a poor connection at the P4 J4 connectors and at the P1 J1 connectors If connections check good refer to Section 6 Trou bleshooting for procedures Test B Move the positive meter lead to pin 9 and connect the negative meter lead to pin 10 otart the genset and allow engine speed to stabi lize Measure the field voltage with no load applied and then with full lo
52. E RECTIFIER CR1 9 l Jj Je Circuit Breaker CB1 30A START RELAY K1 CONTROL PANEL CONTROL 1899 35 ASSEMBLY 1 FIGURE 7 1 SPEC A CONTROL COMPONENT LOCATIONS 7 1 Start Solenoid K1 The start solenoid K1 is used for closing and open ing the circuit between the battery and the starter motor The start solenoid has heavy duty contacts that handle the high current draw of the starter dur Ing cranking Control Fuse F1 A 5 amp luse provides protection for the control wir Ing and remote wiring from a short circuit The con trol fuse is mounted on the front of the control panel Circuit Breaker CB1 The standard 30 amp circuit breaker protects the generator AC windings from a short circuit or over load The circuit breaker is located on the control panel If an overload occurs the breaker can be re set after all loads are removed from the genset Control Assembly A1 The control assembly consists of a printed circuit board with components and relays that are potted encapsulated in a nonconductive material to pro tect them from moisture The control assembly is mounted near the air inlet for cooling See Figure 7 1 on Page 7 1 and Figure 7 2 The control provides the following functions e Starter Solenoid Output e Fuel Pump Output e AVR Field Flash Output e Remote Running Output e Ignition Enable BATTERY CHARGER ASSEMBLY VR2
53. HL 40 ASN aarsnfrav NYO 39VETOA LAdLNO 31ON IL NOI 23NNOO234 17 Oce 1 11 21 11 271 11 21 11 N C1 11 21 11 AOSI 011 Gasn LON 53111185 LV NOILONAr LV Gasn LON 43111145 ree 1 11 LOANNOO 1 17 LOANNOO 1912395 5 LON 31 185 0 01 2 2 0 01 189 3NI 1 c82 8 8 1 189 QVO 1 c82 N3dO QVO 1 189 3NI l c82 1 189 N3dO 9 0 01 189 43111735 1 189 43111735 039 QVO 1 c82 d3L1I ldS QVO 1 182 43111745 ANT 1 c99 43111 7 5 ANT1 199 QVO 1 c829 0 01 189 ANTI 1 c99 1 189 QVO 1 c82 43111735 0 01 189 ANT 1 89 43111745 d3L1I ldS ANT1 199 QNNOY9 QVO 1 c82 0 01 189 ANT 1 89 1 189 9049 c1 0 01 299 N 0 01 189 SNT1 V1L SNT1 1 3NI cCL 11 50 2 12 8 Q31V OSI GSONNOYS 1 T3103N GSALVIOSI WaYLNSN GSONNOYS TV3103N GALVIOSI WaLNAN WaYLNAN AOII2QN9 OL AOZZ QN9 OL ANTI dO Occ AYIM AOc 40 011 AYIM c AOVc Ocl 40 0 011 3adIM
54. IRCUIT BREAKER AC OUTPUT TRANSF ORMER CHARGER ASSY BATTERY REGULATOR VOLTAGE COIL IGNITION SPLICE SPLITTER SWITCH LOW OIL LEVEL SWITCH START STOP POTENTIOMETER SOL REGULATOR LP RELAY STARTER MAGNETO IGNITION GENERATOR FUSE 5 AMP FUEL SHUTOFF SOLENOID FUEL PUMP FUEL SOLENOID LP SPARK PLU CIRCUIT BREAKER AC OUTPUT BATTERY 12 MOTOR STARTER REMOTE CONTROL STANDARD REMOTE CONTROL DELUXE CONTROL ASSY NOTE IS USED ONLY ON GASOLINE SETS K2 IS USED ONLY ON LP SETS 220 240 FIGURE 12 5 WIRING SCHEMATIC 611 1226 MICROLITE SPEC B THROUGH 50 HERTZ 12 6 220 240V Jn I P4 9 VR2 AC ame san _ 4 11 n TS LINE CBI LINE 63 TI LINE SPLITTER TI H2 TRANSFORMER P6 G2 2 P6 5 ES JI 3 e CBI LINE GASOLINE ONLY TI IGN ZN m el IO P4 4 R5 w 2 41 12 A FI P6 2 2 l KI BAT AC r a KI BAT 5 START STOP P5 VR2 CBI LINE D 7 i i LOAD L o te CB I LOAD JI 1 JI 7 CB2 LINE CB NOT USED lt i SEE SHEET 2 LOD 1 e VRI PCB J6 WIRING DIAGRAM SEE FIGURE 12 5 FOR DESCRIPTIONS FIGURE 12 6 WIRING DIAGRAM 612 1226 MICROLITE SPEC B THROUGH 50 HERTZ 12 7 dO ASVAYONI INOIWIXVIN V Ad SDVLIOA AHL 3SV3uUONI TIIM NOILLV LOH ASIMMOOTO I3NVd IOHLNOO AHL JO LNO amp H AHL NO LOd 1 A
55. If a problem with the Control Assembly is suspected use the control circuit board tester if available or check the control outputs with a voltmeter Figure 7 5 on Page 7 7 shows the Control Assembly and the P1 J1 connectors Voltages can be checked using meter with long test prods 7 6 Electrical shock can cause severe personal injury or death Do not touch the volt meter or any wiring when the genset is operat ing Attach and remove meter leads only when the genset is stopped Tables 7 1 and 7 2 on Page 7 7 list the control out puts at the P1 J1 connector plug for each control mode Measure control output voltages between the connector pin listed and ground Refer to the correct chart for Spec A and for Spec B models Battery B voltage must be present at the Control Assembly J1 10 P1 10 at all times If battery volt age is present at the J1 10 P1 10 connector and the control outputs are not present check the J1 P1 connector and the Start Stop switch 1 If the con nector and switch check good replace the Control Assembly with a new Control Assembly and re check genset operation a POSTS START RELAY K1 FIGURE 7 4 SOLENOID CHECK TABLE 7 1 SPEC A CONTROL OUTPUTS CONTROL OUTPUT CONTROL MODE CONNECTOR PIN CRANK RUN STOP STARTER SOLENOID gt 9VDC OVDC J1 8 P1 8 J1 12 P1 12 J1 5 P1 5 REMOTE RUN gt 9vpC J2 5 J2 6 TABLE 7 2 BEGIN SPEC B C
56. M6 7 8 10 11 M8 17 20 24 27 4 2 5 Preparing for Service TROUBLESHOOTING Refer to Section 6 Troubleshooting and work through the appropriate subsections before starting work on the genset It has the following subsec tions e Control System e Generator e Primary Systems The subsections list typical problems along with possible causes and corrective actions Note that some problems might have several possible causes It may be necessary to investigate several possible causes in order to isolate the actual source of the problem SPECIAL TOOLS The following special tools are required to service the genset See the Onan Tool Catalog Engine Tools Torque wrench 0 75 Ibs ft or 0 100 N m Feeler gauge Leak Down Tester Spark plug gap gauge Cylinder compression tester Flywheel puller Snap ring pliers Cylinder ridge reamer Piston ring compressor Piston ring spreader Cylinder hone Valve seat cutter Valve spring compressor Piston groove cleaner Outside micrometer set 0 to 4 in Telescoping gauge set 1 2 in to 6 in Hole gauge 0 300 in to 0 400 in Plasti Gage bearing clearance guide Generator Tools Lead or dead blow hammer Steel rod 45 inch dia x 7 875 inch long 5 1 Battery hydrometer VOM multi tester Frequency meter Armature growler Load test panel Jumper wires SAFETY CONSIDERATIONS Always consider the safety aspects of any service procedure Servicing gensets pres
57. N 1400 73rd Ave NE Minneapolis MN 55432 4KYFA26100E SA A953123456 Model No Made in U S A AC Volts Amps Fuel INI 3461 URC Insulation NEMA Class Ambient 40 C REFER TO OPERATOR S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS THIS ENGINE MEETS 1995 1998 CALIFORNIA EMISSIONS REGULATIONS FOR ULGE ENGINES EM SN5304U1G2RA 304 cc FIGURE 1 1 TYPICAL NAMEPLATE Model Number Identification Serial Number Identification Figure 1 2 shows a breakdown of the model num Figure 1 3 shows a breakdown of the serial number ber for a typical genset for a typical genset MODEL 4 KY FA 26100 1 2 394 5 6 Power capacity in kilowatts 4000 watts Product family designation Starting method Remote startable Voltage and frequency code 120 volt 60 Hz Specification number Code for options and special features Specification letter Used to identify major design or manufacturing changes FIGURE 1 2 MODEL NUMBER IDENTIFICATION 1 2 SERIAL D 95 3 123456 1 2 3 Month genset was built A January B February etc Year genset was built 94 1994 95 1995 etc Location where genset was bullt 0 Fridley Minnesota 3 Huntsville Alabama 4 Active serial number FIGURE 1 3 SERIAL NUMBER IDENTIFICATION 2 Specifications GASOLINE MODELS LPG MODELS 4 0 KY 3 6 KY 3 6 KY 3 3 KY Power 4000 watts 3600 watts 3600 watts 3300 watts 60 He
58. NG GAP 10 14 Piston Ring Thickness 1 Measure the piston ring thickness with an out side micrometer see Figure 10 28 2 If the thickness is less than the allowable limit replace the ring Piston Assembly Install the rings on the piston beginning with the oil control ring Use a piston ring spreader to prevent twisting or excessive expansion of the ring Com pression rings are marked with the word top or a mark on one side of the ring to indicate which side faces the top of the piston Oil ring rails may be installed either way Stagger ring gaps 120 degrees apart Do not position ring gaps on thrust face of cyl inder Clearance between Piston Pin and Connecting Rod Small End Bore 1 Measure the piston pin O D and connecting rod small end bore with a micrometer Figure 10 29 Then calculate the difference 2 If the clearance exceeds the allowable limits replace them 10 15 11 011 FIGURE 10 28 RING THICKNESS SA11F013 SA11F021 FIGURE 10 29 PISTON PIN AND CONNECTING ROD CLEARANCE Clearance between Crank Pin and Connecting Rod Big End Bore 1 Measure the crank pin O D and the connecting rod big end bore with a micrometer and calcu late the difference Figure 10 30 2 If the clearance exceeds the allowable limits replace them Side Clearance of Connecting Rod on Crank Pin 1 Assemble the connecting rod to the crank pin PIGUBES0 SISSIPESUEABANCEGE 2 Measure the side clearance
59. ON SIDE METAL BARRIER REQUIRED PANELS IF INSTALLED BELOW A WOODEN FLOOR FUEL LINE CONNEC TION AC CONDUIT CONNEC TION AAA MOUNTING HOLES SPEC A 4 BEGIN SPEC B 6 CONNECTION DOOR FLOOR BOTTOM RAIL BATTERY POSITIVE AND REMOTE CONTROL HARNESS OPENING BATTERY NEGATIVE CONNECTION M2001s FIGURE 5 2 TYPICAL UNDER FLOOR MOUNT INSTALLATION BEGIN SPEC B SHOWN 5 3 Disconnecting Set from Vehicle Systems Disconnect the following items from the genset Re fer to Figures 5 1 and 5 2 on Page 5 3 for compo nent locations in typical genset 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 Sparks and high current could cause fire and other damage to the battery battery cables and vehicle if the loose ends of cables connected to the battery touch Always disconnect the negative battery cable from the battery before disconnect ing the battery cables from the genset Remove the genset negative battery cable at the battery terminal Disconnect the genset positive battery cable from the B connection on the genset Disconnect the remote control wire connector fro
60. ON AND CRANKSHAFT The piston assembly consists of the piston piston pin and connecting rod assembly After piston re moval all parts must be carefully inspected for damage and wear before reinstalling Remove the carbon from the top of the cylinder bore and check for a ridge Remove ridge with a ridge reamer see Figure 10 17 before attempting piston removal Remove the piston as follows Improper use of a ridge reamer can damage the cylinder bore Follow tool manufac turer s instructions and be careful when using a ridge reamer CAMSHAFT TAPPETS 1133 15 FIGURE 10 15 CAMSHAFT AND TAPPETS 10 9 CRANK GEAR CAM GEAR BALANCER GEAR FIGURE 10 16 CAM CRANK AND BALANCER GEAR ALIGNMENT RIDGE REAMER 1090 15 FIGURE 10 17 REMOVING WEAR RIDGE 1 Remove the two bolts from the connecting rod cap Mark direction of assembly for connecting the rod cap and splasher 2 Remove the rod cap from the rod and push the piston assembly out the top of the cylinder Fig ure 10 18 Be careful not to scratch the crank pin or the cylinder wall when removing the pis ton 3 Carefully pull the crankshaft out of the oil seal and bearing INSPECTION OF ENGINE PARTS The following section describes procedures for in specting each of the major engine components Cylinder Head 1 Clean the cylinder head surface 2 Place a straight edge on the top of the cylinder head as shown in Figure 10 19 Use a
61. ONTROL OUTPUTS CONTROL OUTPUT NN J1 6 P1 6 J1 3 P1 3 J1 9 P1 9 REMOTE RUN 0 VDC 29 VDC 0 VDC desea 00 962 eee CONTROL ASSEMBLY A1 SPEC A P1 CONNECTOR CONTROL ASSEMBLY A1 BEGIN SPEC B J1 CONNECTOR FIGURE 7 5 CONTROL ASSEMBLY A1 CHECK 7 7 Resistor R1 Spec A Only The battery charge resistor can be checked with an ohmmeter Disconnect the leads from the resistor and measure the resistance between terminals on one end to the resistor and the terminals on the oth er end The resistor should measure between 4 and 6 ohms If an abnormal reading is measured re place the resistor Diode Bridge CR1 The diode bridge consists of four diodes connected in a bridge circuit Figure 7 6 The diode bridge can be checked with a diode checker Remove all of the leads from the diode bridge and check each diode individually Continuity should be indicated in the forward bias direction and an open circuit should be Indicated in the reverse bias direction refer to your meter instruction manual If any of the diodes check bad replace the diode bridge AC _ BRIDGE RECTIFIER SCHEMATIC ES2015s SPEC A BRIDGE RECTIFIER CR1 FIGURE 7 6 DIODE BRIDGE CR1 CHECK 7 8 Battery Charger Assembly VR2 Begin Spec B 50 Hz Only The battery charger is located on the left side of the genset housing The battery charger can be checked with a voltmeter A voltage measurement between the
62. R SPARK PLUG E1 J1 CONNECTOR Mns IGNITIONG2 COIL T1 1 Ly 52017 15 FIGURE 6 4 SPEC A START IGNITION MODE 6 6 Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only qualified service personnel with knowledge of fuels electricity and machinery haz ards should perform service procedures Review safety precautions on page iii TABLE 6 2 SPEC A CONTROL TROUBLESHOOTING IGNITION MODE Possible Cause Corrective Action Page Engine Cranks 1 Restricted fuel supply due to 1a Add fuel if tank is low But Does Not a Fuel level below pickup tube in tank 16 Open fuel supply valve if equipped Start b Fuel line supply valve closed 1c Replace clogged fuel filter and check c Fuel filter clogged Faulty ignition due to worn or fouled spark plug faulty plug wire faulty ignition coil or magneto Sticking choke or carburetor mixture screws incorrectly adjusted Fuel pump E2 not working due to a Fuel pump defective b Open circuit between fuel pump and control assembly A1 or control assembly is defective Faulty fuel solenoid priming solenoid or regulator on LPG models Governor linkage stuck or binding Oil level switch 2 closed due to a Low oil level b Defective low oil level switch fuel supply for contamination Refer to gnition System for test and service procedures Refer t
63. RMER T1 SCHEMATIC FIGURE 7 8 TRANSFORMER T1 8 Primary Engine Systems INTRODUCTION This section describes the engine primary systems service procedures Many of the primary systems can be serviced without removing the genset from the vehicle Poor engine performance is often caused by a dirty carburetor Make certain that the carburetor is clean before troubleshooting for per formance problems Primary engine systems include Cooling system e Exhaust system e Ignition system e Crankcase ventilation system e Governor e Fuel system e Electric starter COOLING SYSTEM The genset requires a constant airflow to cool the engine and generator during operation A centrifu gal fan on the generator end of the genset provides the required airflow The fan draws cooling air through the air inlet into the generator and forces it across the engine cooling fins The air is discharged through the air outlet See Figure 8 1 Cooling air can contain poisonous exhaust gases that can result in severe person al injury or death Never use discharged cooling air to heat the vehicle interior The air inlet is sized to allow the required flow rate of cooling air The air inlet opening and the air dis charge opening must be kept free of any obstruc tions to avoid restricting airflow Dirt dust or other debris that clog the air openings should be removed during periodic maintenance Dirt might also be come lodged between the
64. Remove the scroll housing from the endbell rotor shaft and save for reassembly Remove fan hub assembly with a wheel puller Figure Begin Spec B Instructions 9 3 Attach the wheel puller to the fan hub as sembly with three 5 16 inch thread tapping cap screws or tap fan hub with 3 8 inch tap and use 3 8 inch cap screw 4 Remove the exhaust manifold to engine mounting nuts Remove the muffler to base mounting screws and slide the muffler to the right so the exhaust manifold pipe clears the engine 5 Remove the engine and generator to base mounting bolts 4 Apply antiseize lubricant to the treads of these bolts before reinstallation 6 Disconnect the J4 and P1 harness connectors PULLER at the air housing assembly Remove the leads from the start solenoid Remove the control as sembly A1 mounting bracket with the voltage regulator control assembly and start solenoid attached Disconnect the remaining harness connections to the fuel pump ground terminal and load connections 7 Carefully lift the generator end of the genset and place a wooden block under the stator housing to support the genset NOTE For access to the air preheat door re M1904s move the air housing assembly cover at this point FIGURE 9 3 PULLING THE FAN HUB ASSEMBLY 9 5 11 12 13 14 Prepare the brushes for endbell removal Carefully disconnect the wire harness leads from the brush block and pull each brush out ward from the ho
65. Severe personal injury or death can result if it is ignited Eliminate all possible sources of igni tion including fire flame spark pilot light ciga rettes arc producing equipment electrical switch or other ignition sources before per forming this procedure Removal and Disassembly Remove the carbure tor and intake manifold assembly as specified in the Carburetor and Intake Manifold Assembly on Page 8 12 Remove the carburetor from the intake man ifold Carburetor parts are fragile and they must be handled with care Never force a part when disas sembling or assembling Disassemble the carbure tor as follows 1 Remove the main and idle mixture screws 2 Separate the lower section of the carburetor Remove the float chamber and gasket by re moving the chamber set plug OnaFresh is a trademark of Onan Corporation 8 15 3 Slide the float pin out of the float passage Re move the float and float valve NOTE The throttle plate screws are secured with epoxy Do not remove the choke or throttle plates shafts arms or governor link bushing unless they are defective THROTTLE STOP SCREW IDLE MIXTURE ADJUSTMENT FLOAT CHAMBER MAIN ADJUSTMENT SCREW WASHER CHAMBER SET PLUG SPEC A LIMITER MODELS CAP FUEL SHUTOFF SOLENOID E3 BEGIN SPEC B MODELS FS1807 1s FIGURE 8 12 CARBURETOR OVERHAUL PRIOR TO SPEC D Cleaning and Repair Procedure 1 Soak all metal componen
66. Spark Plug Gap 0 025 0 031 0 043 0 63 0 8 1 1 Ignition Timing BTDC Not Adjustable 3 3 3 4 4 Torque Specifications Mounting screws and nuts must be tightened to the specified torque settings listed in the following tables All threads must be clean and lubricated with new engine oil before tightening The cylinder head mounting bolts must be tightened in the proper sequence refer to Section 10 Engine Block Assembly When tightening torques are not specified tighten the screws and nuts according to Tables 4 3 and 4 4 on Page 4 2 The grade numbers are indicated on top of the screw or bolt head TABLE 4 1 ENGINE TORQUE SPECIFICATIONS POUND FEET NEWTON METERS Air Deflector Bolts 8 15 11 22 Connecting Rod Bolts 18 20 24 27 Cylinder Head Bolts Cold 2 thru 5 Cylinder Air Housing Bolts M8 X 10 M8 X 16 Gearcase Cover Governor Lever Bolt Intake Elbow Screws Muffler to Engine Spec A Muffler to Eng Begin Spec B Muffler to Base Begin Spec B Oil Base Bolts Oil Drain Screw Rocker Arm Adjustment Nut Spark Plug Valve Cover 4 1 TABLE 4 2 GENERATOR TORQUE SPECIFICATIONS Tem POUND FEET NEWTON METERS Rotor Through Bolt 40 50 54 68 Stator Through bolt 5 8 7 11 Endbell to Stator Housing Mount Assy Bolt Spec A Mount Assy Bolt Begin Spec B Stator Housing to Engine Block TABLE 4 4 METRIC BOLT TORQUE SPECIFICATIONS 10 9 GRADE POUND FEET NEWTON METERS
