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1. 10 1 11 WIRING DIAGRAMS ere cU 11 1 Section 1 Introduction ABOUT THIS MANUAL This manual provides service information for the Onan BGD and NHD series commercial vehicle generator sets This manual describes troubleshooting disas sembly repair reassembly and adjustments to the engine generator and control system The technician must understand basic principles of electrical genera tion and gasoline engine operation Basic information can be found in the following Onan publications e Electrical Mechanical Fundamentals publication 932 0408 Onan Generator Training Manual publication 932 0404 BGD and Operator s Manual publication 985 0130 e BGD and Installation Manual publication 965 0629 CARBURETOR AND SPARK GOVERNOR PLUG AIR PARK ADJUSTMENTS CLEANER BRACKET WITH RELAYS ie AND BATTERY CHARGING VOLTAGE REGULATOR TERMINAL FOR THE en NEGATIVE BATTERY CABLE NON EXTENDED SHAFT MODELS FILTER OIL FILL AND DIP STICK FAN HOUSING COOLING AIR POWER OUTPUT LEADS NOT SHOWN DRAIN FUEL PUMP AND WARM COCK FUEL INLET AIR GASOLINE a LINE CIRCUIT FLANGE 15 R ACCESSIBLE MOUNTING TRAY BREAKERS THROUGH THE ALTERNATE LOCATION FUSE FAN HOUSING FOR NEGATIVE REMOTE CONTROL DISCHARGE BATTERY CABLE WIRE HARNESS CONNECTION FIGURE 1 1 TYPICAL GE
2. 8 6 Brushes and Slip 5 8 9 Generator Testing 8 11 Testing Voltage Regulator 1 8 13 9 ENGINE BLOCK ASSEMBLY 9 1 c r 9 1 Oil Filter and Adapter Service 9 1 Cylinder HCAS iso E 9 1 Valve 2 EE e DE 9 2 SECTION TITLE PAGE CIL AD 9 7 GOVEMOl CUD oo STR sages aster 9 8 Timing Gears and Camshaft 9 8 System ER a eee 9 9 Piston ASSENIOW isda fe DV LEA ARS ERAS E 9 10 Crankslidit ooi ao LEA IEEE AN ODE GE PE EIE eei adir 9 14 Cylinder eda DID EM Ded ceases Sa 9 14 Beads rod I oie ode RU dod 9 ee Bee 9 17 SIE OFCROETSTTISTT TI 9 18 10 SERVICE CHECKLIST ELENI M TNCS 10 1 oues a critico modice bk dS ed d irs 10 1 eee Rada X Vg ee 10 1 pr FTT 10 1 initial Start 10 1 Output Check 10 1 Exhaust System 10 1 CIR 10 1 llo 10 1 Mechanical
3. eo Service Manual BGD NHD I Printed U S A 965 0529 5 92 Spec A G Safety Precautions Before operating the generator set read Operators Manual and become familiar with it and the equipment Safe and efficient operation can be achieved oniy if the unit is properly operated and maintained Many accidents are caused by failure to follow fundamenta rules and precautions The following symbols found throughout this manual alert you to potentially dangerous conditions tothe operator service per sonnel or the equipment This symbol warns of immediaie haz ards which will resuit in severe personal injury or death This symboi refers a hazard or unsafe practice which can result in severe personal injury or death A CAUTION This symboi refers a hazard or unsafe practice which can result in personal injury er pred uct or property damage FUEL AND FUMES ARE FLAMMABLE Fire explosion and personal injury can result from improper practices e D NOT ill fuel tanks while engine is running Fuel contact with hot engine cr exhaust is a potential fire hazard DO NOT SMOKE OR USE AN OPEN FLAME near the gen erator set or fuel tank Fuel connection at the engine should be made with an ap proved flexible non conductive iine Do not use copper pip ing E flexible lines as copper will work harden and become brittle e sure all tuei
4. RESISTOR FUEL PUMP CIRCUIT BREAKER THERMAL VOLTAGE REGULATOR DC __ SSS VOLTAGE REBULATOR AC GN POINTS CS s2 SWITCH LOW OIL PRESS up I Kif RELAY START SOLENOID CHOKE GASOLINE ONLY GENERATOR FUSE SLOW BLOW BA ma SPARK Peus FUEL PUMP OR FUEL 505 1 i ae CIRGUIT BREAKER AC OUTPUT as CAPACITOR en BATTERY IV Bi STARTER MOTORS REMOTE_CONTROL STANDARD LA2 REMOTE CONTROL DELUXE CONTROL ASSY NHO NHOL 359 1 2 5 REF CONTROL ASSY BGD BGOL 5 GND SCHEMATIC STOP START R7 e 52 E Ll WIRING DIAGRAM NO 611 1182 TYPICAL WIRING SCHEMATIC AND CONNECTION DIAGRAMS FOR SETS PRIOR TO SPEC F AND HAVING BREAKER POINT IGNITION 11 6 Redistribution or publication of this document by any means is strictly prohibited Onon Onan Corporation 1400 73rd Avenue N E Minneapolis MN 55432 1 800 888 ONAN 612 574 5000 International Use Telex 275477 Fax 612 574 8087 Onan is a registered trademark of Onan Corporation
5. IGN COIL F a 8 B ais a E J nC us E M NOTES 1 GROUNDED AC LEAD 2 DISARM SWITCH BY CUSTOMER INSTALLER NOT SUPPLIED BY ONAN REQUIRES CONNECTING WITH NO 611 1215 NECESSARY EXTENSION LEADS FROM JI 6 TO KEY REV B BLACK SWITCH AND CONNECTING FROM KEY SWITCH TO KI I MODIFIED AND DISCONNECTING LEAD KI I USE 16 GA Cu WIRE WIRING SCHEMATIC AND CONNECTION DIAGRAMS FOR SINGLE PHASE GASOLINE FUELED SPEC F GENERATOR SETS 11 3 WIRING DIAGRAM SCHEMATIC AVR 2 H2 91910 Ew 3 GV e f i xi 2 N 3 T7 8 x CO Z T E 220 380 50 HT CODE 2 6 4 240 4 16V L2 254 440 120 240 120 240 l CONNECTION CHART i i i i i i i i f i i i i E b i 8 8 i I 1 i 2 1 i 1 i 1 1 i i 1 1 i i 4 a C5 NOTES DISARM SWITCH BY CUSTOMER INSTALLER T SUPPLIED BY ONAN REQUIRES CONNECTING WITH 611 1216 NECESSARY EXTENSION LEADS FROM JI 6 TO KEY SWITCH AND CONNECTING FROM KEY SWITCH TO 1 REV 5 a 7 AND DISCONNECTING LEAD AT KI I USE 16 GA Cu WIRE MODIFIED WIRING SCHEMATIC AND CONNECTION DIAGRAMS FOR TRHEE PHASE GASOLINE FUELED SPEC F GENERATOR SETS 11 4 WIRING DIAGRAM 110 120 VOLTS 2 WIRE TS TO TBI LI T4 TO TBI LO MOVE TBI L2 TO CB2 TO TBI LI TO CB2
6. store anything in ihe generator compartment such as oil or gas cans oily rags chains wooden blocks portable cylinders etc A fire cculd result cr the generator operation cooling noise and vibration may be ad versely affected Keep the compartment floor clean and dry e Do work on this equipment when mentally or physically fatigued or after consuming any alcohol or drug that makes the operation equipment unsafe RV 9 Table of Contents SECTION TITLE PAGE SAFETY PRECAUTIONS Inside Front Cover 1 INTRODUCTION covet eee cee dessus bxERESS 1 1 About this Manual 1 1 Model identification 1 1 2 GENERAL SPECIFICATIONS 2 1 3 DIMENSIONS AND CLEARANCES 3 1 4 TORQUE SPECIFICATIONS 4 1 5 PREPARING FOR SERVICE 5 1 Troubleshooting Ne pues E E 5 1 Special She enna te tee er 5 1 Safety Considerations 5 1 Set Removal Guidelines 5 2 6 ENGINE PRIMARY SYSTEMS 6 1 a eni va e 6
7. Noise shield Cylinder housings Scroll e Fiywheel e Scroll backplate Cooling System Disassembly Procedure 1 Remove the muffler and tail pipe assembly see Exhaust System section to access the cooling system 2 Remove the capscrews that secure the noise shield see Figure 6 4 to the engine Lift off the noise shield Remove the three nuts along the lower edge of the scroll that hold the fan guard to the scroll 4 Remove the capscrews that fasten the scroll to the backplate and lift it away from the scroll NOISE SHIELD CYLINDER AIR HOUSINGS SCROLL FAN GUARD FLYWHEEL FIGURE 6 4 COOLING SYSTEM 5 Remove the screws that fasten the cylinder air hous ings to the backplate and cylinder heads Lift off the air housings 6 Loosen the flywheel and back it out sev erai turns FLYWHEEL FLYWHEEL PULLER M JACK SCREW A e es FLYWHEEL CAP SCREW CS 1000 FIGURE 6 5 FLYWHEEL PULLER 7 Attach the puller tool to the flywheel see Figure 6 5 The tool has two jack screws that fit into the holes tapped in the flywheel 8 Tighten the puller center screw until the flywheel comes loose Remove the puller flywheel center screw and washer Inspect the flywheel and replace it if any air vanes are missing 9 Remove the lead from the low oil pressure cutoff switch 10 Removethe exhaust manifold see Exhaust System in this
8. From Vehicle When the generator set has been disconnected from the electrical exhaust and fuel systems examine its mount ing bolts and support members The generator set drip tray is normally bolted to the vehicle framework Depending on thieinstallation the set may be removable from the side back or bottom Make certain that the set is firmly supported before loosening any mounting bolts or support members Use aforklift if possible to lift or move the generator set A WARNING The generator set is heavy and can cause severe personal injury if dropped during removal Use the recommended remo val procedures and keep hands and feet clear while removing mounting bolts Oil in the engine cylinders can cause ACAUTION engine damage during starting attempts Oil can enter the cylinders if the generator set is in a tilted position Do not leave the set in this position for more than 30 minutes if the oil has not been drained Removing Under Floor Mounted Set From Vehicle When the generator set has been disconnected from the electrical exhaust and fuel systems the set may be partially removed for limited service or completely removed for major service The set is mounted on a support tray which serves as the bottom of the under floor housing The inner edge of the support tray is hinged to the rear panel assembly The outer edge of the support tray is bolted to a support bracket Two brackets are used on
9. Open circuit breaker Open circuit between voltage regulator and brush block Open circuit between generator wind ings Q1 Q2 and voltage regulator Brushes stuck in holder or not making good contact with slip rings Defective voltage regulator Open grounded or short circuit in rotor or stator Engine governor incorrectly adjusted Brushes worn or not making good contact with slip rings Low AC output voltage Poor wiring connections to from voltage regulator if generator frequency is within specified limits but voltage is incorrect voltage regulator is defective Open grounded or short circuit in rotor or stator Output voltage pot misadjusted Open circuit between terminal block TB1 and voltage regulator wiring harness J4 leads 8 4 Corrective Action Locate cause of overload and correct as required Reset breaker Check for good wiring connections and correct as required Check for continuity and correct if circuit is open Check for good wiring connections and correct as required Check for continuity and correct if circuit is open Release brushes if jammed in holder Clean slip rings if dirty Replace voltage regulator Test each component for open grounded or shorted windings and replace if defective Refer to governor adjustments in section 6 Check length of brushes and replace if worn excess
10. Terminal Board TB1 The AC output power leads from the generator T1 T2 T3 and T4 are connected to terminal board TB1 at terminals L1 L2 13 and LO Refer to the proper Wiring Diagram Schematic for specific information AC power at TB1 terminals is tapped by leads of wiring harness J4 of voltage regulator VR1 and interconnect wiring to the circuit breaker CB1 and CB2 if equipped 3 phase units winding X1 X2 and isolation trans former T2 provide reference voltage to the voltage regu lator see the schematic These leads provide generator outputtothe voltage regulator for proper voltage regula tion and to the circuit breakers for power supply to load Voltage Regulator VR1 The voltage regulator helps provide stable output vol tage under varying loads During initial start of the set the voltage regulator receives DC currentfrom the start ing battery and begins excitation of the rotor through leads J4 9 F1 and J4 10 F2 After the generator set starts and runs it provides AC power to the voltage regulator through leads J4 11 Q1 and J4 12 Q2 The AC voltage is rectified to DC voltage and the proper DC excitation voltage is induced to the rotor in response to changes in demand The potentiometer on the Emerald faceplate acts directly on VR1 and allows a limited range of output voltage adjustment VOLTAGE REGULATOR EN O RING STATOR STATOR CLAMPS THROUGH BOLT RON ai ENGINE TO GENERATOR ADA
11. CONNECT OUTPUT LEADS BLACK TO LOAL AND CB2 TO LOAD TOGETHER TO LOAD GEN TBl csi t um m a S Gum ee ee see GEM Gm 220 TO 240 VOLTS 2 WIRE T4 TO TBI LI REMOVE TBI L TO CBI TO OUTPUT LOAD LEAD BLACK 4 t STANDARD CONNECTION DIAGRAM 120 240 V WIRE i i 1 3 i 8 1 TI LI A T2 LO LO 220 240V 4 12 E 110 120 VOLTAGE REGULATOR DC VOLTAGE REGULATOR AC i IGN COIL IGN MODULE 2 SWITCH LOW OIL PRESS RELAY RELAY START SOLENOID CHOKE GASOLINE ONLY i i ond on rf Sha i ham NOTES E3 E2 1 GROUNDED AC LEAD 1T 2 7 2 DISARM SWITCH BY CUSTOMER INSTALLER SUPPLIED BY REQUIRES CONNECTING WITH RED A NECESSARY EXTENSION LEADS FROM JI 6 TO KEY NO 611 1210 E4 TI SWITCH AND CONNECTING FROM KEY SWITCH TO KI I REV C AND DISCONNECTING LEAD AT KI I USE 16 Cu WIRE MODIFIED WIRING SCHEMATIC AND CONNECTION DIAGRAMS FOR SINGLE PHASE PROPANE FUELED SPEC F GENERATOR SETS 11 5 240VAC LOAD 71 2 CBI T2 LO CB2 GROUNDED AC LEAD RS POTENTIOMETER
12. Check valve stems and guides for wear as shown in Figure 9 6 Use a hole gauge to measurethe valve guide When valve clearance with the stem exceeds the original clearance by 0 002 inch 0 05 mm replace either the valve or guide or both neces sary Always regrind the seat to make it concentric with the newly installed guide VT 1020 FIGURE 9 6 VALVE STEM AND VALVE GUIDE INSPECTION Springs Check the valve springs for cracks worn ends distortion and tension If the spring ends are worn check the valve spring retainer for wear Check for spring distortion by placing each spring on aflatsurface next to a square Measure the height of the spring and rotate it against the square edge to measure its distor tion Check the spring tension at the installed height in both the valve open and closed positions using a valve spring tester Replace any valve spring that is weak cracked worn or distorted Reconditioning Valves and Valve Seats The interference angle method of valve seating is used on all Band N series generator set engines This method uses different seat and face angles and line contact is made between the valve face and seat The valve face angle is 44 degrees The valve seat angle is 45 degrees This 1 degree interference angle results in a sharp seating surface between the valve and the top of the valve seat see Figure 9 7 VT 1021 FIGURE 9 7 VALVE INTERFERENCE ANGLE The valves must not be hand
13. Connect a voltmeter between terminal S on the start solenoid and around Check for battery voltage when 1 is placed in START position If voltage is present fault is due to relay not grounded b Defective K1 relay c Defective starter If voltage is not present as described in step 5 test fault is due to a Open circuit between K1 relay and control PC board b Defective contro board or connector is circuit breaker tripped R4 7 4 2a 4a oa 6a Corrective Action Check fuse F1 Replace if open with Onan supplied fuse only Ensure that wiring harness jack connections are fully seated to PC board Check for continuity and correct if circuit Is open Replace remote start control switch Replace PC board A1 Check condition of battery and recharge or replace Clean and tighten all connections at battery K1 start solenoid and starter motor VR2 battery charge regulator A WARNING Short circuiting the bat tery cables can result in severe personal injury Disconnect the negative battery cable at the batiery terminal before servicing Tighten solenoid bracket mounting screw Replace K1 start solenoid Refer to Electric Starter Section 6 for test and service procedures Check for continuity and correct if circuit is open See Testing of Control Board A1 Wait for circuit breaker to return to local ambient temperature to reset
14. Spark Plug Gap Valve Lash Intake Exhaust Engine Oil Capacity Dry Filter Spec F Prior to Spec F Ignition Timing Electronic Non adjustable Breaker Point Typical Breaker Point Gap Fuel Connections Maximum Gasoline Supply Pressure at Carburetor Maximum Gasoline Fuel Pump Lift Gasoline Supply Fitting Min Max Propane Supply Pressure Vapor Withdrawal Propane Supply Connection Vapor Withdrawal Propane Supply Connection Liquid Withdrawal MODEL BGD 204 pounds 92 kg 14 x 25 1 4 x 19 in 356 x 641 x 478 mm 85 sq in 548 sq cm 2 in 51 mm 1 3 8 in ID 18 Gauge Rigid Steel Tubing 5 amps Slow Blow 10 amps 47 7 in 782 cm 6 971 3 25 82 6 2 87 72 9 75 115 psi 517 793 kPa 0 025 in 0 64 mm 0 005 in 0 127 mm 0 013 in 0 330 mm 3 5 quarts 3 3 L 4 0 quarts 3 8 L 149 189 20 0 016 in 0 41 mm 6 psi 41 kPa 3 Ft 0 9 m 1 4 in ID Hose Barb 7 14 in 178 356 mm WC 3 4 in NPTF Tapping 1 4 in NPTF Tapping Spec A for Model BGD and Specs A and B for Model 0 021 in 0 53 mm for LPG MODEL NHD 230 pounds 104 kg 14 5 8 x 25 946 x 21 1 16 in 371 x 649 x 535 mm 85 sq in 548 sq cm 2 in 51 mm 1 3 8 in ID 18 Gauge Rigid Steel Tubing 5 amps Slow Blow 10 amps 60 in 983 cm 7 01 3 56 in 90 4 3 00 in 76 2 mm 100 120 psi 690 827 kPa