67. Switch 22 2 10 2 Head GOVOl s eric ERE M RE s 10 2 Rocker Arms Push Rods and Cylinder Head 10 3 valve dead 10 4 Grankcase COVEN us xi o ex aic PR td e dit B as 10 8 RON CIN OM ane tat en epee etiam ane Ed et ee te Geant Dept ta 10 8 Camshaft Tappet and Balancer Removal 10 9 Piston and 10 9 Inspection of Engine Parts 10 10 Piston and Crankshaft Installation 10 17 uci do paradero add we a quc eno d BA o hti aon are 10 19 ss 10 19 Compression Release System 10 20 11 SERVICE CHECKLIST x abr DDR p acide te 11 1 GENEL tied perio ue duties eati oA ee Cur MM ce 11 1 MOUNINO SO S uec SU ee 11 1 bd deine pu deese tii ua iuo d piss d bd de uiis s 11 1 AY AVAL NEED ERA M 11 1 Initial Start Adjustments eo yes PLI s 11 1 Exhaust SYSTEM uode aeo devi E A P Eg 11 2 Fuel SVSION 222 ud Ue eto baia ain obere race dudo bead 11 2 OtutDUr GNECK 11 2 Seni EI epe
68. TY TABLE 9 2 STATOR OPEN OR SHORTED WINDING TEST Open Or Shorted Stator Windings Test OHMMETER READING To test for open windings set the ohmmeter for the AGE Keer tae highest resistance scale and then connect the test TEST POINT prods see Figure 9 9 to the terminals specified in Table 9 2 The ohmmeter should indicate continuity T1 to T2 between terminals A high resistance reading indi T3 to T4 cates an open winding If an open circuit is mea 1 to B2 Q1 to Q2 sured replace the stator To test for shorted windings use a digital type ohm Spec A 60 Hz Only meter that reads to within 0 001 ohms Connect the STATOR AC COIL BATTERY CHARGE GROUP 2 GROUP STATOR CONNECTOR ES2019s TI TS BI GI T2 14 G2 B2 WINDING DIAGRAM FIGURE 9 9 STATOR ASSEMBLY 9 11 VOLTAGE REGULATOR VR1 TEST Confirm that the voltage regulator is faulty before replacing it Use a meter with a diode checking func tion Fluke model 73 or equivalent multimeter to perform the following tests 1 Disengage the J4 wiring connector and remove the voltage regulator Figure 9 6 on Page 9 8 2 With the meter set on Diode Check test be tween connector terminal pairs 5 9 7 9 10 9 11 9 12
69. ULATOR VOLTAGE TI IG COIL IGNITION 2 SWITCH LOW OIL LEVEL 2 5 51 SWITCH START STOP K2 SOL REGULATOR LP RELAY STARTER MAGNE TO IGNITION GENERATOR FUSE FUEL SHUTOFF SOLENOID FUEL PUMP FUEL SOLENOID LP SPARK PLUG CIRCUIT BREAKER AC OUTPUT BATTERY 12 MOTOR STARTER REMOTE CONTROL STANDARD REMOTE CONTROL DELUXE CONTROL ASSY J2 6 lt REMOTE START INPUT REMOTE STOP INPUT 9 REMOTE RUN OUTPUT IS USED ONLY ON GASOLINE SETS IS USED ONLY ON LP SETS y Pics AVR FIELD FLASH Tr S MN CBI LOAD LI 20 NEUTRAL 12 GND SCHEMATIC WIRING SCHEMATIC 611 1225 MICROLITE SPEC B THROUGH 60 HERTZ 12 4 9 LP ONLY CB I LOAD P4 11 62 2 TI IGN ES 2e GASOLINE ONLY FI 2 l KI BAT s S2 i JI 4 e O LOAD L CBI LOAD PCB J6 PCB J8 VRI WIRING DIAGRAM SEE FIGURE 12 3 FOR DESRIPTIONS FIGURE 12 4 WIRING DIAGRAM 612 1225 MICROLITE SPEC B THROUGH 60 HERTZ 12 5 gt 2 L J2 6 ss O 3 p B 8 5 P P 8 Al Liga JE i zo amp 5 So LI CB2 SCHEMATIC 2 WIRE 220 240V GROUNDED NEUTRAL THIS DRAWING ILLUSTRATES WIRING FOR 2 WIRE 220 240V OPERATION FOR ALL OTHER CONFIGURATIONS SEE FIGURE 12 7 C
70. UMP E2 FUEL SHUTOFF SOLENOID ON LPG MODELS yw gt s REMOTE CONTROL START RELAY K1 CONNECTOR CONTROL ASSEMBLY A1 ES2017s FIGURE 6 2 COMPONENT LOCATIONS GASOLINE FUELED MODELS BEGINNING WITH SPEC B Spec A Start Cranking Mode Battery positive B is supplied to the control assembly A1 through control fuse F1 Holding the Start Stop switch S1 in the Start position activates control assembly A1 by closing the start signal input circuit While the Start Stop switch is held the control assembly supplies the following outputs e Battery positive B is supplied to the start relay coil K1 This energizes the start relay The start relay con tacts close supplying battery positive B to the starter motor B1 The starter begins to crank the engine to initiate starting BATTERY BT1 m FUSE F1 START STOP SWITCH 1 START A START RELAY K1 ED D EN STARTER MOTOR B1 Lo CONTROL ASSEMBLY 1 P1 CONNECTOR FIGURE 6 3 SPEC A START CRANKING MODE 6 4 Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only qualified service personnel with knowledge of fuels electricity and machinery haz ards should perform service procedures Review safety precautions on page iii Not Crank TABLE 6 1 SPEC A CONTROL TROUBLESHOOTING CRANKING MODE Page Engine Does 1 Open control fuse F1
71. UTPUT J2 E 1 5 BATTERY GND INPUT REMOTE START INPUT J2 C CB1 CB1 LOAD L 120 NEUTRAL L2 GND FIGURE 12 19 WIRING SCHEMATIC 611 1265 MICROLITE BEGIN SPEC G 60 e zi fr J 12 20 O T1 IGN E3 50 ONLY P4 9 Jt 3 143 5 9101 5862 120V AC Fi FIGURE 12 20 WIRING DIAGRAM 611 1265 MICROLITE BEGIN SPEC G 60 SEE FIGURE 12 19 FOR DESCRIPTIONS 12 21 12 22 Onon Cummins Power Generation 1400 73rd Avenue N E Minneapolis MN 55432 763 574 5000 Fax 763 528 7229 Cummins and Onan are registered trademarks of Cummins Inc
72. Working in damp conditions Jewelry touching electrical components e Rotating Machinery Jewelry or loose clothing catching in moving parts e Slippery Surfaces Leaking or spilled oil e Heavy Objects Removing genset from vehicle Removing heavy components In a compartment mount installation a special compartment is built into the coach to house the genset Figure 5 1 on Page 5 3 The compart ment is constructed with a vapor tight barrier that seals off the genset from the coach interior The genset is usually mounted to the floor of the compartment Access to the compartment is through a door located in the exterior of the coach The under floor mount installation uses special brackets to suspend the genset under the floor of the coach The mounting brackets bolt to support members that are built into the vehicle framework Figure 5 2 The genset is mounted near the exteri or of the vehicle Access is provided through a door located in the exterior of the coach Due to the wide variety of coach designs it is not possible to specify the exact removal procedures for each type of installation If after examining the following sections a satisfactory method for remov ing the set cannot be determined contact the coach manufacturer or set installer to obtain their recom mendations before attempting set removai MOUNTING BATTERY POSITIVE AND REMOTE CONTROL HARNESS OPENING FUEL LINE CONNECTION AC CONDUIT CONNECTI
73. ad applied If both readings fall within a range of 40 VDC no load to 100 VDC full load voltage build up is OK and the brushes rotor and stator are working properly If no voltage is measured when the start switch is pushed proceed to the Voltage Regulator VR1 Test on Page 9 12 If 7 to 13 VDC is measured when the start switch is pushed and the genset stops running when the switch is released proceed to Test C Test C Disconnect the voltage regulator connector plug J4 from the harness connector P4 Attach an AC voltmeter to the generator output leads L1 and L2 Apply 12 VDC to the P4 connector at pins 9 positive and 10 negative Start the genset and observe the voltmeter reading If approximately 40 VAC is measured the generator brushes rotor and stator are working properly pro ceed to the Voltage Regulator VR1 Test on Page 9 12 If no voltage is measured proceed to Brushes and Slip Rings on Page 9 12 Rotor Test The rotor can be tested for grounded open or shorted windings using an ohmmeter Figure 9 7 and Figure 9 8 on Page 9 10 show the rotor re moved from the genset for testing The rotor can be tested without removing it from the generator To gain access to the slip rings follow the Generator Disassembly Base Hemoval procedures on Page 9 2 through the fan hub assembly removal proce dure Use a stiff wire to hold the brushes off the slip rings during testing Refer to the Brushes and Sl
74. age minus 10 volts zener diode is defective Replace remote Start Stop switch S2 Check remote running output voltage approximately 12 VDC during run condition from control assembly J2 5 to ground and from J2 6 to ground If voltage is not present replace control assembly A1 If voltage is present check continuity of remote control wiring Turn off the genset disconnect the remote control and check for shorts or too many remote accessories Spec A Battery Charge Mode With the genset running AC voltage is produced in the B1 B2 windings for the battery charge circuit e The AC output voltage from the B1 B2 winding is converted to DC voltage when it passes through the full wave rectifier bridge CR1 The voltage is then supplied through battery charge resistor R1 The 12 volt DC output one ampere maximum Is used to power the control assembly A1 fuel pump E2 the remote control and to prevent discharge of the genset starting battery during genset operation This output is not sufficient to charge a low or dead battery STATOR 2 BATTERY BT1 BRIDGE RECTIFIER CR1 FUSE F1 Dem 1 BATTERY CHARGE REMOTE CONTROL RESISTOR R1 START STOP SWITCH 81 777 FUEL PUMP E2 71 52017 45 FIGURE 6 7 SPEC BATTERY CHARGE MODE 6 12 Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only qualified service person
75. air filter LPG models 2 Mechanical engine defect exhaust valve defect 3 Faulty ignition due to Incorrect spark plug gap 1 Dirty air filter 2 Restricted fuel flow due to a Plugged fuel filter or b Faulty fuel pump c LPG regulator or fuel solenoid dirty or defective 3 Exhaust system blocked or restricted 4 Carburetor air preheater set incorrectly 5 No load speed set too low 6 Incorrect fuel mixture due to a Incorrectly adjusted fuel mixture screws b Dirt or varnish in carburetor 7 Incorrect valve lifter clearance or defective valve 8 Excessive engine wear 6 33 Check choke assembly Test fuel pump and replace if faulty Adjust carburetor main and idle Adjust carburetor main and idle mixture screws Replace air filter Perform Leak Down Test Reset spark plug gap Replace air filter Replace fuel filter Refer to LPG Fuel System section 8 Locate and remove blockage clean spark arrester screen Check automatic preheater setting Adjust governor setting adjustment screws Disassemble carburetor and clean all internal passages Adjust valve clearance if problem continues inspect valves Perform Leak Down Test Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only qualified service personnel with knowledge of fuels electricity and machinery haz ards should perform service procedures R
76. al and mechanical service Unauthorized modifications or re placement of fuel exhaust air intake or speed control system components that affect engine emissions are prohibited by law in the State of California LPG liquified petroleum gas is flammable and explosive and can cause as phyxiation NFPA 58 Section 1 6 requires all persons handling LPG to be trained in proper handling and operating procedures See the Operator s Manual for instructions con cerning operation maintenance and storage and for recommendations concerning engine lubricat ing oil and fuel See the Installation Manual for important recom mendations concerning the installation and for a list of the installation codes and standards for safety which may be applicable oee the Parts Manual for parts identification num bers and required quantities and for exploded views of the genset subassemblies Genuine Onan re placement parts are recommended for best results When contacting Onan for parts service or product information be ready to provide the model number and the serial number both of which appear on the genset nameplate Figure 1 1 Each character of these numbers is significant Figures 1 2 and 1 3 on Page 1 2 MicroLite is a trademark of the Onan Corporation 1 1 NAMEPLATE WITH TYPICAL MODEL AND SERIAL NUMBER DATA IMPORTANT ENGINE INFORMATION Onon ONAN CORPORATIO
77. ar drives the ring gear causing the gen set to crank Starter Voltage Check Before removing the starter for service perform the following starter check to make sure the starter is getting voltage from the control circuit 1 Connect a voltmeter between the output termi nal on the start relay opposite the BAT terminal with the starter motor lead connected and ground See Figure 8 23 2 Press the start switch and observe the meter reading If approximately 12 VDC is measured and the starter does not crank the starter is de fective Proceed to the starter disassembly 8 26 section If low no voltage is measured check the starting battery start solenoid and control wiring START RELAY ES2016 FIGURE 8 23 STARTER VOLTAGE CHECK Starter Disassembly The genset must be removed from the vehicle be fore the starter can be serviced See Section 5 Pre paring for Service 1 Disconnect the genset starting battery cables Disconnect the negative cable first to re duce the risk of arcing 2 Remove the genset outer housing Disconnect the positive cable from the starter lug termi nal 3 Remove the rear mounting nut from the starter ROLL PIN SPRING RETAINER SUPPORT PLASTIC RETAINER WITH A VISE OR OTHER SOLID SURFACE USE CARE NOT TO HAVE SPRING RETURN LEG BETWEEN THE PLASTIC RETAINER amp SUPPORT WHEN DRIVING OUT ROLL PIN Remove the engine bracket behind the starter from th
78. ats atoms s eade Gace cee dae ees 8 1 SYSTEM u nit s lir a oa ds 8 1 Exhaust System dere 8 2 IGNITION SSVSLOTTI ao tan bodie Ge Ep dre a 8 6 Crankcase Ventilation System 8 8 OW ean 8 9 Gasoline Fuel i voee nc Rem m A Wan dedi at 8 11 LPG Fuel System bees E Qum EE eee E ER 8 21 amsa setting ea 8 25 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 9 GENERATOR 9 1 Generator 9 1 Generator Operation 9 2 Generator Service 9 2 Generator TESNO 9 8 Voltage Regulator VR1 Test 9 12 Brushes and Slip Rings 9 12 Rotor Bearing Replacement 9 13 10 ENGINE BLOCK ASSEMBLY 10 1 p E CERE 10 1 beak DOWN TEST scot batte desee abii 10 1 Oil Pan and Oil Level
79. ature winding Q1 Q2 and in the AC windings T1 T2 T3 T4 50 HZ These outputs perform as follows e The battery charge winding B1 B2 is provided on the 50 Hz models only to power battery charger VR2 e The quadrature winding Q1 Q2 output voltage is fed to the voltage regulator VR1 where it is rectified into DC voltage and fed back to the rotor through the brushes to cause further voltage buildup Voltage buildup is con trolled by the voltage regulator that senses the AC output voltage The regulator continually measures the output voltage 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 voltage is obtained e The AC windings T1 T2 provide the output AC voltage 60 Hz models or T1 T2 T3 T4 50 Hz models through the circuit breaker CB1 START STOP SWITCH 61 BATTERY BT1 CONTROL ASSEMBLY A1 J1 CONNECTOR P1 CONNECTOR VOLTAGE REGULATOR VR1 STATOR CONNECTORS P4 CONNECTOR OS lt ni es s SSH RG WT Sy ca e 120 VAC 52017 65 FIGURE 6 16 SPEC GENERATOR OUTPUT MODE 60 HERTZ MODEL SHOWN 6 30 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 page iii
80. ays wear safety glasses with side shields when removing springs to prevent severe eye damage Inspection Valve Face Check the valve face for evidence of burning warping out of round and carbon depos its see Figure 10 8 on Page 10 5 Burning and pitting are caused by the valve failing to seat tightly This condition is often caused by hard 10 4 carbon 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 seat is pounded by a valve whose head is not in line with the stem and guide If a valve face is burned or warped or the stem worn install a new one 9 16 INCH CROWS VT1038 1s FIGURE 19 7 VALVE REMOVAL Too much clearance in the intake guide admits air and oil into the combustion chamber affecting car buretion 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 temper ature which causes warping and burning Unburned carbon residue gums valve stems and causes them to stick in the guide Deposits of hard carbon can form sharp points that become hot and cause pre ignition and pinging Stems and Guides Always check the stems and guides for wear as shown in Figure 10 8 Use a mi crometer to measure the valve stem diameter in at
81. battery A low battery should be charged up with a battery charger Spec A Stop Mode Momentarily pushing the Start Stop switch S1 to the Stop position begins the stop mode with the following results Control assembly de energizes the ignition enable circuit grounding the magneto G2 ignition circuit to stop the engine Control assembly A1 also opens the circuit to the fuel pump E2 and to the remote control e Control assembly A1 start disconnect senses a drop in voltage from the battery charge winding B1 B2 and activates the remote stop latch to prevent restart during the stop mode B2 STATOR 1 B1 5 i Lars START STOP SWITCH 51 STOP L Ac CONTRU ASSEMBLY A1 NN P1 CONNECTOR J1 CONNECTOR MAGNETO IGNITION G2 IGNITION se 5 S SPARK PLUG E1 FIGURE 6 8 SPEC A STOP MODE 6 14 Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only qualified service personnel with knowledge of fuels electricity and machinery haz ards should perform service procedures Review safety precautions on page iii TABLE 6 6 SPEC A CONTROL TROUBLESHOOTING STOP MODE Possible Cause Corrective Action Page Genset 1 set can be stopped from set control 1a Check wiring continuity between Does Not Stop but not from remote control panel control assembly A1 and remote When Switch fault is due to Start Stop switch Is P
82. bly Remove the wire harness connectors from the stator as 9 6 sembly Remove the stator mounting screws Carefully pull the stator straight out from the housing If the stator will not slide out tap on generator housing while pulling on the stator to remove M 1728s FIGURE 9 4 BRUSH BLOCK ROUND BAR 7 7 8 IN 200MM LONG 0 45 IN 11 43 MM DIAMETER 9 16 12 X 1 IN BOLT FIGURE 9 5 ROTOR REMOVAL Install the fan hub assembly onto the rotor shaft and align the key slot on the fan hub with the key slot in the rotor shaft Install the key into the key slot Install the rotor through bolt and wash er Verify alignment of the rotor shaft and the Generator Assembly 6 Use the following procedures to assemble the gen erator 1 Position the stator so the output connector aligns with the opening in the stator housing Carefully slide the stator into the generator housing If necessary the stator can be lightly tapped on the laminations so that the stator is seated into the housing Insert and tighten the two stator through bolts Careless handling of the stator can damage the insulation on the stator windings Do not brush windings against the housing or strike windings during installation Align the pin in the rotor shaft with the notch in the crankshaft and slide the rotor onto the crankshaft Make sure that the rotor is seated Plug in both stator wire connectors Prepare the endbell for i