15. VALVE SPRING COMPRESSOR Valve Inspection Procedure Valve Face Check the valve face for evidence of burn ing warping out of round and carbon deposits see Figure 9 5 VT 1017 FIGURE 9 5 VALVE FACE Burning and pitting are caused by the valve failing to seat tightly This condition is often caused by hard car bon particles on the seat lt may also caused by weak valve springs insufficient tappet clearance valve war page and misalignment Warping occurs chiefly in the upper stem because it is exposed to intense heat Out of round wear results from warping 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 is worn install a new valve Excess clearance in the intake guide admits air and oil into the combustion chamber upsetting carburetion increasing oil consumption and making heavy carbon deposits Carbon prevents heat dissipation Clean metal is a good heat conductor but carbon insulates and retains heat This increases combustion chamber temperatures causing warping and burning Unburned carbon residue gums valve stems causing them to stick in the quide Deposits of hard carbon with sharp points projecting become white hot causing pre ignition and pinging Valve Stem Seal A valve stem Seal is used on the intake valve guides This seal must be replaced each time the valve is removed Stems and Guides
16. and the choke heater H1 when itis powered by engine control board A1 through the start and run relay contacts is mounted next to Relay K5 Fuse F2 Beginning Spec F Fuse F2 protects the ignition and the choke heater cir cuits It is mounted on the side of the control box CONTROL OPERATION When troubleshooting refer to the appropriate wiring schematic in Section 11 Wiring Diagrams Starling Holding the Start Run Stop switch in the Start position energizes start relay K4 by completing the circuit to battery ground B The relay K4 contacts close con necting battery voltage B to the following components Generator Field through VR1 Battery voltage flashesthe field to initiate generator voltage buildup e Starter Solenoid K1 The solenoid connects the starter motor to to crank the engine e Gasoline Fuel Pump E2 or Gas Solenoid Valve E2 The pump or valve delivers fuel to the carburetor e Ignition Coil T1 The ignition system begins firing the spark plugs Stop Relay K5 The relay K5 contacts open to allow run relay to be energized through oil pres sure switch S2 and the relay K2 contacts Ignition Relay Beginning Spec F The ignition coil and choke heater are energized through relay K6 contacts Starter Disconnect Run As oil pressure builds oil pressure switch S2 closes to connect battery ground to the run relay As the engine comes up to sp
17. personal injury or death if it is inhaled To mm exhaust leaks install all gaskets clamps straps and hardware as specified in this man ual and other Onan publications Assembly Procedure 1 install the exhaust manifold using new gaskets Tighten the four manifold screws to the specified torque Install the 5 16 18 screw lock washers and nut that secure the manifold outlet flange to the mani fold support bracket Tighten securely Install the cooling system scroll and noise shield see Cooling System in this section If no other service is required install the generator set in the vehicle before completing the remaining steps Install a new gasket between the exhaust manifold and exhaust tube Secure the flange connector to the manifold using 5 16 18 inch capscrews and lock washers Attach the inlet of the muffler to the exhaust tube using a 1 1 2 inch U bolt type automotive muffler clamp Make certain that the muffler inlet pipe over laps the exhaust tube a minimum of 1 7 inches 38 mm Place the muffler strap on the muffler and position it below the cutout in the bottom of the generator set drip tray Fasten the strap to the strap bracket on the set using a 1 4 20 screw and lock washer Tighten the strap around the using a 1 4 20 screw lock washer and nut Ifreplacingthe original tailpipe refer to the Tailpipe Recommendations section to select and locate the tailpipe Att
18. then turn it out 1 1 4 turns Forcing the mixture adjustment ACAUTION screws tight will damage the needle and seat Turn them in only until light ten sion can be felt When carburetor is installed on set make final idle and main mixture adjustments as described in the Carburetor Fuel Mixture Adjustments section 1 Apply a vacuum of at least 4 inches 100 of mercury to fully pull in the choke breaker arm Choke Spec F Figure 6 23 illustrates the Spec F choke components for 2 Insert a 0 337 inch 8 6 mm drill rod between the gasoline carburetors Replace faulty choke components and reassemble as shown Adjust the choke breaker choke plate and the carburetor throat assembly each time it is assembled to the carburetor as follows 3 necessary bend the link at the point shown until the lip of the choke plate just touches the drill rod Use two pliers to bend the link IF NECESSARY BEND THIS LINK AT THIS POINT WHEN ADJUSTING THE VACUUM BREAKER SUSTAIN VALVE ASSEMBLY ASSEMBLY 1 7 ASSEMBLY CHOKE SHAFT ASSEMBLY GAUGE THE DISTANCE BETWEEN THE CHOKE PLATE AND THE CARBURETOR THROAT WITH A 0 337 INCH 8 6 mm DRILL ROD WHEN ADJUSTING THE CHOKE BREAKER ASSEMBLY FIGURE 6 23 CHOKE ASSEMBLY SPEC 6 22 Choke Prior to Spec The choke consists ofa bi metal coil an electric heating element and a choke pulloff diaphragm The coil is connected
19. 1 Troubleshooting Engine Primary Systems Jo E 6 1 Exhaust Systemi ose o dive eta D aera die 6 4 Cooling SVEM SIS a QS 6 7 Electronic ignition ai ads RON OR 6 9 Breaker Point Ignition 6 11 Crankcase Ventilation System 6 13 Cylinder Compression 5 14 GOVE MO ee 6 14 Fuel System 6 16 Fuel System LPG Liquid 6 25 Fuel System LPG Vapor 6 31 Electio 6 32 7 CONTROL c 7 1 ENS ET ER TUO TU TRO ELI TT TERT CT 7 1 Control DescripliOlh eii otc easi 054 7 1 Control Operation 7 3 Testing Control Board A1 7 3 Control Troubleshooting PEU 7 4 8 GENERATOR 8 1 Generator Control Component Descriptions 8 1 Generator Operation ee 8 3 Generator Troubleshooting 8 4 Generator Service
20. 19 55 Ibs 25 25 ibs 11 3 2 1 9992 2 0000 50 780 50 800 mm 1 6252 1 6260 41 280 41 300 2 0015 2 0040 50 838 50 902 mm 0 0024 0 0042 0 061 0 107 mm 0 006 0 012 0 15 0 30 mm 1 3740 1 3745 34 90 34 91 mm 1 376 1 377 34 95 34 97 0 0015 0 0030 0 038 0 076 0 011 0 048 0 28 1 2 1 662 42 21 1 375 34 92 71 Ibs 32 38 165 17 MODELS Valve Stem 0 2795 0 2800 0 3425 0 3430 Diameter Intake 7 099 7 112 mm 8 700 8 712 mm Valve Stem 0 2780 0 2785 0 3410 0 3420 Diameter Exhaust 7 061 7 074 mm 8 661 8 687 mm Valve Guide Intake Exhaust Intake and Exhaust Diameter 0 2810 0 2820 0 2805 0 2815 0 344 0 346 7 137 7 163 mm 7 125 7 150 mm 8 74 8 79 mm Valve Stem 0 0010 0 0025 l 0 0010 0 0025 Clearance intake 0 025 0 064 mm 0 025 0 064 mm Valve Stem 0 0020 0 0035 0 0025 0 0040 Clearance Exhaust 0 051 0 089 mm 0 064 0 102 mm Valve Lifter Diameter 0 7475 0 7480 0 7475 0 7480 18 987 18 999 18 987 18 999 Valve Lifter Bore 0 7500 0 7515 0 7500 0 7515 Diameter 19 050 19 088 mm 19 050 19 088 mm Valve Lifter To 0 0020 0 0040 0 0020 0 0040 Block Clearance 0 051 0 102 mm 0 051 0 102 mm Intake Valve Seat 1 470 1 471 1 569 1 570 Diameter Outside 37 34 37 36 mm 39 85 39 88 mm Exhaust Valve Seat 1 192 1 193 1 255 1 256 Diameter Outside 30 28 30 30 31 88 31 90 mm
21. 9 10 4 Mark each piston and rod assembly so they can be returned to their respective cylinders after overhaul Keep the connecting rod bearing caps with their respective rods The pistons are fitted with two compression rings and one oil control r ng Removethese rings from the piston using a piston ring spreader as shown in Figure 9 19 CT 1059 FIGURE 9 19 REMOVING PISTON RINGS Mark each piston to make sure the rod is assembled on the piston from which it was removed Remove the piston pin retainer from each side and push the pin out Newer replacement pistons and Spec F pistons have round wire piston pin lock rings Pry out the lock ring with a small screwdriver inserted into the slot behind the ring If necessary push the ring around in its groove until the slot is behind it ACAUTION Wear safety glasses and hold your thumb over the ring to keep the ring from flying out and getting lost or causing personal injury Remove dirtand deposits from the piston surfaces with an approved cleaning solvent Clean the piston ring grooves with a groove cleaner or with the end of a piston ring filed to a sharp point Figure 9 20 Take care not to remove metal from the groove sides Using a caustic cleaning solvent or wire brush for cleaning pistons will cause piston damage Use only paris cleaning solvent for this job 1060 FIGURE 9 20 CLEANING RING GROOVES When clea
22. FIGURE 8 5 ROTOR TOOL 20 Carefully lift the rotor assembly off the end of the engine crankshaft Remove the rotor tooi 21 Lift the brush wires and remove the brush holding wire from housing Remove the brush block mount ing screw and carefully remove the brush block assembly from the stator housing 22 Remove the stator from the stator housing fol lows see Figure 8 6 a Rotate the stator housing assembly onto a smooth clean surface resting on end bearing face shape of housing facing up Disconnect stator leads T2 and from termina board TB1 Q1 Q2 F1 and F2 from voltage regulator VR1 harness J4 e B1 and B2 from control printed circuit board harness J1 Pull the stator leads from the control box Remove the three stator clamps and cap Screws Carefuily lift the stator straight up until it clears the stator housing Set the stator down on a smooth clean surface G1213s FIGURE 8 6 STATOR HOUSING DISASSEMBLY Rotor Bearing Removal Use a gear puller to remove the bearing from the rotor shaft Attach the gear puller so that the gear puller arms contact the inner race of the bearing Figure 8 7 The bearing will be damaged if pulled ACAUTION by the outer race If the bearing is to be reused it must be pulled by the inner race 8 8 ES 1495 G 1175 FIGURE 8 7 BEARING REMOVAL Rotor Bearing Replacement 1 Clean the bearing and
23. Lacks Power Engine Overheats Black Exhaust Smoke Possible Cause 1 Faulty ignition due to incorrect ignition timing b incorrect spark plug gap Dirty air cleaner Restricted fuel flow due to a plugged fuel filter or b faulty fuel pump Incorrect fuel mixture due to a incorrectly adjusted fuel mixture screws b incorrect float level or C dirt in carburetor d vacuum leak Exhaust system blocked or restricted Incorrect valve tappet clearance Excessive engine wear or damage to engine Carburetor air preheater set incorrectly Excessive carbon buildup No load speed set too low Gasoline sets only Prior to Spec B for Model BGD and Spec C for Model NHD Restricted airflow due to dirt or debris blocking air inlet or outlet Dirt or oil covering engine cooling fins Incorrect ignition timing Lean fuel mixture due to a incorrectly adjusted fuel mixture screws b incorrect float level or dirt in carburetor Gasoline sets only 1 Rich fuel mixture due to a dirty air cleaner b choke sticking c incorrectly adjusted fuel mixture SCrews d dirt in carburetor Gasoline sets only injury or death Troubleshooting information is provided for qualified repair personnel only Corrective Aclion Adjust breaker point gap Reset spark plug gap Replace air cleaner Clean fuel filter Test fuel p
24. VR2 input voltage should be 16 21 VAC Measure baitery voltage If less than 13 volts VR must be replaced Check breaker continuity replace i open A WARNING Untrained personnel should not attempt repair due to hazards which can result in personal injury or death Troubleshooting information is provided for qualified repair personnel only Trouble Engine Starts And Runs Then Stops Set Restarts Immediately or Set Restarts After Cooling Down REMOTE CONTROL if equipped Run Lamp Time Meter or Battery Condition Meter Does Not Operate 2 Possible Cause Fuel level is below generator set fuel 1 pickup tube or oil level is low Dirty fuel filter restricting fuel flow 2 Breaker points sticking 3 Contaminated fuel 4 Open circuit between control board A1 1 terminal 6 5 of remote connector plug P2 J2 and terminal 6 or 5 on start stop switch S2 Open circuit between ground terminals 2 on lamp or meters and terminal 1 on remote start stop switch If battery condition meter and run lamp 3 works but time meter does not operate time meter is defective If time meter works but battery condition 4a meter does not operate connect a volt 4b meter between the positive terminal on battery charge meter and ground Use the following to determine fault a If reading equals battery voltage minus 10 volts battery condition meter is defective b If reading
25. and only as instructed 2 Position a floor jack under the reinforcement ribs of the drip tray as shown in Figure 5 3 3 Raise the jack until it makes contact with the drip tray then put slight upward pressure on the tray FRONT SUPPORT BRACKET BOLTS 4 DRIP TRAY PLACE FLOOR JACK UNDER DRIP TRAY REINFORCEMENT RIBS M 1600 2 FIGURE 5 3 PARTIAL SET REMOVAL 5 5 4 Remove the bolts from the front support brackets and the rear brackets only and remove the brackets This may require slight adjustment of the floor jack Whenthe support bracket is removed the floor jack will support all its weight on that side Slowly lower the jack being careful to allow the jack to roll as the generator set swings downward Supportthe driptray assembly with wood blocks so the floor jack can be removed This will allow more access for the service procedure Make sure generator is resting A WARNING securely before removing floor jack Otherwise the generator can swing downward causing severe personal injury Remove the bolts securing the side support to the drip tray and the underfloor bracket Also remove bolts from the rear support bracket if removing a NHD unit Lift the generator slightly until the safety catch on the side support is clear of the tray Pull support forward and upward until disengaged from the tray and underfloor bracket Remove the
26. by moving the rotating hone 250 to 450 rpm up and down in the cylinder bore roughly 40 times per minute 7 Clean the cylinder bores thoroughly with soap water and clean rags A clean white rag should not become soiled on the cylinder wall after cleaning is complete Do not use gasoline or other solvents to clean the cylinder walls Solvents wash oil from the walls but leave metal particles 8 Dry the crankcase and coat it with oil Deglazing Cylinder Bores Deglazing the cylinder bore provides cavities to hold oil during piston ring break in Deglazing produces a good finish but does notenlarge the cylinder diameter so the original pistons with new rings may still be used Deglaze the cylinder bores if there are no scuff marks and no wear or out of round beyond specifications before installing new rings 1 Wipe cylinder bores with a clean cloth which has been soaked in light engine oil 2 Use a brush type deglazing tool with coated bristle tips to produce a crosshatch pattern in the cylinder bore 3 The deglazing tool should be driven by a slow speed drill Movethe deglazing tool up and down in the cylinder 10 to 12 complete strokes rapidly enough to obtain a crosshatch pattern as shown in Figure 9 30 9 16 PRODUCE CROSS HATCH SCRATCHES FOR FAST AVOID THIS FINISH RING SEATING FIGURE 9 30 CROSSHATCHING Abrasives not removed from the ACAUTION engine will rapidly wear the rings cylinder walls a
27. carbon monoxide inhalation includes proper installation and regular frequent visual and audible inspections of the complete exhaust system 1 P EM 40 2 Section 11 Wiring Diagrams This section consists ofthe set wiring diagrams ref erenced in the text The following drawings are in cluded e Page 11 3 Wiring Schematic and Connec tion Diagrams for Single Phase Gasoline Fu eled Spec F Generator Sets e Page 11 4 Wiring Schematic and Connec 11 1 tion Diagrams for Three Phase Gasoline Fu eled Spec F Generator Sets e Page 11 5 Wiring Schematic and Connec tion Diagrams for Single Phase Propane Fu eled Spec F Generator Sets e Page 11 6 Typical Wiring Schematic and Connection Diagrams for Sets Prior to Spec F and Having Breaker Point lgnition 11 2 WIRING DIAGRAM SCHEMATIC 110 120 VOLTS 2 WIRE T3 TO TBI LI T4 TO TBI LO MOVE TBI L2 TO TO TBI LI TO CB2 CONNECT OUTPUT LEADS BLACK CBI TO LOAD AND 2 TO LOAD TOGETHER TO LOAD GEN 12 LO XH 14 LO 220 TO 240 VOLTS 2 WIRE T4 TO TBI LI REMOVE 1 1 1 TO TO OUTPUT LOAD LEAD BLACK 2 T2 LO RS f STANDARD CONNECTION DIAGRAM 120 240 V 3 WIRE i 1 1 1 1 i 1 f i a cel i 12 LO T3 LO pa 220 240V 8 982 10 120V i 4 a 1 1 1 h VOLTAGE REGULATOR DC VOLTAGE REGULATOR