83. brushes NOTE Replacement brushes are supplied preassembled in the endcap Remove the brush retainers after installing armature Make sure that all brush wires are clear of the commutator and that uninsulated sections of wires do not touch the inside of the housing or adjacent brush boxes Place the magnetic housing over the armature Hold down the armature and the end cap by pressing a nut driver over the end of the shaft TORQUE TO 5 10 IN LBS 57 1 13 NeM IMPORTANT THIS INSULATED SHUNT MUST BE ROUTED THROUGH UNINSULATED SHUNT AS SHOWN TO PREVENT CONTACT WITH COMMUTATOR IN FINAL ASSEMBLY POSITIVE TORQUE TO 25 30 IN LBS 2 83 3 39NeM NEGATIVE BRUSH TERMINAL NEGATIVE BRUSH TERMINAL 5 1612 25 FIGURE 8 28 BRUSH ENDCAP 8 29 Place a spring washer and a flat washer on the shaft as shown in Figure 8 29 Place the mounting bracket on the motor with the through bolt lead ins to the inside of the motor The near one mounting hole should line up with the positive stud on the end cap so the through bolts line up Insert the through bolts and torque to 35 45 Ib in 3 96 5 09 Nm Wipe dust from the helix and gear and apply a light coat of GE Versilube 322 L to the outside diameter of the helix the inside diameter of the gear and the unchamfered end of the gear Place the clutch and helix assemblies on the motor shaft with flats engaged in the clutch hole If
84. cates an open circuit between the commutator bars and ar mature windings Replace an open armature with a new one Brush Inspection Measure brushes Figure 8 27 and replace them if worn to less than 0 315 8 mm 8 28 COMMUTATOR ES1614s FIGURE 8 25 TESTING ARMATURE FOR GROUNDS HACKSAW BLADE GROWLER 0 315 INCH 8 MM NEW 0 472 INCH WEAR LIMIT 12 MM FIGURE 8 27 BRUSH INSPECTION Starter Re assembly Use this procedure to return the electric starter as sembly to service 1 Wipe all of the dirt and oil from the starter com ponents with a clean cloth Blow off dust with fil tered low pressure compressed air Oil on the armature will damage the starter Do not immerse bearings in cleaning fluid Use a brush dipped in clean engine oil to remove dirt from bearings Avoid getting oil on brushes or commuta tor 2 Push the negative brush terminals over the through bolt holes on the brush endcap Figure 8 28 3 Insert the positive brush stud into the hole and torque to 25 30 Ib in 2 83 3 39 Nm Insert the brush springs into brush holders In sert the brush tabs into the spring ends and slide brushes into brush holders in endcap Make sure all brush wires are facing up Place a washer on the commutator end of the shaft then put the armature into the brush end cap Push the four brushes toward the commu tator make sure that the springs are correctly positioned on the
85. ce spark plug Control Trouble 4 Faulty fuel system flooded 4 Refer to Gasoline Fuel System shooting table 6 4 5 Choke not opening 5 Check choke operation 6 Faulty ignition system 6 Check for spark Engine Runs 1 Fouled spark plug 1 Clean or replace spark plug On After 2 Engine carbon build up 2 Remove carbon from engine Shutdown 6 36 7 Control INTRODUCTION Control Assembly 1 This section covers control operation component Optional Remote Start Stop Control A2 locations basic troubleshooting and test proce e Battery Charge Resistor R1 dures The control consists of the circuitry used for Rectifier Bridge CR1 starting monitoring fault conditions instrumenta tion battery charging and stopping Battery Charger Assembly VR2 e Transformer T1 NTROL DESCRIPTION ue Start Stop Switch 51 The control circuitry consists of the following com ponents See Figure 7 1 The Start Stop switch S1 is a single pole double throw SPDT rocker type switch used for starting or e Panel mounted Start Stop Switch 51 stopping the genset Holding the switch in the Start Start Solenoid K1 position will initiate engine cranking Pushing the switch to the Stop position will initiate the stop func Control Fuse F1 tion The switch will automatically return to the cen Circuit Breaker CB1 ter Run position when released BATTERY CHARGE RESISTOR 1 BRIDG
86. ch or other ignition source near the fuel system Keep a type ABC fire extinguisher nearby 1 Close the fuel supply valve if equipped or re move the fuel line from the fuel filter Plug the end of the fuel line to prevent fuel leakage and vapor accumulation See Figure 8 16 Run the genset until it runs out of fuel Allow the genset to cool down before replacing the fuel filter Use a deep 11 16 inch socket to unscrew the filter from the fuel pump Install a new fuel filter and tighten it securely to prevent fuel leakage Connect the fuel line to the new filter Open the fuel valve If equipped Start the genset and check for fuel leaks Repair any leaks immedi ately Incorrect replacement of service parts can result in damage to equipment Use genuine Onan replacement fuel filter only Fuel Pump An electric fuel pump is used to supply fuel to the carburetor If the pump malfunctions or if insufficient fuel delivery is suspected use the following proce dures to test the fuel pump Do not substitute an automotive electric fuel pump for the Onan supplied fuel pump The output pressure from an automotive pump is much higher and can cause carburetor flooding or fuel leakage creating a fire hazard 8 19 Fuel presents the hazard of fire or explosion that can cause severe personal injury or death Do not permit any flame spark pilot light cigarette arc producing equipment elec trical switch or other i
87. ck for recirculation of outlet air Replace air filter 8 14 Clean choke and choke linkage Adjust carburetor idle and main 8 14 adjustment screws Disassemble carburetor and clean all 8 15 internal passages Lower oil level Drain and refill fuel tank Perform Leak Down Test 10 1 Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only qualified service personnel with knowledge of fuels electricity and machinery haz ards should perform service procedures Review safety precautions on page iii Engine Hunts or Surges High Oil Consumption Note New engines can have high oil consump tion during break in TABLE 6 18 TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Possible Cause Corrective Action Page 1 Fuel supply problem caused by a Faulty fuel pump b Contaminated fuel supply c Vapor locking d Plugged fuel filter e Carburetor passages plugged Incorrect fuel mixture due to a Incorrectly adjusted fuel mixture screws b Dirt or varnish in carburetor Governor problem due to a Sticking or binding governor linkage b Incorrect governor adjustment c Faulty governor spring d Governor mechanism worn excessively Oil viscosity too light or oil is diluted Crankcase breather valve is dirty faulty or improperly installed Oil leaks Excessive engine wear Light loading Intake valve seal worn or defective
88. cooling fins on the engine block and cylinder head If this happens heat trans fer is greatly reduced and overheating can occur The cooling system consists of the genset housing and base assembly enclosure insulation duct scroll assembly fan hub assembly and air duct The following section covers service procedures for the cooling system 8 1 Inspection Inspect the air inlet and outlet passages Remove the access panel and inspect the engine and control area If the engine is clean and the air inlet area is clean disassembly for engine cleaning will not be necessary If debris is visible proceed to the Disas sembly section following Disassembly Remove the genset as described in Set Removal Guidelines on Page 5 2 1 Follow the genset disassembly procedures in Section 9 Generator through the scroll assem bly removal 2 Inspect and clean the fan hub assembly using a brush or low pressure compressed air If the cooling fins are damaged replace the fan hub assembly as described in Section 9 Genera for 3 Remove the top and bottom air guide housings cowling to access the engine cooling fins for cleaning 4 Use a brush or low pressure compressed air to remove any dirt or debris that may be lodged on the engine cooling fins OUTLET 1900 35 FIGURE 8 1 AIRFLOW 5 SHOWN Assembly Assemble cooling system in reverse order of disas sembly Follow the generator assembly ins
89. ct a separate battery charger to Too much DC load on genset bring battery up to full charge Starting battery Reconnect and check battery connec tion Disconnect load and recharge battery Remove other DC loads from genset Starting battery 50 Hertz only Genset Check all wiring connections between charging circuit not functioning due to the generator B1 B2 windings and the a Open wire connection in charging Battery B connection including all circuit see Figure 6 13 connections to battery charger VR2 b Battery Charger ZR2 defective Refer to battery charger VR2 test c Generator B1 B2 defective Refer to generator test section NOTE The battery charging circuit is not available on the Spec B or later 60 Hz models Spec B 50 Hz models have a maximum 10 amp 12 VDC output designed to maintain and charge the genset starting bat tery 6 25 Begin Spec B Stop Mode Momentarily pushing the Start Stop switch S1 to the Stop position begins the stop mode wilh the following results Control assembly de energizes the ignition enable circuit grounding the magneto G2 ignition circuit to stop the engine Control assembly also opens the circuit to the fuel pump 2 the fuel shutoff solenoid and to the remote control e Control assembly A1 start disconnect senses a drop in voltage from the output voltage and activates the remote stop latch to prevent restart during the stop mode
90. curing the side panels to the rear panel note slotted holes or braces and pull side panels away from genset Retighten side panels to back panel bolts 5 Remove side and rear panel to genset base mounting bolts Slowly lower the genset until it clears all obstructions and can be safely moved out from under the vehicle When reinstalling the genset be sure that all bolts brackets and electrical exhaust and fuel system components are connected exactly as they were before removal 222 ae a SN T l iii FORKLIFT FIGURE 5 3 COMPLETE GENSET REMOVAL SPEC A SHOWN 5 6 6 Troubleshooting INTRODUCTION Use the following troubleshooting guide to help diagnose genset problems The troubleshooting section is divided into four parts e Control Spec A models page 6 4 e Control Begin Spec B models page 6 16 e Generator All specs Page 6 28 E Primary Systems All Specs page Common problems are listed with their possible causes Refer to the Corrective Action column for the appropriate test or adjustment procedure The section and page number in the right column lists 6 1 the location of the test or adjustment procedure in this manual Refer to Figures 6 1 and 6 2 on Pages 6 2 and 6 3 to identify the component locations for the opec A and Spec B models Conditional schematics are used to highlight the cir cuitry that is energized during the sequence of events These con
91. current to the generator Refer to Generator AC Output Mode on page 6 30 START STOP SWITCH 1 BATTERY BT1 RE FUSE F1 CONTROL ASSEMBLY A1 FUEL PUMP E2 FUEL SHUTOFF LPG 228 RS _ FUEL SHUTOFF ES T p i a CONNECTOR CONNECTOR MAGNETO IGNITION SPARK PLUG IGNITION G2 COIL T1 S y 4 FIGURE 6 12 SPEC RUN MODE 6 22 Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only qualified service personnel with knowledge of fuels electricity and machinery haz ards should perform service procedures Review safety precautions on page iii TABLE 6 10 BEGIN SPEC B CONTROL TROUBLESHOOTING RUN MODE Possible Cause Corrective Action Page Engine Starts and Runs Then Stops Set Restarts Immediately or After Cool Down Hemote Control Run Lamp Time Meter or Battery Condition Meter Inoperative Fuel level is below genset fuel Eo tube or oil level is low Faulty choke operation Vapor lock from high ambient temperature Contaminated or incorrect fuel Open circuit in remote control wiring If battery condition meter and run lamp 2 work but time meter does not time meter is defective If time meter works but battery condition 3a meter does not operate a Defective battery condition meter b Defective zener diode inside remote control Meters and switch function pr
92. d by some state and federal agencies as causing cancer or reproductive toxicity Do not ingest inhale or contact used oil or its vapors e Benzene and lead in some gasolines have been iden tified by some state and federal agencies as causing cancer or reproductive toxicity Do not ingest inhale or contact gasoline or its vapors e Do not work on the genset when mentally or physical ly fatigued or after consuming alcohol or drugs e Carefully follow all applicable local state and federal codes GENERATOR VOLTAGE IS DEADLY e Generator output connections must be made by a qualified electrician in accordance with applicable codes The genset must not be connected to the public utility or any other source of electrical power Connection could lead to electrocution of utility workers damage to equipment and fire An approved switching device must be used to prevent interconnections Use caution when working on live electrical equip ment Remove jewelry make sure clothing and shoes are dry and stand on a dry wooden platform on the ground or floor FUEL IS FLAMMABLE AND EXPLOSIVE Keep flames cigarettes sparks pilot lights electrical arc producing equipment and switches and all other sources of ignition well away from areas where fuel fumes are present and areas sharing ventilation Fuel lines must be secured free of leaks and sepa rated or shielded from electrical wiring Use approved non conductive flexible fuel h
93. d into the crankcase cover The bearing in the engine block can be pressed out after the oil seal is removed fol lowing section The bearings in the crankcase cov er can be pulled out using a puller Clean the bear ing 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 OIL SEAL is flush with cylinder block boss see Figure 10 37 CT1093 1s Lubricate the lips of the oil seal with a light coating of grease This provides initial lubrication until engine oil reaches the seal FIGURE 10 37 OIL SEAL 10 19 COMPRESSION RELEASE SYSTEM SPEC A D ONLY ENGINE START POSITION This engine has a compression release system that COM SER decreases the amount of effort required to start the engine and reduces engine run on when stopping Figure 10 38 The system works as follows FLYWEIGHT CAMSHAFT 1 As the engine is started a spring holds in the flyweight which in turn pushes a decompres sion pin upward 2 The decompression pin pushes up on the ex lt haust tappet and opens the exhaust valve mo DECOMPRESSION S mentarily to release compression and make PIN SPRING starting easler 3 As the engine speeds up the flyweight is forced outward by centrifugal force and the de compress
94. defective area Re place a cracked cylinder block 2 Inspect all machined surfaces and threaded holes Carefully remove any nicks or burrs from machined surfaces Clean out tapped holes and clean up any damaged threads 3 Check the cylinder head mounting area for flat ness with a straight edge and a feeler gauge Cylinder Bore Inspection Inspect the cylinder bore for scuffing scratches wear and scoring If the cylinder bore is scuffed scratched scored or worn the block must be bored to an oversize or re placed When the appearance of the cylinder bore is good and there are no scuff marks check the cyl inder bore for wear or out of round as follows 1 Measure the 1 0 of the cylinder liner with a cyl inder gauge at six points as shown in Figure 10 20 2 If the measurement exceeds the allowable lim it the cylinder will need to be bored to an over size and then be honed 10 11 FIGURE 10 20 MEASURING CYLINDER WEAR Cylinder Bore Deglazing Before installing new rings deglaze the cylinder bore Make sure that there are no scuff marks and no wear or out of round beyond the specifications Deglazing gives a fine finish but does not enlarge the cylinder diameter so the original pistons with new rings can be used The reason for deglazing a cylinder is to provide cavities to hold oil during piston ring break in 1 Wipe the cylinder bore with a clean cloth that has been dipped in clean light engine oil
95. ditional schematics are for a typi cal gasoline fueled genset Always refer to the wir ing schematic and diagram in Section 12 Wiring Diagram Schematic that corresponds to the model and spec of the genset when troubleshooting Make a thorough inspection of the genset wiring to make sure that good wire harness and ground con nections are made Correct wiring problems before performing tests or replacing any components lt STARTER MOTOR B1 STATOR CONNECTOR P5 STATOR CONNECTOR P6 IGNITION COIL T1 BATTERY CHARGE RESISTOR 1 BRIDGE RECTIFIER CR1 START STOP SWITCH 1 FUSE F1 CIRCUIT BREAKER CB1 ge SPARK PLUG E1 Y P4 CONNECTOR J4 CONNECTOR MAGNETO IGNITION G2 7 Ae A ne 4 VOLTAGE REGULATOR VR1 START RELAY 1 FUEL PUMP E2 FUEL SHUTOFF SOLENOID ON LPG MODELS P1 CONNECTOR 9 J1 CONNECTOR REMOTE CONTROL Q CONNECTOR MON CONTROL ASSEMBLY A1 ES2017s FIGURE 6 1 COMPONENT LOCATIONS GASOLINE FUELED SPEC A MODELS STATOR CONNECTOR P5 STARTER MOTOR B1 v sd STATOR CONNECTOR P6 50 HZ MODELS HAVE BATTERY CHARGER VR2 MOUNTED INSIDE THE HOUSING NOT SHOWN SEE FIGURE 7 7 TRANSFORMER 1 50 HERTZ ONLY Tn 02 X Ail FUEL SHUTOFF gt pit SOLENOID E3 BRUSH BLOCK joo 5 f FUSE F1 lt START STOP SWITCH S1 IGNITION COIL T1 MAGNETO IGNITION G2 VOLTAGE REGULATOR VH1 FUEL P
96. e engine Torx T 30 and muffler Remove the starter mounting nuts bolts on Spec A Carefully disengage the starter from the end bell Use a 1 8 to 5 32 inch nail set to remove the roll pin from the armature shaft When reassem bling use a new roll pin Remove the return spring gear and clutch assembly as required See Figure 8 24 Remove the starter through bolts Carefully separate the brush end cap housing from the armature assembly STARTER POSITIVE 4 TERMINAL STARTER THROUGH BOLTS ES 1608s SUPPORT ES 1609 1s FIGURE 8 24 DRIVING ROLL PIN OUT OF STARTER ASSEMBLY 0 27 Testing Armature for Grounds Touch one ohmmeter lead to a commutator bar touch the other lead to the armature shaft and the core laminations A low resistance reading indi cates a grounded armature Replace a grounded armature with a new one See Figure 8 25 Testing Armature for Shorts Use a growler Figure 8 26 to locate shorts in the armature Place the armature in the growler and hold a thin steel blade hacksaw blade parallel to the core and just above the armature while slowly rotating the armature in the growler A shorted ar mature will cause the blade to vibrate and be tracted to the core Replace a shorted armature with a new one Testing Armature for Opens Touch one ohmmeter lead to a commutator bar then touch the other lead to each of the other com mutator bars in turn A high resistance indi