28. center run position when released It is mounted on the circuit board and is not field replaceable Fuse F1 This 5 amp fuse protects printed circuit board A1 from overcurrent conditions It is removable from the front ofthe control panel Spare fuses are inside the fuse holder use only Onan supplied fuses SPARK PLUGS E4 IGNITION COIL T1 RELAYS K5 AND K6 VOLTAGE REGULATOR VR 2 CIRCUIT BREAKERS CB1 CB2 CB3 FUEL PUMP E2 GASOLINE UNITS FUEL SOLENOID E2 LPG UNITS REMOTE CONTROL 1609 2 IGNITION CHOKE FUSE CONNECTION A1 P2 12 F 2 FIGURE 7 1 TYPICAL GENERATOR SET 7 1 Start Solenoid K1 The K1 start solenoid opens and closes the circuit between the starter motor and the battery The starting current load requires that the solenoid contacts have a 300 amp contact rating single terminal connects to the 12 voltsolenoid coil Two studs provide connection points to the battery and starter cables the battery B stud connection protrudes through the control panel to ihe outside of the control housing for convenient access Stop Relay K5 The K5 stop relay Figure 7 1 latches the generator set off when switch S1 is moved to the STOP position This prevents the set from restarting when the switch is momentarily placed inthe STOP position then released Ignition Coil T1 The ignition coil is energized at the same time as start solenoid K1 when start relay K4 on A1 c
29. governor rod is correct Make this static adjustment with the genera tor set completely cold Refer to Figure 6 14 or 6 15 for the arrangement of these components 1 Loosen the jam nutat the ball joint end of the gover nor rod 2 Disconnect the governor rod from the throttle lever 3 With the carburetor throttle fully open and the gov ernor arm in its full counterclockwise position adjust the governor rod until the end of the rod aligns with the hole in the throttle lever 4 Turn the governor rod in shorter one full turn 5 Reconnect the governor rod and retighten the jam nut while holding the ball socket in the vertical position Adjustment 1 Run the genset at least 15 minutes at 50 to 75 of its rated load Adjusting a set which has not warmed up may cause low power or genset de rating Warmup must be performed on a load bank 2 Remove the load and let the set stabilize 10 to 15 seconds Make certain that the set is running with no load 3 Read the genset frequency With no load frequency mustread 62 63 Hz 51 5 52 5 Hz for 50 Hz sets If within the specification proceed to Step 7 If out side the specification proceed to Step 4 4 Turn the speed nut until the no load frequency is 48 50 Hz 38 42 Hz for 50 Hz sets Make certain the throttle does not touch the idle stop screw they touch turn the screw out until there is no contact 5 Slowly turn the idle stop screw in to increase t
30. journal surface while maintaining the correct bearing clearance When making major repairs on the engine always inspect the drilled passages of the crankshaft Clean them to remove any foreign material and to ensure lub rication of the connecting rods Installation Procedure 1 Lubricate the front and rear main bearings with engine oil 2 Use oil or gear lubricant to hold the front thrust washer in place against the engine block see Fig ure 9 32 The flat side of the thrust washer goes against the block 3 Position the crankshaft so that the crank throw is aligned with the notch at the rear of the crankcase and install the crankshaft Make sure the frontthrust washer did not slip out of place during installation 4 Place the oil seal loader on the oil seal guide and driver and insert into the rear bear ng plate Remove the seal guide and driver leaving the loader in the bearing plate The loader prevents the seal from being cut on the crankshaft keyway during installation of the rear bearing plate 5 Use oil or gearlubricantto hold the shim s and rear thrust washer in position on the rear bearing plate see Figure 9 32 The shim goes against the bear ing plate and the flat surface of the thrust washer goes against the shim 6 Place the bearing plate gasket in position on the block making sure the oil hole on the back of the block is exposed 7 Install the rear bearing plate and fasten with two nuts or caps
31. lapped because the sharp contact between the valve and the seat will be des troyed This is especially important where chrome cobalt faced valves and seats are used Valve faces must be finished to 44 degrees in a machine Each valve must have a minimum of 1 32 inch 0 8 mm margin see Figure 9 8 Ifthe valve has less margin than this it will heat up excessively It will retain this heat during the compression stroke and pre ignite the mix ture causing loss of power and economy This valve is also susceptible to warping and breakage Not all valves can be reconditioned A badly warped valve must be replaced because the amount of grinding required to make it seat correctly removes its margin To make a valve gas tight remove all pitting from the valve face and seat Deeply pitied or cut valves must be replaced because grinding removes the margin 9 4 WARPED VALVE WITH KNIFE EDGE KNIFE EDGE GOOD MARGIN 0 30 INCH MINIMUM 8 MM M 1184 FIGURE 9 8 VALVE MARGIN Grind valve seats with a 45 degree stone The width of the seat band should be 1 32 inch to 3 64 inch 0 79 to 1 2 mm wide Grind only enough to ensure proper valve seating Place each valve in its proper location Check each valve for a tight seat Make several marks at regular intervals acrossthe valve face using machinist s bluing Observe if the marks rub off uniformly when the valve is rotated part of a turn against the seat The valve seat should
32. load Adjust the governor speed nut to 50 2 Hz 50 Hz sets 40 2 hz atno load With the throttle lever against the idle stop screw adjust the idle stop screw to 55 1 hz 50 hz sets 45 1 hz Release the governor linkage and observe the sta bility of the set Set the voltage and frequency and adjust the governor sensitivity of the governor as specified in this section Add and remove a full load several times to make certain the set does not bog down or hunt Carburetor Overhaul Carburetion problems not corrected by mixture or float adjustments are often caused by gummed up fuel pas sages or worn internal parts The most effective remedy is a complete carburetor overhaul Overhauling a carburetor consists of complete disas sembly thorough cleaning and replacement of worn parts Carburetor repair kits include new gaskets and replacements for the parts most subject to wear Carefully note the carburetor position while removing ail parts for correct reassembly Read and understand these procedures before beginning Carburetor com ponents are illustrated in Figure 6 19 IDLE CHOKE SHAFT ADJUSTMENT SCREW THROTTLE STOP SCREW CHOKE PLATE 7 SHAFT FUEL INLET Pr VALVE BUOYANCY SPRING FLOAT FLOAT BOWL MAIN ADJUSTMENT e SCREW ASSEMBLY B e FIGURE 6 19 CARBURETOR OVERHAUL THROTTLE Gasoline is exiremely flammable A WARNING Severe personal injury or death ca
33. manufacturer s recommendations when clean ing parts Remove the throttle stop collar and throttle stop lever from the end of the throttle shaft Remove the throttle plate retaining screws and throttle plate Remove the dust seals from the throt tle shaft and carefully pull out the throttle shaft Remove main and idle mixture screw assemblies Separate the lower section bowl of carburetor from the upper section bowl cover THROTTLE STOP SCREW IDLE ADJUSTMENT SCREW FS 1602 FIGURE 6 29 CARBURETOR OVERHAUL Cieaning and Repair Procedures 1 Soak all metal components have not been replaced in carburetor cleaner Do not soak any non metal parts they may be damaged by the clean ing solution Follow the cleaner manufacturer s recommendations Clean all carbon from the throttle bore especially where the throttle plate seats Be careful notto plug the idle or main fuel ports Blow out all passages with low pressure 30 kPa compressedair Do not use wire or other objects for cleaning that might increase the size of critical passages Checkthe condition ofthe mixture screws see Fig ure 6 30 and replace them if worn or damaged Replaceall old components seals and gaskets with new parts included in the kit ii L DAMAGE AND WEAR OCCUR HERE FS 1483 FIGURE 6 30 MIXTURE NEEDLE INSPECTION Reassembly and Installation Procedure 1 Slide in the throttle shaftan
34. not present check for opens or shorts in the control wiring If this voltage is present at the heating element cover terminals stop the set and remove the heating element cover Inspect the heating element and replace it if burned outor broken Also inspectthe bi metal coil and replace it if it is damaged deteriorated or dragging in the housing When installing a new bi metal strip maintain the origi nal direction of the spiral see Figure 6 25 The outer tab must point in a clockwise direction Make sure the coil sets squarely in the housing and that the inner end of the coil engages the slot in the choke shaft When installing the element cover make sure that the slotted tang on the cover engages the bi metal strip FS 1606 OUTER TAB FIGURE 6 25 BI METAL SPIRAL STRIP Choke Pulloff Diaphragm Adjustment The choke pul loff diaphragm partially opens the choke plate after engine startup This helps prevent flooding and pro motes smooth engine operation as the set warms up Choke Pulloff Diaphragm Adjustment Procedure Prior to Spec F 1 Removethe complete air intake assembly as speci fied in Air Intake Assembly in this section to access the choke plate 2 Disconnect the diaphragm hose from the intake manifold and apply 4 to 18 inches 13 5 to 60 8 kPa Hg vacuum to the diaphragm 3 Apply light finger pressure against the choke lever to take up free play in the pulloff linkage see Figure 6 26 6
35. ofthe engine crankshaft and replace the rotor through bolt Tighten the rotor through bolt only enough to hold the rotor in place Tightening the rotor through ACAUTION bolt to the specified torque before the stator assembly is installed can result rotor shaft misalignment Follow the recom mended installation procedures to avoid any pos sibility of shaft misalignment Carefully place the stator assembly straight down over the rotor and into position for assembly to the engine to generator adapter The rotor end bearing should fit snugly into the bearing bore hole Careless handling of the stator ACAUTION can result in damage to the sta tor windings Do not brush the stator windings against the rotor as it is lowered into position Install the four nuts locking washers and caps crews that secure the stator housing to the engine to generator adapter Tighten the capscrews to the specified torque Note that each locking washer 1 installed under the capscrew head Tighten the rotor through bolt to the specified torque Mount the starter on the generator stator housing using capscrews lock washers and nuts Tighten to the specified torque Connect the leads to the starter terminal stud Hold the drip pan in position to mount to the under side of the set and install the vibration isolator cen ter screws Note that proper flat washers are used large flat washers at two generator isolator p
36. open the gas supply shutoff valve 11 Adjust the gas adjustment screw as described in the previous section Operate the generator set to assure that it starts correctly ELECTRIC STARTER Removal and Disassembly Procedure 1 Disconnect the generator set negative battery cable from the set starting battery 2 Disconnect the generator set positive battery cable fromthe starter lug terminal See Figure 6 37 3 Remove the starter mounting screws then carefully disengage the starter from the stator housing 4 Remove starter through boits and carefully separ ate the brush end cap housing and armature assembly 5 Use a 1 8105 32 inch nail setto remove the roll pin Remove the return spring gear and clutch assem bly as required When reassembling always use a new roll pin See Figure 6 38 POSITIVE TERMINAL ROLL PIN 1 m oe t am mea STARTER THROUGH BOLTS SPRING RETAINER ES 1508 FIGURE 6 37 STARTER MOTOR SUPPORT PLASTIC RETAINER WITH 5 32 to 1 8 NAIL SET A VISE OR OTHER d SOLID SURFACE USE CARE NOT TO HAVE SPRING RETURN LEG BETWEEN THE PLASTIC RETAINER amp SUPPORT WHEN DRIVING OUT ROLL PIN aaa SOLID SUPPORT AJ ES 1609 FIGURE 6 38 DRIVING ROLL PIN OUT 6 33 Testing Armature for Grounds Touch one ohmmeter lead to a commutator bar then touch the other lead to the a
37. power flat spots in acceleration and a greater tendency to burn valves and spark plugs Mixture adjustments should be checked with every tuneup and whenever a carburetion problem is sus pected Before adjusting be sure that the ignition sys tem is working properly and that the governor is set correctly If the carburetor is grossly out of adjustment make these preliminary adjustments 1 Turn both mixture screws in until lightly seated 2 Turn the idle mixture screw out one full turn 3 Turn the main mixture screw out 1 1 4 full turns ACAUTION Voltage frequency sensitive equipment such as VCRs televi sions computers etc may be damaged by power line frequency variations Some solid state devi ces are powered whenever connected to an outlet even if the device is not in actual operation For this reason disconnect all devices which are voltage or frequency sensitive before attempting any carburetor governor adjusiments If discon necting the devices is not possible open the circuit breaker s at the distribution panel or at the gener ator set if so equipped Forcing the mixture adjustment ACAUTION screws tight will damage the needle and seat Turn them in only until light ten sion can be felt Start the engine and allow it to run about 10 minutes The adjustment screw location is shown in Figure 6 18 Mixture Adjustment Procedure 1 Stop the set and connect a voltmeter frequency meter and load ba
38. side support to provide the clearance needed for lowering the set Remove the safety catch from the center of each hinge assembly then remove the U shaped hinge pin Slowly lower the generator set uniil it is clear of all obstructions and can be removed from under the Complete Set Removal vehicle Fuel exhaust electrical and control connections must be discon nected as described previously 1 Park the vehicle on a level surface which is capable of supporting the floor jack wheels Put the trans mission in its PARK position lock the brakes and remove the ignition key Make sure no one moves the vehicle while performing this procedure AWARNING Propping the generator set can cause severe personal injury or death Make sure no one moves the vehicle during this procedure and that the procedure is performed very carefully and only as instructed Use a forklift to support the generator set tray at the points shown in Figure 5 4 Place a wooden on one fork so the set will remain level Raise the forklift so it contacts the drip tray then put slight upward pressure on the tray Make certain that the generator set is supported by the forks before continuing 5 6 ee N FORK FIGURE 5 4 COMPLETE SET REMOVAL 1601 2 Section 6 Engine Primary Systems INTRODUCTION Primary engine systems include e Exhaust system e Cooling system Ignition system Electric star
39. supplies have a positive shutoff valve GASOLINE AND LPG FUEL MAY BE ACCIDENTALLY iG NITED BY ELECTRICAL SPARKS presenting the hazard fire or explosion which can result in severe personai in jury or death When installing the generater set e Do tie electrical wiring to fuel lines Do run eleciricai lines and fuei lines through the same compartment openings Keep electrical and fuel lines as far apart as possible lines wherever pcssible if electrical and fuel must pass through the same com partment opening make certain that they are physically separated by running them through individual channels or by passing each line through a separate piece of tubing DC NOT SMOKE while servicing batteries Lead acid bat emit a highiy explosive hydrogen gas that can be ig nited by electrical arcing or by smoking EXHAUST GASES ARE DEADLY e Neversieep in the vehicle with the generator set running Un iess vehicle is equipped with an operating carbon monoxide detector e Provide an adequate exhaust system te expel dis charged gases inspect exhaust system daily for leaks per ihe mainienance schedule Be sure that exhaust manifolds are secure and not warped Do not use exhaust gases 10 heat compartment e Be sure the unit is well ventilated MOVING PARTS CAN CAUSE SEVERE PERSONAL IN JURY OR DEATH e Before starting work on the generator set disconnect batt