97. e governor linkage toward the front of the genset so that the throttle lever on the carbure tor is resting against the throttle stop screw Ad just the stop screw to obtain a setting of 55 1 Hz 45 1 Hz on 50 Hz units 6 Release the governor linkage and observe the stability of the genset Set the voltage and fre quency and adjust the sensitivity of the gover nor as specified under Governor on Page 8 9 Add and remove a half load several times to make certain the genset does not bog down or hunt Carburetor problems not corrected by the 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 car buretor This may require carburetor cleaning to re store satisfactory operation Cleaning the carburetor includes complete disas sembly thoroughly cleaning and replacement of parts and gaskets THROTTLE STOP SCREW MAIN ADJUSTMENT FIGURE 8 22 LPG CARBURETOR ADJUSTMENTS PRIOR TO SPEC E ELECTRIC STARTER A 12 volt electric starter with a negative ground is used for cranking the genset When the starter is energized an inertial engagement system causes the starter pinion gear to engage the ring gear on the fan hub assembly As the starter spins the start er pinion ge
98. e seat sur face and valve guide diameter Figure 10 10 Always wear safety glasses with side shields when grinding to prevent severe eye damage Install the valve and check for contact between the valve face and the valve seat with red lead If the valve has been in use for a long time the seat tends to come in contact with the upper side of the valve face Cut and readjust the width using a 15 cutter so the valve seat width makes contact in the same dimension as the valve face width Cut the valve seat surface again with a 45 cut ter and recheck the contact between the valve and seat Repeat steps three and four until the correct contact Is achieved Lap the valve seat until the seated rate is more than 70 of the total contact area 10 6 7 Use grinding compound to finish the seat face Valve stem guides or valve seats that are worn loose cracked or severely pitted should be re placed The valve guide and seat have to be pressed out of the cylinder head and replacement parts must be pressed in The replacement cylinder head assembly includes the valve stems and seats D 0 26 rad 15 79 452 054 064 1 VALVE SEAT CUTTER IDENTICAL DIMENSIONS 2 0 79 RAD 45 CUTTER b SEAT SURFACE WIDTH 3 CONTACT CHECK 4 0 26 RAD 15 CUTTER 5 0 79 RAD 45 CUTTER 6 CONTACT CHECK FIGURE 10 10 REGRINDING VALVE SEAT Valve Clearance Adj
99. e starts but sputters or stops before it warms up the choke set ting is too lean Choke Adjustment Check the choke linkage to make sure it is not bent or rubbing Rotate the choke lever on the carburetor The choke shaft should move freely and it should return to its original posi tion when released Inspect the heater hose to make sure it is installed properly and in good condi tion Refer to Figure 8 15 on Page 8 18 8 17 The choke housing becomes very hot during operation and can cause severe burns if touched Allow the genset to cool down before handling the choke assembly 1 Allow the genset to cool down The tempera ture inside the housing must be the same as the ambient temperature Loosen the adjustment screw holding the ad justment plate Slowly rotate the adjustment plate until the bi metal choke shaft connection is visible in the sight window This is the correct setting for an ambient temperature of 70 F 21 C If the ambient temperature is higher or lower than 70 F 21 C make a mark on the choke coil housing opposite the center mark on the adjustment plate Each mark on the adjustment plate is equal to 10 F 12 2 C of difference from 70 F 21 C If itis warmer than 70 21 C rotate the plate clockwise If the tempera ture is less than 70 F 21 C rotate the plate counterclockwise Tighten the adjustment screw Example If the ambient temperature is 90 F 32 C rotate
100. efore removing the cylin der head Remove all carbon deposits from the cylinder head Handle the cylinder head carefully be cause it can be easily damaged Clean the cylinder block and cylinder head thoroughly in the head gasket mating area Install a new head gasket on the block Place the head in position and follow the head torque tightening sequence shown in Figure 10 5 Start out tightening all bolts to 11 15 Nm then tighten to the specified torque see Section 4 Torque Specifications ROCKER LOCKING ua 1119 25 FIGURE 10 4 ROCKER ARM AND PUSH ROD REMOVAL C1131 2s FIGURE 10 5 CYLINDER HEAD TIGHTENING SEQUENCE EXHAUST VALVE INTAKE VALVE VT1037 2s CYLINDER HEAD VALVE SPRINGS RETAINERS KEEPERS FIGURE 10 6 OVERHEAD VALVE SYSTEM VALVE SYSTEM This engine uses an overhead valve design as shown in Figure 10 6 A properly functioning valve system is essential for good engine performance Access to the valve system is gained by removing the head cover and cylinder head Use the following procedures to inspect and service the valve system Valve Removal The intake and exhaust valves can be removed from the cylinder head without the use of special tools Depress the valve spring retainer using a 9 16 inch crows foot on a 6 inch extension then remove the keeper Figure 10 7 Remove the spring retain er spring and valve Alw
101. ents several hazards that the service technician must be aware of to safely complete the job Study the safety pre cautions at the beginning of this manual and famil yourself with the hazards listed in Table 5 1 on Page 5 2 Approach the job in a safety conscious manner Being safety conscious is the most effec tive way to avoid injury to yourself and to others Re duce the risk of an accident by adopting the follow ing safeguards Safeguards to Avoid Hazards Use personal protection Protect your body by wearing the appropriate safety equipment such as e Safety shoes e Gloves e Safety glasses e Hard hats e Ear plugs Do not wear rings jewelry or loose clothing these can get caught on equipment or conduct electricity Reduce the hazard A safe orderly work area and well maintained equipment reduce the risk of haz ard Leave all guards and shields in place on ma chinery and maintain equipment in top condition Store flammable liquids in approved containers away from fire flame spark pilot light arc produc ing equipment and other ignition sources Keep the work area Clean well lighted and well ventilated Keep fire extinguishers and safety equipment nearby and be prepared for any emergency TABLE 5 1 HAZARDS AND THEIR SOURCES e Fire and explosions Leaking or spilled fuel Hydrogen gas from charging battery Oily rags improperly stored Flammable liquids improperly stored Any fire flame spark pilot
102. eposits Normal plug color 8 6 If the spark plug is in good condition proceed to the Ignition Coil section following Ignition Coil T1 The ignition coil is a transformer that steps up the magneto output voltage to about 20 000 volts for spark plug firing The coil consists of a primary and a secondary winding Perform the following checks Gasoline vapor is extremely flam mable and can result in severe personal injury or death if ignited Make certain that no gasoline or other flammable fumes are present Park the vehicle in a well ventilated area and leave the genset compartment door open for several min utes before performing this test Ignition Spark Check This checks all of the igni tion system components and wiring 1 Make sure the engine oil level is adequate and that the genset is level 2 Remove the spark plug reconnect the spark plug lead and ground the plug side electrode to bare metal on the engine 3 Do not touch the plug or plug wire during test ing Crank the engine and observe the plug If a good spark is observed the ignition system is good If no spark or a weak spark is ob served proceed to the coil winding check SPARK PLUG GAP SEE SECTION 2 SPECIFICATIONS ES1374s FIGURE 8 4 MEASURING PLUG GAP Ignition Coil Ohmmeter Check Remove the con trol panel mounting screw Torx T 30 to access the Ignition coil Check the ground lead for continuity between the ground lead te
103. er lead on start solenoid S and gnd 4 1 ohm Check wiring continuity between battery B and the start solenoid BAT Measure voltage between starter terminal and ground with switch S1 held in the Start position If voltage is not present and continuity checks OK start solenoid K1 is defective If voltage is present in step 4c starter is defective Check wiring continuity between control assembly A1 and remote otart Stop switch Test remote Start Stop switch Spec A Start Ignition Mode Holding the Start Stop switch 51 in the Start position activates the following ignition circuit e Control assembly A1 enables the ignition circuit to open a ground path through the control assembly to the magneto assembly G2 so that output from the magneto will energize the ignition coil T1 e With the engine cranking a permanent magnet in the flywheel rotates at the proper time past the magneto to induce a voltage at the ignition coil T1 that fires the spark plug E1 for ignition e Battery positive B is supplied to the fuel pump E2 or fuel shutoff solenoid E2 and regulator K2 on LPG models Schematic for gasoline fueled model shown BATTERY BT1 rusEFi START STOP SWITCH 81 4 as START a gt STARTER MOTORB1 EU KI Ae JUL OIL LEVEL SWITCH S2 atk air a Sot Ts Si qh m FUEL PUMP E2 FUEL SHUTOFF OOJ f SOLENOID ON LPG MODEL P1 CONNECTO
104. eview safety precautions on page iii TABLE 6 17 TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Possible Cause Corrective Action Page Engine Overheats Black Exhaust Smoke White or Blue Exhaust Smoke Restricted airflow due to dirt debris or insulation blocking air inlet or outlet Dirt or oil on engine cooling fins mCooling fan plugged or broken Lean fuel mixture due to a Incorrectly adjusted fuel mixture screws b Dirt or varnish in carburetor Loose or missing service access cover or improper seal around the endbell assembly Improper installation due to a Insufficient air inlet size b Air inlet location allowing recirculation Rich fuel mixture due to a Dirty air filter b Choke sticking c Incorrectly adjusted fuel mixture screws d Dirt or varnish in carburetor Oil level too high Contaminated fuel Excessive engine wear 6 34 Clear air inlet and outlet areas Do not store anything in compartment area Clean all dirt and oil from engine cooling fins Inspect cooling fan clean or replace as needed Adjust carburetor main and idle 8 14 adjustment screws Disassemble carburetor and clean 8 15 all internal passages Check for proper fit of service access cover and check seal around endbell Make sure air inlet is not blocked and that it is properly sized refer to Installation Manual Make sure that air outlet is not blocked and che
105. f inder wall Compress the rings with a ring com pressor as shown in Figure 10 35 3 Tap the piston down into the bore with the han dle end of a hammer until the connecting rod is seated on the crankpin C105F092 FIGURE 10 33 SIDE CLEARANCE OF CRANKSHAFT 10 17 CONNECTING ROD MARK 1091 15 FIGURE 10 34 ROD ASSEMBLY 1066 25 FIGURE 10 35 INSTALLING PISTON Crankpin Clearance 1 Wipe the oil off the rod cap and crankpin 2 Place a piece of the correct size Plasti gage across the full width of the rod cap about 1 4 inch 6 mm off center Figure 10 36 Install the rod cap and tighten to the specified torque Do not rotate crankshaft after the rod cap is in place Remove the rod cap and leave the flattened Plasti gage on the part to which it adheres Compare the widest point of the flattened Plas ti gage with the graduations on the envelope to determine the crankpin clearance Remove the Plasti gage Lubricate the rod crankpin and cap Install the connecting rod cap The rod cap must be tapped several times to properly align it with the connecting rod Tighten the connecting rod bolts to the speci fied torque Crank the engine several times to see that the crankshaft turns freely ENVELOPE GRADUATION CT1092 1s FIGURE 10 36 MEASURING CRANKPIN CLEARANCE BEARINGS The crankshatt bearing is pressed into the engine block and three bearings are presse
106. filed to a sharp point Care must be taken not to remove metal from the groove sides Using caustic cleaning solvent or wire brush for cleaning pistons will damage pis ton Use parts cleaning solvent only When cleaning the connecting rod in solvent include the rod bore Blow out all passages with low pressure compressed air Piston and Connecting Rod Inspection Piston Inspection Inspect the piston for fractures at the ring lands skirt and pin bosses Check for wear at the ring lands using a new ring and feeler gauge as shown in Figure 10 24 Replace the pis ton when the side clearance of the rings exceed the specified limit CT1061s FIGURE 10 24 CHECKING RING LAND 10 13 Piston Skirt O D Measurement 1 Measure the piston skirt O D with an outside micrometer Figure 10 25 2 If the measurement is less than the allowable limit replace the piston Piston Boss 0 1 Measure the piston boss 1 0 in both the vertical and horizontal direction with a cylinder gauge Figure 10 26 2 If the measurement exceeds the allowable lim it replace the piston SA11F016 Piston Ring Gap FIGURE 10 25 PISTON SKIRT MEASUREMENT 1 Insert piston ring into cylinder Use piston head to push ring down to bottom of cylinder 2 Measure the ring gap with a feeler gauge as shown in Figure 10 27 3 If the ring gap exceeds the allowable limit re place the ring 9 11 012 CT1123s FIGURE 10 27 MEASURING RI
107. gnition source near the fuel system Keep a type ABC fire extinguisher nearby Fuel Pump Test Test the fuel pump by checking the fuel pump outlet pressure as follows 1 Make sure the fuel tank has sufficient fuel to supply the genset The genset fuel pick up tube ends well above the bottom of the vehicle fuel tank The genset can be out of fuel even when the tank is partly full FUEL FILTER FUEL PUMP N FS1868 1s FIGURE 8 16 FUEL FILTER REPLACEMENT Check the the genset starting battery voltage when cranking and running the genset Mea sure battery voltage between the brown lead and ground Figure 8 17 The pump will not work properly if the cranking or running voltage is less than 6 VDC If the battery voltage is low charge the battery and retest Remove the fuel line from the carburetor inlet and install a pressure gauge Press the Start switch and hold it for several seconds until the pressure reading stabilizes The pressure reading should be 3 25 psi 22 4 kPa to 4 psi 27 5 kPa The pressure should hold constant or drop off very slowly 6 20 If the pressure reading is below 3 25 psi 22 4 kPa tap the pump body with a screw driver handle to free the piston from fuel deposits If the pump still does not work and the battery voltage is adequate re place fuel pump with an Onan supplied pump If the pressure is higher than 4 psi 27 5 kPa fuel can overcome the needle and float assembly
108. he engine and repair leaks immediate ly FUEL SYSTEM With the genset operating inspect the fuel supply line and fittings for leaks Check flexible section for cuts cracks and abrasions and make sure it is not rubbing against anything that could cause damage Leaking fuel creates a fire hazard which can result in severe personal injury or death if ignited by flame spark pilot light ciga rette equipment electrical switch or other ignition source If fuel leaks are detected shut off the genset and correct leak immediately OUTPUT CHECK Apply a full load to make sure the genset can pro duce its full rated output Use a load test panel to ap ply a progressively greater load until full load is reached CONTROL Stop and start the genset several times at the gen set control and remote control if equipped to verify that it functions properly MECHANICAL Stop the genset and inspect it for leaking gaskets loose fasteners damaged components or interfer ence problems Repair as required Inspect the genset compartment and verify that there are no breaks or openings in the vapor proof wall that sep arates the compartment from the vehicle interior Seal openings as required Make sure that all soundproofing material is in place 12 Wiring Schematic Diagram DRAWING NO 611 1194 611 1194 611 1225 611 1225 611 1226 611 1226 611 1226 611 1245 611 1245 611 1245 611 1246 611 1246
109. he frequency and voltage first with a load applied and then with no load applied The frequency and voltage should stay within the limits shown in Table 8 1 on Page 8 10 5 Adjust the governor sensitivity to give the clos est regulation east speed arid voitage diifer ence between no load and full load without TABLE 8 1 CHECKING VOLTAGE AND causing a hunting condition To increase the SPEED FREQUENCY sensitivity turn the adjustment screw counter clockwise To decrease the sensitivity turn the adjustment screw clockwise 60 Hz 50 Hz 50 Hz 6 Recheck the speed setting made in step 3 and 12 2 Wire 12 2 Wire 12 2 Wire readjust if necessary 120 V 220 V 240 V 7 Set the carburetor throttle stop screw as speci Voltage SEN Maximum No Load fied in the Fuel System section Typical No Load Minimum Full Load If the governor action is erratic after adjustments Typical Full Load are made loosen the governor arm mounting bolt Speed Erequene and rotate the shaft fully clockwise then retighten ad the bolt Reset the governor adjustments and re Speed rpm check speed and droop Springs tend to lose their Frequency Hz calibrated tension through fatigue after long usage It may be necessary to put the stationary end of the Minimum Full Load MANC Speed rpm spring in a different hole to change the tension or Frequency Hz replace the spring altogether If this does not im Typical Frequency
110. he valve guide 3 Press the valve seal into the valve guide by hand until the shoulder of the seal rests against the cylinder head Figure 10 12 10 7 FEELER sss s FIGURE 10 11 VALVE CLEARANCE ADJUSTMENT INTAKE VALVE VT1043 1s FIGURE 10 12 VALVE SEAL INSTALLATION CRANKCASE COVER 1 The crankcase cover is located in two places with dowel pins Figure 10 13 Do not attempt to pry the crankcase cover off or damage can result Remove the crankcase cover mounting bolts Hold the crankcase cover and lightly tap the end of the crankshaft with a plastic ham mer 2 Remove the crankcase cover very carelully to prevent the shaft from scraping the lip surface of the oil seal 3 Remove and tag shims from the crankshaft camshaft and balancer shaft Shim thick nesses differ and they must be reassembled in their original positions 4 Make sure the governor shaft is properly posi tioned when installing the cover Use a new gasket and clean the crankcase cover and the engine block gasket mating surfaces Place crankcase cover in position and secure all bolts in a star pattern to the specified torque see Section 4 Torque Specifications GOVERNOR With the crankcase cover removed the governor can be inspected or disassembled for service The governor assembly must spin freely on the center pin without excessive looseness or wobble Sleeve tip wear is the most common cause of governor fail ure Check f