40. that secure the muffler support bracket to the set and tighten muffler clamp To prevent excessive vibration ACAUTION transfer to the vehicle mount muffler and tailpipe hanger brackets directly above the component being supported and NOT at an angle Ifreplacing the original tailpipe refer to the Tailpipe Recommendations section to select and locate the tailpipe Attach the tailpipe to the outlet end of the muffler Secure it using a 1 3 8 inch U bolt type automotive muffler clamp Support the tailpipe using a shock mounted sup port hanger with clamp EXS 1120 1 FIGURE 6 2 UNDERFLOOR MOUNT EXHAUST SYSTEM 8 Run generator set for five minutes and check entire exhaust system visually and audibly for leaks or excessive noise Fire can cause severe personal A WARNING injury or death Do not operate the generator set when vehicle if parked in high grass or brush Clean spark arrester muffler every 100 hours of operation Remove 1 8 inch pipe plug in bottom of muffler and run set for five minutes Then replace pipe plug Inspect exhaust system visually and aud ibly for leaks daily at least every eight hours of running time Tailpipe Recommendations Tailpipes are supplied by the vehicle manufacturer They must meet specific design requirements for safe generator set operation Make certain that a replace ment tailpipe is the same size and configuration as the original part Refer to the g
41. the control panel to obtain access to the specified lead wires during testing Ground Test To test for grounds disconnect the trans former and stator leads listed below Stator leads T1 and T3 from TB1 Stator lead B1 from 1 1 1 Stator lead Q1 from VR1 J4 11 Insulate or position the lead wire ends so they do not touch the set housing or other components within the control Set the ohmmeter to its highest resistance scale then connect one test prod to the generator hous ing Touch the other test prod see Figure 8 12 to the listed leads individually A reading less than one megohm indicates a ground Replace a grounded stator with a new stator TEST LEADS T1 B1 AND 01 FOR GROUNDS G1214s FIGURE 8 12 TESTING STATOR FOR GROUNDS Open or Shorted Windings Test To test for opens disconnect the leads listed below Stator leads T1 T2 and T4 from TB1 3 phase units leads 1 12 Stator leads B1 and B2 from A1 Stator leads Q1 and Q2 from VR1 single phase units Set the ohmmeter to the highest resistance scale Con nect the test prods see Figure 8 13 to the generator lead ends in pairs as shown in the tables below The ohmmeter should indicate continuity between lead ends A high resistance reading indicates an open wind ing Replace an open stator with a new stator Test the rotor in the same manner 8 12 TEST LEADS T1 T2 T3 T4 B1 B2 AND Q1 Q2 FOR OPEN OR SHORTED WINDIN
42. to the choke shaft and holds the choke plate nearly closed when the engine is cold When the engine starts vacuum from the intake manifoid causes the pul loff diaphragm to pull in and partially open the choke As the engine runs electric current is supplied to the heat ing element Heat from the element causes the bi metal strip to coil The coiling action ofthe bi metal strip turns the choke shaft and gradually opens the choke plate Heat from the element keeps the choke open while the engine is running The choke becomes very hot during AWARNING normal operalion and can cause severe burns if touched Do not remove the choke cover while the set is operating If the engine starts but runs rough and blows out black smoke after a minute or two of operation the choke is setfortoo rich a mixture Ifthe engine starts but sputters or stops before it warms up the choke is setfortoo lean a mixture Choke Adjusiment Table 6 1 lists choke settings for various ambient temperatures Stop the set and allow it to cool before adjusting 1 Remove the plastic choke cover see Figure 6 24 and loosen the heating element cover screws 2 Rotate the heating element until the choke plate is halfway open HOUSING 2 N ELEMENT COVER FIGURE 6 24 CHOKE ASSEMBLY 6 23 BI METAL SPIRAL STRIP 3 Slowly rotate the cover counterclockwise while tapping the carburetor choke lever and making it bounce Contin
43. with the low oil pressure switch or generator no voltage Go back to the Troubleshooting Guide Replace control board A1 if the oil pressure switch and generator are functioning properly 8 Reassemble the control board and cover CONTROL TROUBLESHOOTING Use the following troubleshooting guide to help locate problems related to the control circuits Figures 7 2 and 7 3 show the location of most of the control compo nents Refer to the appropriate wiring diagram sche matic in Section 11 for location of all terminal connections The troubleshooting guide is divided into sections After identifying the problem refer to the guide for the possi ble cause and the recommended corrective action Untrained personnel should not attempt repai o hazards which can result personal injury or A WARNING p ttempt repair due to haz whi p jury death Troubleshooting information is provided for qualified repair personnel only Trouble Engine Does 1 Not Crank Possible Cause Control fuse F1 may be open lf engine cranks at set but not at remote control panel fault is due to a PC board P2 J2 connection not secure b Open circuit in remote control c Remote start switch faulty If engine cranks at remote contro panel but not at set fault is due to faulty 1 switch Insufficient voltage for cranking due to See Low Battery Voltage also a Battery not charged b Terminal connections loose or dirty
44. 0 025 in 0 64 mm 0 005 in 0 127 mm 0 013 in 0 330 mm 3 5 quarts 3 3 L 4 0 quarts 3 8 L 149 18 BTC 20 BTC 0 016 in 0 41 mm 6 psi 41 kPa 3 Ft 0 9 m 1 4 in ID Hose Barb 7 14 in 178 356 mm WC 3 4 in NPTF Tapping 1 4 in NPTF Tapping Specifications Cont These values are for generators having a Series Delta connection 2 2 MODEL BGD MODEL NHD Voltage 12 12 Startor Motor Terminals Buring Cranking Battery Charging Voltage at No Load AC 144 144 Battery Charging Voltage at Fuli Load AC 14 6 14 6 Battery Charging Amperage 10 10 Trickle Battery Charging Amperage 0 5 0 5 50 Hertz 60 Hertz 50 Hertz 60 Hertz 1500 RPM 1800 RPM 1500 RPM 1800 RPM Rated Power Output 4 0 kW 4 5 kW 5 0 kW 6 5 kW Full Load Current 1 Phase Generators At 110 220 Volts 36 4 18 2 amps 45 5 22 7 amps At 120 240 Volts 37 5 18 8 amps 54 2 27 1 Ful Load Current 9 Phase Generators At 110 220 21 0 10 5 amps 26 3 13 2 amps zm At 120 240 Volts 21 7 10 8 amps 31 3 15 7 amps Gasoline Consumption Under Full Load 0 73 gph 2 8 L h 0 8 gph 3 0 L h 0 8 gph 3 0 L h 1 3 gph 4 9 L h Under Half Load 0 53 gph 2 0 L h 0 6 gph 2 3 L h 0 57 gph 2 2 L h 0 7 gph 2 5 Lh Under No Load 0 35 gph 1 3 L h 0 4 gph 1 5 L h 0 35 gph 1 3 L h 0 4 gph 1 5 L h Propane Fueled Sets Rated Power Output 3 5 kW 4 0 k
45. 189 Groove Width Prior to Spec F 4 78 4 80 mm 4 78 4 80 mm Piston Ring 1 Top 0 003 0 008 0 002 0 008 Side Clearance 0 076 0 203 mm 0 051 0 203 mm Piston Pin 0 6875 0 6877 0 7500 0 7502 Diameter 17 46 17 47 mm 19 05 19 06 mm Piston Pin Fit 0 0002 0 0007 0 0002 0 0008 In Rod 0 005 0 018 mm 0 005 0 020 Connecting Rod 0 002 0 016 0 002 0 016 Side Clearance 0 051 0 406 mm 0 051 0 406 mm Connecting Rod 0 0020 0 0033 0 002 0 0033 Bearing Clearance 0 051 0 084 mm 0 051 0 084 mm The bore is 0 005 inches oversize if the engine serial number has suffix E CRANKSHAFT AND CAMSHAFT Crankshaft Main Bearing Journal Diameter Crankshaft Rod Journal Bearing Diameter Crankshaft Main Bearing Diameter Crankshaft Main Bearing Clearance Crankshaft End Play Camshaft Journal Diameter Camshaft Bearing Diameter Camshaft Bearing Clearance Camshaft End Play VALVE AND LIFTERS Valve Spring Free Length Valve Spring Compressed Length valve closed Valve Spring Tension Valve Spring Tension 5 4 pam 1 9992 2 0000 50 780 50 800 1 6252 1 6260 41 280 41 300 2 0024 2 0034 50 860 50 886 mm 0 0024 0 0042 0 061 0 107 mm 0 006 0 012 0 15 0 30 1 3740 1 3745 34 90 34 91 1 376 1 377 34 95 34 97 0 0015 0 0030 0 038 0 076 0 011 0 048 0 28 1 2 1 600 40 64 _ 1 346 34