111. he vehicle install the muffler bracket hardware Install the 5 Reconnect the genset starting battery nega rear starter mounting nut tive terminal last 6 31 8 32 9 Generator GENERATOR DESCRIPTION The KY genset uses a 2 pole revolving field gener ator design Output voltage is controlled by an elec tronic voltage regulator A circuit breaker provides overcurrent protection for the generator and also functions as an on off switch in the load circuit AC load connections are made through generator lead wires that connect directly to a customer supplied junction box The generator section consists of the following components and controls Stator and housing Rotor Brushes Electronic Voltage Regulator VR1 Circuit Breaker CB1 Wiring Harness Stator and Housing The stator consists of steel laminations stacked to gether with three separate windings wound into slots in the laminations Winding T1 T2 is the main power winding that provides the voltage and current to operate the connected loads Winding B1 B2 is for battery charging and internal low voltage loads Winding Q1 Q2 is an excitation winding that pro vides power to the voltage regulator for the rotor field winding The stator assembly mounts inside the stator housing Refer to Figure 9 1 on Page 9 3 Rotor The rotor consists of steel laminations stacked to gether on a shaft A field winding is wrapped around the laminations The rotor shaf
112. hould 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 screw in until lightly seated For a preliminary ad justment turn the screw out 2 turns Forcing the mixture adjustment screw tight will damage the needle and seat Turn in only until light resistance can be felt Start the engine and allow it to run for about 15 min utes at half load Figure 8 22 shows the location of the adjustment screw Use the following procedure to adjust 1 Stop the genset and connect a voltmeter fre quency meter and load bank to the generator output leads 2 Start the genset and apply full rated 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 re quired frequency 3 Turn the main adjustment screw inward until voltage 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 If a CO me ter is available follow the manufacturer s in structions for use and adjust the main adjust ment screw to obtain 1 to 2 percent CO 4 Remove the load and verify that frequency is within 62 5 0 5 Hz 52 0 5 on 50 Hz units Adjust governor speed adjustment nut if neces sary to obtain required frequency 5 Pull th
113. ing good contact with slip rings Poor wiring connections to voltage regulator If generator frequency is within specified limits but voltage is incorrect voltage regulator is defective 6 28 as required Reset breaker Check for good wiring connections betwen regulator and brush block Check for good wiring connections between regulator and stator Check for continuity between control connector P1 5 and regulator connector P4 7 Spec A or J1 9 to P4 7 Spec B If connections are good and 12 VDC is not present at voltage regulator pin 7 during start control assembly A1 is defective Check brushes for wear and for contact Check slip rings Perform field voltage test Refer to governor adjustments in Section 8 Check length of brushes and replace if worn excessively Check slip rings Check for good wiring connections between the voltage regulator and the brush block and between stator connec tions Q1and Q2 Correct if required Replace electronic voltage regulator ES EL w CL w ur wa r waar wa r waar OA Spec A Generator AC Output Mode When the engine starts and begins to come up to speed AC voltage is produced in the battery charge winding B1 B2 the quadrature winding Q1 Q2 and in the AC windings T1 T2 These outputs perform the following functions e The battery charge winding B1 B2 is used to
114. ion pin moves down so that it no lon ger opens the exhaust valve 4 When the engine is stopped engine speed drops and the flyweight pulls in and the decom pression pin moves up The pin opens the ex haust valve again releasing compression ENGINE RUNNING POSITION The most common cause of problems with this sys tem is a faulty spring the spring may be too long or it may not be connected A spring that is too long will reduce the decompression cutoff speed Make sure oe that the spring is properly attached If a problem with the cutoff speed is still suspected replace the spring FIGURE 10 38 COMPRESSION RELEASE SYSTEM 10 20 11 Service Checklist A WARNING 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 e Dizziness Throbbing in Temples e Nausea Muscular Twitching Headache Vomiting Weakness and Sleepiness Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist seek medi cal attention Shut down the unit and do not operate until it has been in spected and repaired Never sleep in the vehicle with the genset running unless the vehicle interior is equipped with an operating carbon monoxide detector Protection against carbon monoxide inhala
115. ip Rings section on Page 9 12 for the procedures for inserting the wire Ground Test Set the ohmmeter to the highest re sistance scale or use a megger 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 9 7 on Page 9 9 A reading of infinity should be measured A reading of less than one megohm one million ohms indicates the rotor is grounded Re place a grounded rotor with a new rotor SLIP RINGS 51764 15 FIGURE 9 7 GROUNDED ROTOR TEST Open or Shorted Test To test for open windings set the ohmmeter on the highest resistance scale Place the test prods on the slip rings as shown in Figure 9 8 The ohmmeter should indicate continu ity between the slip rings of approximately 19 to 27 ohms A high resistance reading indicates a poor connection or an open winding Check the connec tion between the slip rings and rotor lead wires Re place the rotor if a winding is open To test for a shorted winding set the ohmmeter on the lowest scale Place the test prods on the slip rings as shown in Figure 9 8 A reading of less than 17 ohms at 77 F 25 C indicates shorted windings Replace the rotor if a winding is shorted Open or shorted tests can also be performed by re moving the P4 plug from the regulator J4 connector and measuring across the P4 9 and P4 10 connec tions If an abnormal reading is measured recheck by measuring at the collector ri
116. ju ry or death Only qualified service personnel with knowledge of fuels electricity and machinery haz ards should perform service procedures Review safety precautions on page iii TABLE 6 7 BEGIN SPEC B CONTROL TROUBLESHOOTING CRANKING MODE Page Engine Does 1 Open control fuse F1 Not Crank Insufficient cranking voltage due to Also see Table 6 11 on page 6 25 a Battery not charged b Battery connections loose or dirty c Battery cable size too small Start solenoid K1 not energized due to a Open circuit to start solenoid coil b Defective start solenoid coil c Defective Start Stop switch d Defective control assembly A1 Starter B1 not energized due to a Open circuit to starter B1 b Open circuit between battery B and the start solenoid contact BAT c Defective start solenoid K1 d Defective starter B1 If engine cranks from set but not from remote control panel fault is due to a Open circuit between control assy A1 and remote Start Stop switch b Remote Start Stop switch faulty Check fuse If open locate and correct cause of overload Replace fuse Check condition of battery and recharge or replace Clean and tighten all connections at battery K1 start solenoid and starter motor Increase starting battery cable size Check wiring continuity to the start solenoid K1 coil from control assy A1 and from ground to sta
117. laced by output voltage from the generator when the engine comes up to speed so the control remains en ergized on Spec A and begin Spec B 50 Hz only e Start solenoid K1 is de energized opening the circuit to the starter motor M1 to stop cranking The start disconnect is activated at approximately 2500 rom e Fuel Pump E2 remains energized during the run condition Fuel shutoff solenoid E3 re mains energized on begin Spec B models e LPG model Priming solenoid K2 is de ener gized e Field flash is no longer required and is turned off e Ignition Enable remains on Output from the magneto assembly G2 energizes the ignition coil T1 to provide spark e Remote run output energizes the running time meter and the battery condition meter in the op tional deluxe remote control A2 7 4 A low oil level will cause the low oil level switch S2 to close This closes a ground path to the magneto assembly G2 eliminating ignition spark and pre venting the engine from operating If the oil level goes below the low oil level during operation the genset will shut down Charging Circuit A 12 volt DC output one ampere maximum on Spec A or ten ampere maximum Spec B 50 Hz from the generator is used to prevent discharge of the genset starting battery during genset operation opec B 60 Hz models do not have a battery charge winding Stopping Pressing the Start Stop switch 51 to the Stop posi tion de ene
118. lder and at the same time in sert a piece of wire into the small hole in the endbell at the bottom of the brush block See Figure 9 4 Carefully guide the wire through the brush block and then release each brush Verify that each brush is held off the slip rings by the wire Remove the wires from the magne to assembly Loosen the two screws holding the brush block to the endbell The brushes will be damaged during disassembly if not held off the slip rings Make certain wire is in place before removing the generator endbell Also the brush block must be loose so it will clear the bearing when the endbell is removed Disconnect the starter bracket from the rear of the starter Remove the endbell mounting screws and place the endbell along side the front of the genset to eliminate more wire re moval Pull outward on the rotor shaft to remove it If the rotor does not come loose from the tapered engine crankshaft install a solid round bar stock 7 7 8 inches 200mm long by 0 45 inch es 11 43 mm in diameter into the rotor through bolt hole Figure 9 5 Thread a 9 16 12 x 1 inch bolt into the end of the rotor shaft and slowly tighten the bolt until the rotor comes loose Careless handling of rotor or stator can damage the insulation on the windings Do not allow windings to be brushed or scraped during removal Do not touch the slip rings or corrosion will occur Wear gloves to protect hands from sharp edges on the stator assem
119. le skirt Excessive vibration transfer and exhaust pipe damage can be caused by angular mounting Tailpipe hanger clamps must be mounted directly above the com ponent being supported and not at an angle 6 Run the genset for five minutes and check the entire exhaust system visually and audibly for leaks or excessive noise Correct any prob lems immediately Tailpipe Recommendations Tailpipes must meet several design specifications to provide safe genset operation If replacing the tailpipe make certain the replacement part is the same size and configuration as the original part Refer to the following guidelines for selecting and locating the tailpipe Inhalation of exhaust gases can re sult in severe personal injury or death Exhaust gases can enter the vehicle interior if the tail pipe is damaged missing or improperly installed Follow the recommended exhaust system replacement procedures Spec A Use 1 1 2 inch O D 18 gauge aluminized or stainless steel tubing for tailpipe Begin Spec B Use 1 1 4 inch O D 1 1 8 inch 1 0 18 gauge aluminized steel or stainless steel tubing for tailpipe Do not use flexible tailpipe since it might break due to road shock and vibration 8 4 Hot exhaust components present the risk of fire that can result in severe personal injury death or equipment damage Follow the recommended clearances between the exhaust system and any combustible materials The exhaust system mus
120. ll other causes have been eliminated see Section 6 Troubleshooting It is not necessary to adjust fuel mixture These carburetors are calibrated at the factory and the adjustments are sealed A throttle stop screw is provided for adjusting the closed position of the throttle plate to obtain prop er governor response when loads are being discon nected See Governor Adjustments on Page 8 9 To adjust the throttle stop screw 1 Connect a frequency meter and start and run the genset until it has warmed up to normal op erating temperature 2 Disconnect all loads Pull the governor linkage toward the front of the genset so that the tang on the throttle lever bears against the throttle stop screw Adjust the stop screw to obtain a frequency of 44 to 46 Hz on 60 Hz gensets 36 to 38 Hz on 50 Hz gensets 8 24 FIGURE 8 20 FUEL SOLENOID VALVE THROTTLE STOP SCREW THROTTLE GAS HOSE FITTING FIGURE 8 21 LPG CARBURETOR BEGINNING SPEC E LPG Carburetor Prior to Spec E See Figure 8 22 LPG carburetors prior to Spec E have two adjustment screws that must be properly set for satisfactory operation The throttle stop screw controls how much the throttle plate remains open when the governor closes the throttle The main adjustment screw controls the fuel mixture No other adjustments are required with an LPG carbu retor since there are no float or choke adjustments Mixture Screw Adjustment The mixture screw s
121. lways refer to the specific wir ing diagram that corresponds to the model and spec number of the genset when troubleshooting Start Mode Holding the Start Stop switch 51 in the Start posi tion activates the control assembly A1 by closing the start signal input circuit While the Start Stop switch is held the control assembly supplies the fol lowing outputs and results e Energizes the start solenoid K1 causing the start solenoid contacts to close energizing the starter The starter begins to crank the engine to initiate starting e Energizes the fuel pump E2 the fuel pump begins pumping fuel to the carburetor for en gine operation Begin Spec B models the fuel shutoff solenoid E3 is energized allowing fuel to pass through the carburetor LPG models the fuel shutoff solenoid E2 and priming solenoid K3 are energized to allow fuel flow to the carburetor e Flashes the generator field winding to ensure that there is adequate magnetism to induce generator voltage buildup e Enable the ignition circuit this opens a ground path through the control assembly to the mag neto assembly G2 so output from the magne to will energize the ignition coil 1 The igni tion coil energizes the spark plug E1 for igni tion Run Mode When the engine starts release the Start Stop switch and it will return to the center Run position The following control assembly functions occur e Voltage from the battery is rep
122. ly section Electrical shock can cause severe personal injury or death Do not touch electrical wiring or components during testing Discon nect electrical power by removing the starting battery negative cable before handling elec trical wiring or components Do not connect meters while circuit is energized Use rubber in sulative mats placed on dry wood platforms over floors that are metal or concrete when test ing electrical equipment Do not wear jewelry or damp clothing particularly wet shoes or allow skin surfaces to be damp when handling electri cal equipment 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 If the spark plug is badly fouled or deformed replace it Measure and reset the spark plug gap as shown in Figure 8 4 See Section 2 Specifications An examination of the spark plug can often help diagnose an engine problem Refer to the following spark plug conditions e Carbon Fouled Check for a poor high tension lead connection faulty choke operation rich fuel mixture or dirty air filter e Oil Fouled Check for low compression Burned or Overheated Check for leaking in take manifold gasket lean fuel mixture or incor rect spark plug type e Splash Fouled Check for accumulated com bustion chamber deposits See Rocker Arms Push Rods and Cylinder Head section on Page 10 3 e Light Tan or Gray D
123. m the left side of the genset housing Disconnect the generator load wires from in side the genset Remove the control assembly mounting bracket Figure 6 1 on Page 6 2 or Figure 6 2 on Page 6 3 Raise the control as sembly and disconnect the ground and neutral L2 lead from the ground terminal Disconnect the inline load L1 lead connection Tag the wires for identification when reconnecting Loosen the conduit connector elbow and pull the load wires and flexible conduit free of the genset Disconnect the exhaust tail pipe from the gen set Disconnect any exhaust support brackets or hangers that restrict removal of the genset Disconnect the fuel line from the genset Follow the applicable instructions depending on the fuel A Gasoline fueled Gensets Disconnect the fuel line from the genset and securely 5 4 plug the end of the fuel line to prevent leak age or an accumulation of explosive gaso line vapor LPG fueled Gensets Close the fuel shut off valve s at the LPG container s and move the vehicle outside and away from below grade spaces where LPG could ac cumulate To purge most of the LPG from the fuel line and genset run the genset if it starts until it runs out of fuel LPG con tainer valve closed To purge some of the remaining LPG press the regulator primer plunger Figures 8 18 and 8 19 on Pages 8 22 and 8 23 while cranking the engine for 10 seconds Disconnect the fuel line
124. n Figure 8 3 illustrate typical mounting locations Exhaust gas presents the hazard of severe personal injury or death Do not mount any portion of the exhaust system into the ap proach or departure angle unless it is adequate ly protected Use only Onan specified exhaust equipment with the genset Use a sufficient number of hangers to prevent dislocation of the system Do not terminate the exhaust tailpipe under the fuel Excessive exhaust back pressure tank fill soout to prevent spilled fuel from being ig can cause engine damage If tailpipe deflector is nited by a hot tailpipe used make sure it is large enough to prevent back pressure SEALED WINDOW TAILPIPE RV REAR VIEW L 3 a DEPARTURE NL cael ANGLE 7 WE yu Der GROUND ANGLE SKID BARS SHADED ZONE IS AREA _ LE LOWER OF RECOMMENDED CLEARANCE LINE TAILPIPE INSTALLATION 6 IN 152 4 mm TAIL PIPE NO OPENINGS INTO THE VEHICLE S INTERIOR INCLUDING ENTRY DOORS ARE ALLOWED IN THE SHADED AREA FIGURE 8 3 DEPARTURE ANGLE AND RAMP ANGLE IGNITION SYSTEM The ignition system consists of the magneto as sembly ignition coil spark plug and ignition wiring 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 pro ceeding to the Magneto Assemb
125. nel with knowledge of fuels electricity and machinery haz ards should perform service procedures Review safety precautions on page iii TABLE 6 5 SPEC A CONTROL TROUBLESHOOTING BATTERY CHARGE MODE Possible Cause Corrective Action Page Low Battery 1 Weak or discharged battery due to Replenish electrolyte and recharge Voltage Low electrolyte level in battery battery Long periods of non use Connect a separate battery charger to Improperly wired battery bring battery up to full charge Load connected to battery while set Reconnect and check battery connec is turned off tion Too much DC load on genset Disconnect load and recharge starting battery battery Remove other DC loads from genset starting battery Genset charging circuit not Check all wiring connections between functioning due to the generator B1 B2 windings and the a Open in circuit between generator Battery B connection including all B1 B2 winding and battery B connections to the diode bridge CR1 b Open charging resistor R 1 and battery charge resistor R1 c Diode bridge CR1 defective Remove wires from the charge resistor d Generator B1 B2 defective R1 and measure its resistance A normal reading is 4 to 6 ohms Refer to diode bridge CR1 test Refer to generator test section NOTE The battery charging circuit is designed to maintain the genset starting battery The charging cir cuit will not charge a low or bad
126. ng cranking e An LPG carburetor and air filter Before servicing the LPG fuel system check to see that the LPG container s is at least half full The problem may be that there is not enough LPG to provide the rate of vaporization necessary to meet genset demand especially on cold days and or when the genset is under full load Carefully follow the instructions for disconnecting the LPG fuel line from the genset under Disconnect ing Set from Vehicle Systems on Page 5 4 LPG sinks and can accumulate in explosive concentrations Before disconnect ing the LPG fuel line close the fuel shutoff valve s at the LPG container s and move the vehicle outside and away from pits or base ments or other below grade spaces where LPG could accumulate oee the instructions on how to remove and replace the carburetor under the subheadings Air Filter and Preheater Assembly on Page 8 11 and Carburetor and Intake Manifold Assembly on Page 8 12 Refer ences to preheaters and chokes are not applicable to LPG carburetors Demand Regulator with Automatic Priming Solenoid oee Figure 8 18 The demand regulator assembly supplies fuel to the carburetor It is usually not the cause of fuel system problems All other possible causes should be checked out before adjusting or replacing the demand regulator assembly OUTLET HOSE FITTING INLET HOSE FITTING ka AUTOMATIC PRIMING HOSE FITTING LOCK OFF ADJUSTMENT SCREW Beginning Spec E
127. ngs If the rotor tests good proceed to Stator Test follow ing Stator Test The stator can be tested for grounded or open wind ings using an ohmmeter Testing for shorted wind ings requires a digital type ohmmeter that can read to within 0 01 ohms Figure 9 9 on Page 9 11 shows the stator removed from the generator for testing The stator can be tested without removing it from the generator To perform the stator test carefully remove both connector plugs from the stator Ground Test Set the ohmmeter for the highest re sistance scale and then connect one test prod to the generator housing or stack if stator is removed Touch the other test prod see Figure 9 9 on Page 9 11 to the terminals specified in Table 9 1 on Page 9 11 A reading of less than one megohm indicates a ground Replace a grounded stator with a new stator 9 10 51765 15 FIGURE 9 8 OPEN OR SHORTED ROTOR TEST TABLE 9 1 STATOR GROUND TEST test prods to the terminals specified in Table 9 2 A reading of less than the value shown in Table 9 2 at TEST POINT OHMMETER READING a 77 F 25 C indicates a shorted winding If stator T1 to ground INFINITY tests indicate a shorted winding replace the stator T2 to ground INFINITY If stator tests good check stator connectors and B1 to ground INFINITY leads for continuity and for good electrical connec B2 to ground INFINITY tion with the stator terminals Q1 to ground INFINITY Q2 to ground INFINI
128. nic voltage regulator takes power from the stator excitation winding rectifies it and feeds it into the field winding through the brushes and slip rings The regulator continually measures the output of the power wind ing and regulates how much current should be fed into the field winding to maintain the proper output at various load levels Circuit Breaker CB1 AC output from the generator is supplied to a circuit breaker located along side the control panel The circuit breaker protects the generator windings from an overload or short circuit Wiring Harness A wiring harness is provided for connecting the gen 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 that must be provided by the RV manufacturer or genset installer A 1 2 inch conduit elbow is pro vided to facilitate installation The load wire conduc tor is black the neutral conductor is white and the ground conductor is green GENERATOR OPERATION Refer to the schematic in Section 12 Wiring Sche matic Diagram that corresponds to your genset to follow the generator operating description Always refer to the specific schematic that corresponds to the model and spec number of the genset when troubleshooting problems When the Start Stop switch is placed in the START position the rotor begins to turn and the field wind Ing is momentarily connected to the battery
129. nnection If an abnormal reading is obtained check the conti nuity between the connector pins and the switch Use an ohmmeter with pointed test leads to pierce the insulation at the back of the switch on Spec A models BEGIN SPEC B J1 CONNECTOR SPEC A P1 CONNECTOR Q gt 7 4 ON OW OW O START STOP SWITCH 51 1899 45 1899 45 FIGURE 7 3 START STOP SWITCH 7 5 Start Solenoid K1 A check can be made by measuring the resistance of the coil terminals I and S Figure 7 4 With the harness leads removed the coil should read be tween 3 and 5 ohms If an abnormal reading is mea sured replace the Start Solenoid If the coil checks good and a problem with the sole noid is still suspected remove the leads from the side terminal posts An open circuit should be mea sured between the side terminal posts with the coil de energized With 12 VDC applied across the coil I and S terminals the solenoid should be ener gized and continuity should be measured between the side posts Control Assembly A1 The Control Assembly consists of a printed circuit board with components and relays that are potted encapsulated in a nonconductive material to pro tect them from moisture It is difficult to isolate indi vidual components on the control assembly for test ing Use Section 6 Troubleshooting to identify pos sible problems in the control circuit
130. nstallation Lubricate the o ring on the bearing Verify that the brushes are held inside the holder with a piece of wire and that the brush block is loose See Figure 9 4 on Page 9 6 Install the endbell onto the rotor bearing and secure to the stator housing with the endbell mounting screws The brushes will be damaged during assembly if not held off the slip rings and the brush block is loose enough to clear the bearing Make certain wire is in place before installing the generator end bell Center the brush block on the slip rings and tighten the mounting screws Remove the piece of wire holding the brushes off the slip rings Connect the F2 lead wire to the outer brush terminal near bearing and the F1 lead wire to the inner brush terminal Connect the magneto assembly wires 9 7 10 11 12 13 fan hub then secure the fan hub assembly and tighten the rotor through bolt to the specified torque Spec A Assemble the starter bracket to the starter Install the scroll housing Begin Spec B Install the air housing assembly Remove the wooden block from under the sta tor housing and slowly lower the genset Install the muffler assembly and make sure new gaskets are used Install the generator and engine to base mounting bolts use anti seize lubricant on bolt threads Secure all hardware to the specified torque Reconnect the load leads the fuel pump leads and ground terminal block or connec
131. nting for the proper speed Governor Adjustments This procedure is used to adjust the governor to bring frequency and voltage within the specified range and to set governor stability Contact with moving parts can cause severe personal injury Keep clothing hair jewelry and fingers clear when adjusting the governor A hot genset can cause severe burns Always allow the genset to cool before touching any components or removing any parts An accurate voltmeter frequency meter and a load bank capable of providing a load of 4000 watts are needed to properly set the governor adjustments Equipment required for governor adjustment in cludes e Digital frequency voltmeter with 0 3 frequen cy accuracy 0 5 voltage accuracy Recom mended Fluke 8060A or 85 series e Digital ammeter Recommended Beckman 4410 e Variable load bank with 4 kW capacity Connect an accurate voltmeter ammeter and fre quency meter to the generator A small speed drop not noticeable without instruments will cause an objectionable voltage drop If a carburetion problem is suspected make certain that the carburetor is adjusted correctly before at 6 9 tempting to adjust the governor see the Gasoline Fuel System section on Page 8 11 A binding governor shaft governor linkage or car buretor throttle will cause hunting Also a fouled spark plug can cause missing and hunting Check for these conditions before making governor adjust
132. o Gasoline Fuel System for adjustments Measure voltage between fuel pump connector and ground with the engine cranking If B voltage is not present proceed to 4b If voltage is present min 6 VDC fuel pump is defective Check continuity between control assembly and fuel pump If connections are good and voltage was not measured in 4a replace control assembly A1 Refer to LPG Fuel System for service procedures Check governor arm movement See Governor section 7 Check oil level and add oil if low 70 Check low oil level switch Spec A Start Field Flash Mode Holding the Start Stop switch S1 in the Start position activates the following field flash circuit e Battery positive B is supplied to the control assembly A1 and the voltage regulator VR1 at pin 7 From pins 9 and 10 of the voltage regulator excitation voltage is sensed through the brushes to the rotor field winding e The excitation voltage flashes the generator field winding to ensure that there is adequate magnetism to induce generator voltage buildup START STOP SWITCH S1 START BATTERY BT1 CONTROL ASSEMBLY A1 j FUSE F1 P1 CONNECTOR P4 CONNECTOR 7 fi BRUSH BLOCK 9501 Y Ne lt 7 1 GOO 9 9 a 2V VOLTAGE REGULATOR VR1 J4 CONNECTOR 52017 25 FIGURE 6 5 SPEC A START FIELD FLASH MODE 6 8 Many troubleshooting procedures pre
133. o lift or move the set The genset is heavy and can cause severe personal injury if dropped during remov al Use the recommended removal procedures and keep hands and feet clear while removing mounting bolts Make certain that all vehicle systems have been disconnected before per forming this procedure 5 5 Park the vehicle on a level surface which can sup port the forklift Move the transmission to PARK lock the brakes and remove the ignition key Do not move the vehicle during this procedure Dropping the genset can cause se vere personal injury or death Make sure no one moves the vehicle during this procedure and that the procedure is performed very carefully and only as instructed Compartment Mount 1 Use a forklift to support and move the genset 2 Make sure that the genset is adequately sup ported before removing any of the mounting bolts 3 Remove all mounting bolts then slide the gen set out of the compartment and onto the forklift Slowly lower the genset before moving it to the service area Under Floor Mount 1 Use a forklift to support the genset at the points shown in Figure 5 3 Raise the lift so it contacts the bottom of the genset housing then place slight upward pres sure on the set Make certain that the genset is fully supported by the lift before continuing Loosen bolts between genset base pan and side mounting panels loosen bolts about six turns 4 Loosen bolts se
134. oduced in the B1 B2 windings for the battery charge circuit in the 50 Hz mod els only The 60 Hz Spec B models do not have battery charging e The AC output voltage from the B1 B2 winding is converted to DC voltage when it passes through the battery charger assembly VR2 The 12 volt DC output ten ampere maximum is used to charge the battery and supply power to the control assembly A1 and its outputs BATTERY CHARGER ASSEMBLY VR2 STATOR u EX BATTERY BT1 ter EP FUSE F1 p REMOTE CONTROL START STOP SWITCH 1 CONTROL ASSEMBLY A1 J1 CONNECTOR P1 CONNECTOR 52017 45 FIGURE 6 13 SPEC BATTERY CHARGE MODE 50 Hz MODELS ONLY 6 24 Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only qualified service personnel with knowledge of fuels electricity and machinery haz ards should perform service procedures Review safety precautions on page iii TABLE 6 11 BEGIN SPEC B CONTROL TROUBLESHOOTING BATTERY CHARGE MODE Possible Cause Corrective Action Page Low Battery 1 Weak or discharged battery due to Voltage No battery charging Spec B 60 Hz models require a battery Low electrolyte level in battery charger These models do not have a Long periods of non use battery charge winding Improperly wired battery Replenish electrolyte and recharge Load connected to battery while battery genset is turned off Conne
135. old assembly 1 Disconnect the fuel line and plug it to prevent fuel spill and fuel vapor accumulation Begin Spec B models Disconnect the fuel solenoid leads 2 Remove the air filter assembly 3 Remove the carburetor mounting screws from the left side of the endbell Close the choke and throttle plates by rotating their shafts in a counterclockwise direction Pull the carburetor with its gaskets out slowly Disengage the governor and choke linkages from the carburetor it may be necessary to re move the automatic choke assembly mounting screw to remove its linkage Remove the intake manifold mounting nuts and lift off the manifold Remove the intake man ifold gasket and plug the intake port with a rag to prevent loose parts from accidentally enter ing the port Assembly Perform the assembly steps in reverse order of disassembly Use new gaskets between the intake manifold and the engine between the in take manifold and the carburetor and between the carburetor and the air cleaner adapter Do not use sealer on the gaskets Tighten the intake manifold capscrews to the specified torque CARBURETOR ASSEMBLY AIR FILTER MOUNTING ASSEMBLY INTAKE ELBOW FIGURE 8 9 CARBURETOR AND INTAKE MANIFOLD ASSEMBLY 8 12 Carburetor Replacement Beginning Spec D Other than turning the altitude adjust knob shown in Figure 8 10 which changes the main fuel mixture within a limited range fuel mixture adjus
136. old to the muffler 6 Remove the screws securing the muffler to the base Remove the muffler and the exhaust gasket SUPPORT 51170 55 SHORT RADIUS ELBOW SPEC A MODELS HANGER BRACKET IF REQUIRED DUE TO i LENGTH OF TAILPIPE ga SUPPORT 51170 75 BEGIN SPEC MODELS TAILPIPE SUPPORT FIGURE 8 2 COMPARTMENT MOUNT EXHAUST SYSTEM Muffler Assembly Obtain the required replacement parts including a new exhaust gasket Install the muffler in reverse order of removal 1 Install a new exhaust gasket Secure the mounting hardware to the specified torque Exhaust gas can cause severe per sonal injury or death To prevent exhaust leaks always install a new exhaust gasket and re place corroded or worn clamps straps and hardware before occur 2 Install the genset housing and reinstall the gen 3 If replacing the original exhaust tailpipe refer to the Recommendations section 4 Attach the exhaust pipe to the exhaust outlet using a U bolt type automotive muffler clamp marked 1 3 8 inch I D Spec or 1 1 4 inch I D Begin Spec B 5 Attach an automotive type tailpipe hanger ev ery 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 being pushed up under the vehic
137. operly but run lamp does not illuminate Lamp internal to switch is burned out If remote switch functions properly for starting and stopping genset but meters and run lamp do not operate and step 1 checks OK control assy A1 defective Too much DC load over 2 amps connected to the remote output 6 23 Check fuel and oil level and refill if low Refer to choke section for adjustments Remove any objects or debris that may restrict airflow Make sure fuel system is installed correctly Refill tank with fresh fuel 8 17 Check continuity between remote control and control assembly A1 Replace time meter Connect a voltmeter between the positive terminal on battery charge meter and ground Use the following to determine fault If reading equals battery voltage minus 10 volts battery condition meter is defective If reading does not equal battery voltage minus 10 volts zener diode is defective Replace remote Start Stop switch S2 Check remote running output voltage approximately 12 VDC during run condition from control assembly J2 5 to ground and from J2 6 to ground If voltage is not present replace control assembly A1 If voltage is present check continuity of remote control wiring Turn off the genset disconnect the remote control and check for shorts or too many remote accessories Begin Spec B Battery Charge Mode 50 Hz Only With the genset running AC voltage is pr
138. or flat spots on the sleeve tip If the gov ernor sleeve gear or flyweights are worn or other wise damaged replace them To disassemble remove the snap ring from the gov ernor center pin and slide the governor gear assem bly off the mounting shaft Be careful not to lose the outer washer See Figure 10 14 To install the gov ernor assemble in reverse order of removal See in set drawing Figure 10 14 for position of flyweight and sleeve The snap ring can be installed by plac ing it over the end of the shaft then use the sleeve to push it into position To remove the governor shaft remove the retainer clip outside the block and then lower the governor shaft into the crankcase 10 8 KNOCKOUT CRANKCASE COVER GASKET 1113 18 FIGURE 10 13 COVER SNAP RING RUBBER WASHER BEGIN SPEC E FLYWEIGHTS FIGURE 10 14 GOVERNOR CAMSHAFT TAPPET AND BALANCER REMOVAL 1 Place the engine cylinder down on a clean flat surface Figure 10 15 2 Carefully pull out the camshaft assembly 3 Remove the valve tappets Mark the tappets because tappet clearances differ and the tap pets must be reassembled in their original posi tions 4 Pull out the balancer shaft assembly 5 For installation apply oil to the tappets and the tooth surface of the gears Align the marks on the cam gear and crank gear and also on the balancer gear and crank gear as shown in Fig ure 10 16 PIST
139. or re moval or installation can cause damage to the bearing and the collector ring Do not heat rotor bearing MEASURE SPACE BETWEEN BEARING AND COLLECTOR RING ASSEMBLY 1216 15 FIGURE 9 12 ROTOR BEARING SPACING 2 Use a small puller with grips that will fit between the bearing and the collector ring assembly Figure 9 13 or use an arbor press to remove the bearing Cover the end of the rotor shaft J with a steel plate to prevent deformation of the lt shaft during removal NOTE Inspect the rotor shatt for dirt or corro sion If necessary clean with emery cloth before installing new bearing 3 Place the rotor engine end down in an arbor press Protect the end of the rotor shaft taper by placing it on a flat steel plate 4 Refer to the measurement taken in Step 1 Press the bearing onto the rotor shaft press e PULLER on inner race only until it rests at the same distance from the collector ring as the original 01239 18 bearing Check the bearing seal for damage af ter installation FIGURE 9 13 ROTOR BEARING REMOVAL 9 14 10 Engine Block Assembly INTRODUCTION This section covers service procedures for the en gine block assembly A leak down test can be per formed to determine the condition of the engine Use the procedures in the following section to per form the leak down test Performing any major service will require genset re moval from the vehicle see Set Removal Guide lines on
140. ose for fuel connections at the genset ENGINE EXHAUST IS DEADLY Learn the symptoms of carbon monoxide poisoning in this Manual Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector The exhaust system must be installed in accordance with the genset Installation Manual Do not use engine cooling air to heat the vehicle interi Or Make sure there is ample fresh air when operating the genset in a confined area MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Do not wear loose clothing or jewelry near moving parts such as PTO shafts fans belts and pulleys Keep hands away from moving parts Keep guards in place over fans belts pulleys etc BATTERY GAS IS EXPLOSIVE Wear safety glasses and do not smoke while servic ing batteries When disconnecting or reconnecting battery cables always disconnect the negative battery cable first and reconnect it last to reduce arcing 2 Redistribution or publication of this document by any means is strictly prohibited 1 Introduction This is the service manual for the KY 4000 Series MicroLite generator sets gensets Read and carefully observe all of the instructions and precau tions in this manual Improper service or parts replace ment can lead to severe personal injury or death and to damage to equipment and property Ser vice personnel must be qualified to perform electric
141. power the control assembly A1 fuel pump E2 the remote con trol and to prevent discharge of the genset starting battery during genset operation This output is not sufficient to charge a low or dead battery The control assembly A1 monitors this voltage as part of the start disconnect function e The quadrature winding Q1 Q2 output voltage is fed to the voltage regulator VR1 where it is rectified into DC voltage and fed back to the rotor through the brushes to cause further voltage buildup Voltage buildup is con trolled by the voltage regulator that senses the AC output voltage The regulator continually measures the output voltage 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 voltage is obtained e The AC windings T1 T2 provide the 120 VAC output voltage through the circuit breaker CB1 BRIDGE RECTIFIER CR1 BATTERY CHARGE RESISTOR 1 T5 RN _ START STOP SWITCH 1 CONTROL ASSEMBLY A1 P1 CONNECTOR VOLTAGE REGULATOR 1 STATOR CONNECTORS gt gt P4 CONNECTOR BRUSH L2 NEUT BLOCK O GND O 120 VAC CIRCUIT BREAKER CB1 L1 LOAD gt gt O Lu FIGURE 6 15 SPEC A GENERATOR OUTPUT MODE 6 29 Spec B Generator AC Output Mode When the engine starts and begins to come up to speed AC voltage is produced in the battery charge winding B1 B2 50 Hz only the quadr
142. problem with the preheat door assembly is suspected refer to Sec tion 9 Generator for details on removing the air housing assembly The preheater door should be fully open at 70 F 21 C and should align with the top of the housing Rotate the door down over the round air inlet open ing in the housing then release it The door should move freely back to the open position If the door does not move freely clean the spring and housing with low pressure compressed air and retest 8 11 SPEC A MODELS AIR FILTER TOP OF HOUSING HOUSING PREHEAT DOOR ROUND AIR INLET OPENING FS1866s BEGIN SPEC B MODELS TOP OF PREHEAT HOUSING DOOR FOAM BLOCK 60 HZ ONLY AIR FILTER FILTER HOUSING COVER M1896 7 COVER FIGURE 8 8 AIR FILTER AND PREHEATER ASSEMBLY Carburetor and Intake Manifold Assembly This assembly consists of the carburetor and the in take manifold assembly See Figure 8 9 It is easier to disconnect the carburetor linkages if the genset housing is removed Fuel presents the hazard of fire or explosion that can cause severe personal injury or death Eliminate all possible ignition sources such as open flame sparks cigarettes pilot lights arc producing equipment and electrical switches from the work area and rooms with common ventilation Keep a type ABC fire extin guisher nearby Disassembly Use the following procedures to re move the carburetor and intake manif
143. reinstalla tion 5 Remove the muffler exhaust mounting bolts from the base assembly 6 Remove the mounting screws from the voltage regulator the control panel and the solenoid control module bracket 7 Lift the solenoid control module bracket and re move the ground terminal block from the left side of the base assembly Disconnect the fuel pump leads Disconnect the AC ground neu tral L2 and load L1 leads if they were not dis connected during genset rernoval STATOR HOUSING 7 Mf OAKS amp gt S ROTOR ENDBELL FAN HUB HEEL THRU BOLT 12 ASSEMBLY ASSEMBLY SCROLL HOUSING G1247s FIGURE 9 1 SPEC A GENERATOR COMPONENTS 9 3 STATOR HOUSING oe e B FAN HUB WHEEL WASHER ASSEMBLY AIR HOUSING ASSEMBLY G1247s FIGURE 9 2 BEGIN SPEC B GENERATOR COMPONENTS 9 4 8 Connect a lifting hoist to the lifting eye on the 8 Remove the air housing assembly from the top of the endbell and slowly raise the genera endbell Figure 9 2 on Page 9 4 tor end of the genset so the bottom of the end bell is higher than the side of the base assem Spec A and Begin Spec B bly Place a wooden block under the stator 9 Secure the fan hub assembly and remove the housing to support the genset Use the endbell rotor through bolt and washer and engine lifting eye if the genset is to be 10 Remove the alignment key from the end of the moved away from the base
144. rgizes the ignition enable circuit and grounds the magneto assembly G2 output This causes the engine to stop running The Stop posi tion also activates the remote stop latch feature pre venting restart At the same time the fuel pump is de energized L PG models the fuel shutoff solenoid E2 is de en ergized stopping fuel flow to the carburetor CONTROL COMPONENT TESTS The following control component checks can be made to verify if components are defective Discon nect the starting battery cables negative cable first before performing these tests Accidental starting or electrical shock can cause severe personal injury or death Disconnect both genset starting battery cables before performing maintenance Re move the negative battery cable first and connect it last to reduce the risk of arcing Start Stop Switch 1 Disconnect the P1 or J1 for Spec B connector from control assembly A1 See Figure 7 3 Continuity should be measured between pin 1 and pin 3 pin 13 and pin 7 for Spec B when the switch is held in the Start position Continuity should be measured be tween pin 2 and pin 3 pin 1 and pin 7 for Spec when the switch is held in the Stop position An open circuit should be measured between pins 1 2 and 3 13 7 and 1 Spec B when the switch is in the center Run position If the switch tests good also check the control con nector P1 to J1 connections to make sure they are making a good co
145. rminal and a clean ground point on the intake manifold Disconnect the spark plug lead from the spark plug and disconnect the primary lead from the terminal on the coil Remove the ignition coil mounting screws and remove the ignition coil from the genset for testing See Figure 8 5 1 Inspect the terminal and leads for signs of cor rosion or looseness and look for cracks or other damage Look for evidence of electrical leak age around the high tension connection indi cated by carbon tracking Replace a coil with any defects 2 Measure the primary winding resistance Con nect one ohmmeter lead to the primary terminal and the other lead to the ground lead ring termi nal The resistance should be approximately 0 5 ohms at 75 F 24 C Replace the coil if a high or low reading is measured 3 Measure the secondary winding resistance Connect one ohmmeter lead to the spark plug connector inside the boot and the other lead to the ground lead ring terminal The resistance should be approximately 1 100 ohms at 75 F 24 C Replace the coil if a high or low reading is measured If the coil windings check good proceed to the Igni tion Wiring check Ignition Wiring The ignition wiring consists of the following e One ground wire connected to the ignition coil and one ground wire connected to the magneto assembly 8 7 e One wire from the magneto to the ignition coil primary e One ignition enable wire from the con
146. rt solenoid Test start solenoid K1 Test Start Stop switch 51 Measure voltage between start solenoid terminal I and ground with switch 51 held in the Start position If voltage is not present and continuity and battery check OK Cont assy A1 is defective Check continuity between starter lead on start solenoid S 4 1 ohm Check wiring continuity between battery B and the start solenoid BAT Measure voltage between starter terminal and ground with switch S1 held in the Start position If voltage is not present and continuity checks OK start solenoid K1 is defective If voltage is present in step 4c starter is defective Check wiring continuity between control assembly A1 and remote otart Stop switch Test remote Start Stop switch Begin Spec B Start Ignition Mode Holding the Start Stop switch S1 in the Start position activates the following ignition circuit e Control assembly A1 enables the ignition circuit to open a ground path through the control assembly to the magneto assembly G2 so that output from the magneto will energize the ignition coil T1 e With the engine cranking a permanent magnet in the flywheel rotates at the proper time past the magneto to induce a voltage at the ignition coil T1 that fires the spark plug E1 for ignition e Battery positive B is supplied to fuel pump E2 fuel shutoff solenoid E3 and regulator K2 on LPG mod
147. rtz 36 16 4 15 7 33 15 0 14 3 3600 rpm 3000 rpm 3600 rpm 3000 rpm load 0 29 gph 1 1 0 21 gph 0 8 1 5 lbs h 0 7 kg h 1 1 Ibs h 0 5 kg h Half load 0 48 gph 1 8 0 37 gph 1 4 2 4 Ibs h 1 1 kg h 2 2 Ibs h 1 0 kg h Full load 0 71 gph 2 7 0 58 gph 2 2 3 1 Ibs h 1 4 kg h 2 9 Ibs h 1 3 kg h ENGINE 1 Cylinder 4 Cycle Spark Ignited OHV Air Cooled Bore 3 11 inch 79 mm 3 11 inch 79 mm Stroke 2 44 inch 62 mm 2 44 inch 62 mm Displacement 18 5 inch 304 cc 18 5 inch 304 cc Compression 8 51 Oil Capacity Beginning Spec 1 6 quart 1 5 l Oil Capacity Spec A 1 7 quart 1 61 1 7 quart 1 6 Intake Valve Clearance Cold 0 002 inch 0 05 mm 0 002 inch 0 05 mm Spark Plug Gap 0 025 inch 0 64 mm 0 020 inch 0 51 mm Spark Plug Tightening Torque 13 lbs ft 17 N m 13 lbs ft 17 N m ema magneto type gni 25 BIDC non adjustable 25 BIDC non adjustable LPG Vapor 9 to 13 inch 229 to 330 mm Supply Pressure Range W C water column DC SYSTEM Nominal Battery Voltage 12 volts 12 volts Minimum Battery Cold Cranking Capacity Above Below Freezing 360 450 amperes 360 450 amperes Maximum Regulated Voltage Bat i5 meros tery Charging Current p Exhaust Valve Clearance Cold 0 002 inch 0 05 mm 0 002 inch 0 05 mm i 0 10 amperes See Periodic Maintenance in the Operator s Man
148. sent hazards that can result in severe personal inju ry or death Only qualified service personnel with knowledge of fuels electricity and machinery haz ards should perform service procedures Review safety precautions on page iii TABLE 6 3 SPEC A CONTROL TROUBLESHOOTING FIELD FLASH MODE Possible Cause Corrective Action Page Engine Starts 1 Low oil level 1 Check oil level and add oil if low But Stops 2 Defective low oil level switch 2 Disconnect low oil level switch and When Start check set operation Replace if defective Switch Is 3 No field flash voltage due to 3a Check wiring continuity to the brush Released a Open circuit in wiring block F1 F2 voltage regulator VR1 b Brushes not making good contact control assembly A1 and generator with slip rings B1 B2 and Q1 Q2 windings Check c Slip ring surface is rough or pitted connections of P5 and P6 connectors on the generator housing 3b Check brushes for wear and for contact with the slip rings 3c Check slip rings 4 Defective generator control assembly 4 Perform field voltage test or voltage regulator Spec A Run Mode When the engine starts release the Start Stop switch and it will return to the center Run position The following events occur e Control assembly A1 opens the circuit to the start solenoid K1 which opens the circuit to the starter motor M1 to stop cranking Control assembly A1 also opens the field flash circuit
149. t energized Faulty fuel solenoid priming solenoid or regulator on LPG models Governor linkage stuck or binding Oil level switch 52 Spec B F if applicable closed due to a Low oil level b Defective low oil level switch 1a Add fuel if tank is low 1b Open fuel supply valve if equipped 1c Replace clogged fuel filter and check fuel supply for contamination Refer to gnition System for test and service procedures Refer to Gasoline Fuel System for adjustments Measure voltage between fuel pump connector and ground with the engine cranking If B voltage is not present proceed to 4b If voltage is present min 6 VDC fuel pump is defective Check continuity between control assembly and fuel pump If connections are good and voltage was not measured in 4a replace control assembly A1 Measure voltage at fuel shutoff sol E3 terminals with the engine cranking If B voltage is not present check the wiring connections and control assembly A1 output test If voltage is present min 6 VDC and engine is not receiving fuel fuel shutoff solenoid is defective Refer to LPG Fuel System for service procedures Check governor arm movement See Governor section 8a Check oil level and add oil if low 8b Check low oil level switch Begin Spec B Start Field Flash Mode Holding the Start Stop switch S1 in the Start position activates the following field flash circuit e Ba
150. t also has molded slip rings and a pressed on bearing The entire as sembly is connected directly to the tapered engine crankshaft by means of a through bolt The rotor is supported by the engine bearing and by the endbell The rotor field winding provides the rotating mag netic field which in turn generates the voltage in the stator windings to power the connected loads The magnetic field is established by a DC current flow ing from the brushes through the slip rings and the field winding 9 1 Generator Cooling Cooling air for the generator is provided by a centrif ugal fan mounted on the rotor shaft next to the bear ing A portion of the airflow from the fan is directed into the generator Airflow through the generator cools the rotor and stator windings Brushes and Brush Block The brush block is a one piece molded part that mounts on the endbell There are two carbon brushes in the brush block that make contact with the slip rings on the rotor The brushes provide the path for the controlled DC current from the regulator to the rotor field winding Each brush is kept in con tact with a slip ring by a spring located inside the brush block behind the brush The spring exerts the right amount of pressure to provide good contact and long brush life Electronic Voltage Regulator VR1 The electronic voltage regulator controls the output of the generator so the voltage remains constant under any load condition The electro
151. t be placed no closer than 3 inches 76 mm from combustible material wood felt cotton organic fibers etc or be so located in sulated or shielded that it does not raise the temper ature of any combustible material more than 117 F 65 C above the ambient air inlet temperature The exhaust system must extend a minimum 1 inch 25 mm beyond the perimeter of the vehicle Do not terminate the exhaust tailpipe under the vehicle Be aware that any vent window storage compartment or opening that can be opened and that is not per manently sealed from the vehicle living space can be an avenue for carbon monoxide The tailpipe must not terminate so that any vent window or opening into the living area is within a six inch 152 4 mm radius of the tail pipe as shown in Figure 8 3 on Page 8 5 Exhaust gas presents the hazard of severe personal injury or death Do not termi nate an exhaust pipe under the vehicle The tail pipe must not terminate so that any vent win dow or opening into the living area is within a six inch 152 4 mm radius of the tail pipe as shown in Figure 8 3 on Page 8 5 Keep all openings closed when the genset is running To reduce the chance of damaging the tailpipe and emitting exhaust gases under the vehicle make certain that no part of the exhaust system intrudes into the departure angle or approach angle of the vehicle unless it is protected by a skid bar or other protection device The shaded areas i
152. ter to shop air and set calibra tion Perform the leak down test according to the manufacturer s instructions Secure the fan wheel to prevent the piston from moving during this test Screw the air fitting into the spark plug hole At tach plug fitting to tester The tester needle indicates the percentage of cylinder leakdown The following describes the general condition of the engine e 0 10 Percent leak down Excellent condi tion e 10 20 Percent leak down Normal condi tion e 20 30 Percent leak down Nearing ser vice limit If leakage is greater than 30 percent the en gine could need major service work With the tester still connected listen for air leakage at the points listed in Table 10 1 on Page 10 2 and note probable cause of the engine prob lem AIR LEAKAGE GAUGE REGULATOR M1907s FIGURE 10 1 TYPICAL LEAK DOWN TESTER TABLE 10 1 LEAK DOWN CHECK POINTS AIR LEAKAGE AT PROBABLE CAUSE 1 Dipstick hole or 1a Broken Ring Breather valve 1b Worn cylinder bore rings 2 Carburetor throat Intake valve stuck Broken intake valve Damaged intake valve seat OIL LEVEL SWITCH 3 Muffler Exhaust Exhaust valve stuck pipe outlet open Damaged exhaust valve Damaged exhaust valve seat OIL PAN OIL PAN AND OIL LEVEL SWITCH OIL PLUG Remove the oil plug and drain the crankcase oil FIGURE 10 2 OIL PAN REMOVAL SPEC A Remove the oil pan mounting bolts and pan Figure
153. the adjustment plate two marks clockwise from the 70 F 21 C position marked on the housing Move the choke lever back and forth to check for free movement Verify that the choke does not bind or stick CHOKE LINKAGE CHOKE COIL HOUSING SIGHT WINDOW ADJUSTMENT SCREW x gue N N ADJUSTMENT PLATE FS1867s FIGURE 8 15 CHOKE ASSEMBLY Bimetal Coil Replacement After making the choke adjustment start the genset and observe en gine operation If the choke does not open properly replace the bimetal coil in the choke housing as fol lows Refer to Figure 8 15 1 Remove the adjustment screw and washer from the choke coil housing 2 Remove the housing Straighten the tab from 8 18 the adjustment plate to release the bimetal coil Remove choke linkage from the bimetal coil and install linkage on the new coil Assemble the new coil to the adjustment plate and bend the tab on the adjustment plate to se cure coil Install choke coil housing and secure with screw and washer Perform the choke adjust ment procedure Fuel Filter Change the fuel filter at the interval recommended in the Operator s Manual or if performance prob lems occur and bad fuel is suspected Fuel presents the hazard of fire or explosion that can cause severe personal injury or death Do not permit any flame spark pilot light cigarette arc producing equipment elec trical swit
154. the return spring is unassembled A Place a 1 1 16 inch O D washer over the end of the shaft B With the chamfered side of the shaft hole facing up place a plastic retainer on the shaft and line up the hole with a hole in the shaft C Support the plastic retainer with a vise or other solid surface Using a 5 32 or 1 8 inch nail set and hammer drive in a new roll pin The pin should be driven about 1 10th of an inch 2 5 mm from the edge of the plastic retainer or in such a way that itis evenly spaced from each side D Place the spring cover over the top of the plastic retainer then place the return spring on top of the retainer E With a washer placed over the point of the plastic retainer push the metal retainer into the hole of the plastic retainer as far as it will go WASHER FLAT SPRING ROLL WASHER WASHER PIN CLUTCH amp SPLINE ASSEMBLY T METAL SPRING RETAINER amp WASHER ARMATURE MOUNTING M BRACKET BRUSH SPRING 171 16 INCH RETURN RETURN WASHER SPRING COVER THROUGH BOLT e 6 MAGNETIC HOUSING ES 1613 1s FIGURE 8 29 STARTER ASSEMBLY 8 30 1 Carefully mount the starter on the endbell and 3 Connect the positive cable to the starter ter tighten the mounting bolts to 30 33 Ib ft 41 45 minal Nm 4 Mount the housing on the genset and install the 2 Install the engine bracket to the engine and genset into t
155. tion also includes proper exhaust system installa tion and visual and audible inspection of the complete exhaust system at the start of each genset operation GENERAL After the genset has been serviced and reinstalled in the vehicle inspect the installation and test the genset to confirm that the genset will operate prop erly and produce its full rated load capacity Check each of the following areas before putting the gen set into service MOUNTING Examine all mounting bolts and supporting mem bers to verify that the genset is properly mounted All fasteners should be tightened securely to pre vent 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 1 RV WIRING Verify that all wiring connections are tight and installed properly Make certain that wires do not run over hot sharp or rough surfaces and are not kinked or worn Check each of these connections e Load wires Control wires e Ground strap e Battery cables INITIAL START ADJUSTMENTS Voltage frequency sensitive equip ment such as VCRs televisions computers etc can be damaged by power line frequency variations Some solid state devices are pow ered whenever connected to an AC outlet even if the device is not in actual operation For
156. tions Install the control panel on Spec A Install the voltage regulator and control assembly On Be gin Spec B models reconnect the start sole noid leads and the P4 and J1 connectors Inspect the assembly check all electrical and mechanical connections for correct fit and loca tion Place the enclosure cover on the genset and secure with the side mounting screws Begin Spec B 50 Hz models Connect the leads to the battery charger assembly mounted to the left side of the housing Install the genset in the vehicle and securely fasten all mounting screws and hardware Con nect the fuel line exhaust system and electrical systems in reverse order of disassembly Refer to Set Removal Guidelines on Page 5 2 for the recommended genset removal procedures Fill the crankcase with oil of the recommended classification and viscosity refer to the Opera tor s Manual GENERATOR TESTING This section covers test procedures for the rotor and stator windings Begin with the Field Voltage Test following to help locate possible problems Check all wire harness connectors and leads for continuity prior to generator testing Refer to Sec tion 12 Wiring Schematic Diagram Field Voltage Test Perform the Field Voltage Test if low or no generator output voltage is produced to confirm that field volt age is available to the rotor brushes through the SPEC A MODEL SHOWN FOR REFERENCE SEE FIGURE 6 2 FOR BEGIN SPEC B MODELS P4
157. tments should not be attempted Nor should the carburetor be overhauled Instead a malfunctioning carbure tor should be replaced Before replacing a carbure tor however make certain that e All other necessary engine and generator ad justments and repairs have been performed e The carburetor is actually malfunctioning by carefully following the troubleshooting proce dures in Section 6 Troubleshooting See the instructions on how to remove and replace the carburetor under the subheadings Air Filter and Preheater Assembly on Page 8 11 and Carburetor and Intake Manifold Assembly on Page 8 12 A throttle stop screw is provided for adjusting the closed position of the throttle plate to obtain prop er governor response when loads are being discon nected See Governor Adjustments on Page 8 9 To adjust the throttle stop screw 1 Connect a frequency meter and start and run the genset until it has warmed up to normal op erating temperature 2 Disconnect all loads Pull the governor linkage toward the front of the genset so that the tang on the throttle lever bears against the throttle stop screw Adjust the stop screw to obtain a frequency of 54 to 56 Hz on 60 Hz gensets 44 to 46 Hz on 50 Hz gensets 8 13 THROTTLE STOP SCREW THROTTLE LEVER RESISTANT PLUG OVER IDLE MIXTURE NEEDLE ALTITUDE SCALE FUEL SHUTOFF SOLENOID ALTITUDE ADJUST KNOB
158. to AVR pin 7 e Voltage from the battery used to power the control assembly A1 and the fuel pump E2 is replaced with output voltage from the generator charge winding B1 B2 Refer to Battery Charge Mode on page 6 12 The control assembly senses this output for the start disconnect function e Remote run output is energized through the control assembly A1 to power the time meter battery condition meter and run lamp in the optional remote control e Voltage from the generator Q1 Q2 winding provides power to the voltage regulator VR1 to use for supplying field current to the generator Refer to Generator AC Output Mode on page 6 29 START STOP SWITCH S1 RUN LAS BATTERY BT1 CONTROL ASSEMBLY 1 i d FUSE F1 A manan IF FUEL PUMP E2 gt L P1 CONNECTOR MAGNETO e IGNITION G2 IGNITION 2 COIL T1 A E SPARK PLUG E1 J1 CONNECTOR ES2017 3s FIGURE 6 6 SPEC A RUN MODE 6 10 Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only qualified service personnel with knowledge of fuels electricity and machinery haz ards should perform service procedures Review safety precautions on page iii Engine Starts and Runs Then Stops Set Restarts Immediately or After Cool Down Remote Control Run Lamp Time Meter or Battery Condition Meter Inoperative TABLE 6 4 SPEC A CONTROL TROUBLESHOOTING RUN MODE
159. trol as sembly to the magneto e One wire from the low oil level switch to the control assembly Spec A F only if applica ble e One high tension lead from the ignition coil sec ondary to the spark plug Refer to the figure in Section 12 Wiring Schematic Diagram that corresponds to your particular genset Do not disassemble the genset to check the mag neto wiring at this time Thoroughly inspect the ignition wiring for loose con nections and cuts or breaks in the insulation Test suspect leads for continuity with an ohmmeter Use a megger to check for breaks in the spark plug lead Also check control wiring for loose or grounded con nections If any problems are found correct them and repeat the ignition spark check If no problems are found proceed to the Magneto Assembly sec tion following SPARK PLUG BOOT SECONDARY GROUND LEAD PRIMARY TERMINAL ES1767 1s FIGURE 8 5 IGNITION COIL Magneto Assembly G2 The magneto assembly is a noncontact capacitive discharge breakerless type that is mounted to the generator endbell As the engine cranks two per manent magnets on the fan hub assembly pass very close to the magneto inducing a voltage in two coils in the magneto One coil charges a capacitor that discharges a voltage to the coil when triggered The other coil powers the circuit that triggers the charge circuit The discharge voltage from the mag neto approximately 16 to 60 VAC when measured
160. tructions Section 9 Generator for installing the fan hub as sembly Overheating can result in engine damage To avoid overheating never operate the genset with any of the cooling system com ponents removed EXHAUST SYSTEM The condition of the exhaust system is extremely critical on RV gensets because of the possibility of exhaust gases entering the vehicle The exhaust system must not have any leaks and it must be well supported The tailpipe must extend 1 inch 25 4 mm beyond the the perimeter of the vehicle and it must not terminate so exhaust can enter the ve hicle Exhaust gasses contain carbon monoxide an odorless and colorless gas that can cause severe personal injury or death Make certain that the exhaust components are in good condition and that there are no leaks The exhaust system consists of the muffler the ex haust pipe and the clamps and hangers needed for installation of the exhaust pipe On Begin Spec B the muffler has a flexible inlet pipe On Spec A the muffler has a flexible outlet pipe Figure 8 2 on Page 8 3 shows a typical exhaust system for a compart ment mount genset The following section covers the service procedures for the exhaust system The exhaust system must be serviced immediately if inspection reveals leaking joints or connections loose fasteners or broken or damaged compo nents Always replace worn components with new original equipment replacement parts Do not attempt to re
161. ts to be reused in car buretor cleaner Do not soak rubber or plastic parts or they will be damaged Follow the in structions on the cleaner container Most parts cleaning solvents are flammable and can result in severe per sonal injury if used improperly Follow the manufacturer s recommendations when cleaning parts Remove the carbon from the carburetor bore especially where the throttle and choke plates seat Be certain not to plug the idle or main fuel ports Blow out all passages with compressed air Do not use wire or any cleaning utensil that might widen critical passages Wear goggles while performing this procedure Examine any needle valves not included in the repair kit and replace if damaged Figure 8 13 Replace the float if it is damaged or con tains fuel Check the choke and throttle shafts for exces sive play in their bore Replace them if neces sary Replace old components with the new parts from the repair kit Carburetor Reassembly 1 If removed during overhaul slide in the throttle shaft and install the throttle plate using new screws if needed Center the plate in the throttle bore before tightening the screws To do this back the throttle stop screw out as nec essary and close the throttle lever Seat the plate by gently tapping it with a small screwdriv er then tighten the screws Install the choke shaft and plate in the same manner Screw in the main nozzle
162. ttery positive B is supplied to the control assembly A1 and the voltage regulator VR1 at pin 7 From pins 9 and 10 of the voltage regulator excitation voltage is sensed through the brushes at the rotor field winding e The excitation voltage flashes the generator field winding to ensure that there is adequate magnetism to induce generator voltage buildup START STOP SWITCH S1 p oce CONTROL ASSEMBLY A1 BATTERY BT1 j FUSE F1 L J1 CONNECTOR VOLTAGE REGULATOR VR1 V P4 CONNECTOR 3 Ox M OCON BRUSH BLOCK Oo Vat gt lt I x d A Ca 1230 IS p i i J4 CONNECTOR ES2017 2s FIGURE 6 11 SPEC B START FIELD FLASH MODE 6 20 Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only qualified service personnel with knowledge of fuels electricity and machinery haz ards should perform service procedures Review safety precautions on page iii TABLE 6 9 BEGIN SPEC B CONTROL TROUBLESHOOTING FIELD FLASH MODE Possible Cause Corrective Action Page Engine Starts 1 Low oil level But Stops 2 Defective low oil level switch When Start Spec B F if applicable Switch Is 3 No field flash voltage due to Released a Open circuit in wiring b Brushes not making good contact with slip rings c Slip ring surface is rough or pitted 4 Defective generator control assembly A
163. ual for oil filling instructions 2 1 2 2 3 Dimensions and Clearances All clearances are at 70 F 21 C room temperature All measurements are listed in inches with millimeter measurements in parentheses Measurements are for standard size parts FACTORY as ALLOWABLE DESCRIPTION MIN LIMIT Cylinder Head Cylinder Head Distortion 0 0157 0 4 Cylinder Block Cylinder Bore I D 3 1138 79 09 Crankshaft Connecting Rod Journal O D 1 3157 33 42 Side Clearance 0 0098 0 25 Connecting Rod Piston Pin Bore 1 0 0 7093 0 7096 0 7106 18 015 18 025 18 050 Large Bore I D 1 3189 1 3199 1 3204 33 500 33 525 33 540 Large Bore Clearance 0 0008 0 0022 0 0047 0 020 0 055 0 120 0 tig Side Clearance on Crankshaft 0 0157 0 0433 0 40 1 10 Camshaft Lobe Height Intake and Exhaust 1 3997 35 55 Piston Piston Skirt O D 3 1063 78 90 Pin Bore 1 0 0 7084 0 7087 17 994 18 002 3 1 All clearances are at 70 F 21 C room temperature All measurements are listed in inches with millimeter measurements in parentheses Measurements are for standard size parts FACTORY SPECIFICATION ALLOWABLE DESCRIPTION MIN MAX LIMIT Piston Pin Piston Pin O D 0 7087 0 7089 Between Pin Bosses 18 000 18 005 Piston Rings Top Compression Ring 0 0579 0 0587 Thickness 1 47 1 49 Second Compression Ring 0 0579 0 0587 0 0570 Thickness 1 4
164. ushed To a Open circuit between control assy 1b Check remote Start Stop switch Stop A1 and remote Start Stop switch b Remote Start Stop switch faulty Always remove the load a few 2 If genset can be stopped from remote Check wiring continuity between minutes before control but not from genset fault due to control assembly A1 and Start stopping the a Open circuit between control assy Stop switch S1 genset to allow A1 and Start Stop switch S1 Check Start Stop switch S1 cool down b Start Stop S1 switch faulty 6 15 Begin Spec B Start Cranking Mode Battery positive B is supplied to the control assembly A1 through control fuse F1 Holding the Start Stop switch S1 in the Start position activates control assembly A1 by closing the start signal input circuit While the Start Stop switch is held the control assembly supplies the following outputs e Battery positive B is supplied to the start relay coil K1 This energizes the start relay The start relay con tacts close supplying battery positive B to the starter motor B1 The starter begins to crank the engine to initiate starting BATTERY BT1 E FS FUSE F1 START STOP SWITCH 1 START RELAY K1 ap a EL STARTER MOTOR B1 Lo J1 CONNECTOR P1 CONNECTOR FIGURE 6 9 SPEC B START CRANKING MODE 6 16 Many troubleshooting procedures present hazards that can result in severe personal in
165. ustment The valve clearance can be checked and adjusted Adjust the valve clearance only when the engine is at ambient temperature Follow head cover removal instructions in the Head Cover section on Page 10 2 Inspect the valve stems for proper alignment with the rocker arms Advanoe the engine until both of the valves are closed and there is no pressure on the valve lift ers piston at top dead center Clearances are shown in Section 3 Dimen sions and Clearances For each valve the gauge should just pass between the top of the valve stem and the rocker arm See Figure 10 11 o correct the valve clearance place a wrench on the adjusting nut and a wrench on the outer locking nut Loosen the outer locking nut and turn the adjusting nut as needed to obtain the correct clearance Tighten locking nut after ad justment is made 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 re sult of adjusting the valve lash Reinstall the head cover and torque the head cover bolts to the specified torque Intake Valve Seal Replacement A worn or cracked intake valve seal can cause high oil consumption and spark plug fouling Replace a defective intake valve seal as follows 1 Pull the old valve seal out carefully to avoid damaging the valve guide 2 Coat the intake valve stem with engine oil and insert it into t
166. with a digital voltmeter is supplied to the primary of the ignition coil If no spark was seen in the gnition Spark Check on Page 8 6 and all accessible ignition wiring checks good perform the Magneto Assembly Check next Magneto Assembly Check Use a known good new ignition coil 1 Make sure the cranking circuit and battery are in good condition 2 Disconnect the low oil level shut down circuit Locate the lead from the low oil level switch that comes out of the top the oil base below the spark plug Separate the in line quick connect where lead S2 J1 7 connects to the low oil level switch 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 test ing 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 Section 9 Generator for generator disassem bly to access the magneto assembly CRANKCASE VENTILATION SYSTEM The crankcase breather prevents pressure from building up in the crankcase It also prevents oil contamination by removing moisture gasoline va pors and other harmful blow by materials from the crankcase These vapors are routed to the carbure tor where they are mixed with the incoming air and 8 8 burned in the combustion chamber A stuck or dam aged breather valve
167. wn b Start Stop S1 switch faulty 6 27 GENERATOR TROUBLESHOOTING Use the following troubleshooting guide to help lo cate problems related to the generator Figures 6 1 and 6 2 on pages 6 2 and 6 3 show the location of the generator components Refer to the wiring diagrams in Section 12 Wiring Schematic Diagram for wiring connections Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only qualified service personnel with knowledge of fuels electricity and machinery haz ards should perform service procedures Review safety precautions on page iii Possible Cause Corrective Action Page 1 Locate cause of overload and correct No AC Output Voltage Note This condition may cause the genset to stop when start switch S1 is released AC Output Voltage Too Low TABLE 6 13 GENERATOR TROUBLESHOOTING 1 Open circuit breaker 2 Open circuit between voltage regulator and brush block Open circuit between stator connec tions Q1 or Q2 and voltage regulator This condition will give approx 30 VAC output voltage in start mode Open circuit between battery Pos and voltage regulator pin 7 for field flash Brushes not making good contact with slip rings Slip ring surface is rough or pitted Defective generator control assembly A1 or voltage regulator VR1 Engine governor out of adjustment Brushes worn or not mak

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MicroLite™ 4000 Series