46. 24 CHOKE LEVER CHOKE PLATE CLOSED PULL OFF LINKAGE PULL OFF DIAPHRAGM f if e t THIS DISTANCE DIAPHRAGM MTG BRKT BEND HERE owe FIGURE 6 26 CHOKE PULLOFF DIAPHRAGM 4 Check the alignment of the diaphragm stem pulloff linkage and slot in the choke lever as viewed from the top Correct the alignment as required 5 Measure the distance between the choke plate and the bottom of the carburetor at the pointindicated in Figure 6 26 If necessary bend the diaphragm mounting bracket to obtain 0 39 to 0 43 inches 9 9 to 10 9 mm clearance 6 Move choke lever back and forth to check for free movement Verify that the choke does not bind or stick 7 Remove the vacuum supply from the diaphragm and install the filter assembly on the carburetor Fuel Pump All gasoline fueled generator sets are equipped with an electric fuel pump All fuel pumps have an integral shu toff valve that prevents fuel flow to the carburetor when the set is not in operation If the pump malfunctions or insufficient fuel delivery is suspected use the approp riate procedure listed below to test and repair replace the pump Do not substitute automotive electric AWARNING fuel pumps for standard Onan supplied electric pumps Other pumps output pres sure is much higher and can cause carburetor flood ing or fuel leakage creating a fire hazard Pump Test Procedure 1 Remove the fuel from the pump outl
47. 5 Cya FLAT WASHER BAFFLE REED VALVE C 1101 FIGURE 6 13 CRANKCASE BREATHER Most parts cleaning solvents are AWARNING flammable and can result in severe personal injury if used improperly Follow the manu facturer s recommendations when cleaning parts The reed valve must be flat and uncreased Assemble the valve using a new gasket Do not overtighten th valve cover capscrew The reed valve must be assembled as shown in Figure 6 13 with a washer on top and the breather baffle on the bottom Over tightening the valve cover can ACAUTION cause an air leak and allow dirt to enter the engine Be careful not to distort the valve cover when tightening CYLINDER COMPRESSION TEST Careful examination of the spark plugs and the results of compression testing will help determine the condition of the valves pistons piston rings and cylinders Use the following procedure to check cylinder compression 1 Start generator set and allow to warm up 2 Stop generator set Remove and inspect spark plugs see Ignition System in this section 3 Insert compression gauge in one spark plug hole 4 Place throttle and choke in full open position 5 Crank the engine and note compression reading 6 Stop cranking and perform steps 3 through 5 to other cylinder Refer to Specifications section for compression pres sures There may be variations due to equipment temperature atmospheric condit
48. AC power to the voltage regulator through leads J4 11 Q1 and J4 12 Q2 for the excitation system The AC voltage is rectified to DC voltage and the proper DC excitation voltage is induced to the rotor in response to changes in demand Leads from J4 2 and J4 3 are connected to monitor output voltage The voltage regulator is protected from moisture reduc ing the risk of component failure The printed circuit board control is encased in the regulator housing with a potting compound the ends ofthe J4 wiring harness are booted covering the terminals of capacitor C5 mounted to the outside of the regulator housing and the wiring harness plug in P4 is treated with a lubricant prior to connection More protection is provided by mounting the voltage regulator assembly inside the generator control housing Voltage Regulator VR2 Voltage regulator VR2 maintains a full charge on the generator set starting battery Itaccepts 16 21 VAC from generator terminals B1 and B2 and provides a steady 14 2 VDC output VR2 regulates battery charging cur rent to 10 13 amps Circuit breaker CB2 40 amps protects the battery and VR2 from overcurrent conditions Terminal Board TB1 The generator leads T1 T2 T3 etc and the line circuit breaker leads CB1 CB2 etc are interconnected at terminal board TB1 See the appropriate wiring diagram for specific connections Ignition Relay K6 Beginning Spec F Relay K6 energizes the ignition coil T1
49. AWARNING Untrained personnel should not attempt repair due to hazards which can result in personal injury or death Troubleshooting information is provided for qualified repair personnel only Trouble Engine Cranks But Does Not Start Engine Starts But Stops When Start Switch is Released Low Battery Voltage Low oil pressure switch S2 not Stop relay K5 contacts not opening Output voltage from generator not Defective control board 1 or connector Possible Cause 1 Faulty ignition due to worn or fouled spark plugs worn ignition points incorrect ignition timing faulty plug wires faulty condenser or faulty electronic module Faulty fuel system due to low fuel level in tank supply valve not open sticking choke faulty fuel pump or carburetor mixture screws incor rectly adjusted Connect a voltmeter between positive terminal T1 ignition coil and ground Check for battery voltage when S1 is placed in the START position If the voltage is not present fauit is due to a Open circuit between T1 coil and control b Defective control board or connector c Fuse F2 has blown Beginning Spec F d Relay K6 is faulty Beginning Spec closing due to a Low oil level b Open circuit between switch and control c Defective low oil pressure switch d Low oil pressure due to a K5 relay circuit open b Defective K5 relay being supplied to control due t
50. Clear away ali dirt or debris as required Clean stator windings Test each component for open grounded or shorted windings and replace if defective Test voltage regulator and replace if faulty GENERATOR SERVICE This section describes generator disassembly assem bly procedures Refer to Figure 8 1 to locate and identity the various generator components and to the approp riate wiring diagram Generator Disassembly Procedure 1 Drain the engine oil while the generator set is mounted in the vehicle 2 Remove the generator set from the vehicle and place iton asturdy work bench Refer to Section 5 of this manual for set removal procedures 3 Remove the flywheel guard from the scroll opening Remove the noise shield 4 Remove the carburetor and intake manifold to pro vide clearance to lift the generator stator assembly Disconnect the following parts choke heater lead wires gasoline units e throttle linkage d fuel line crankcase breather hose air preheater tube Remove the intake manifold screws and lift off the carburetor and intake manifold as an assembly Refer to the Fuel System description in Section 6 for detailed removal procedures 5 Disconnect the leads to the charge resistor the low oil pressure cutoff switch and the B terminal on the ignition coil 6 Remove the brush block cover and disconnect the F1 outboard and F2 inboard lead wires from the brush block term
51. E PROPER TOOL CHECK THIS SURFACE FOR BURRS BEFORE INSERTING SEAT VALVE SEAT 427 22 42 per te 4 cd K E ve a 3 4 RAR MALES 1025 FIGURE 9 11 INSERTING NEW VALVE SEAT 3 Insert a valve seat staker into the cylinder block valve guide hole Rotate the staking tool until it drops to the original stake marks Rotate the staking tool another 60 1 6 turn Using a lead hammer strike the staking tool a sharp blow to wedge the new valve seat securely in place The valve seat must be staked to ensure a tight fitand eliminate the danger of its loosening in the bore Before installing the valves refinish the valve seat inserts Tappet Adjustment Procedure The engine is equipped with adjustable valve tappets Adiust the valve clearance only when the engine is at ambient temperature 1 Remove all parts that block access to the valve tappets 2 Removethe spark plugs to make turning the engine easier 3 Place a socket wrench on the flywheel capscrew and rotate the crankshaft in a clockwise direction until the left intake valve viewed from flywheel end opens and closes Continue turning the crankshaft until the TC mark on the flywheel is lined up with the TC mark on the gear cover This should place the left piston 1 at the top of its compression stroke Verify that the left intake and exhaust valves are closed and that th
52. GS G1214s 1 B1 B2 FIGURE 8 13 TESTING STATOR FOR OPENS OR SHORTS To test for shorted windings use a digital ohmmeter that reads to within 0 01 ohms Disconnect the stator leads as specified in the Open Test section Connect the test prods see Figure 8 13 to the leads in pairs as specified in the Open Test section The readings for lead pairs should be as follows plus or minus 10 T1 T2 Rotor T3 14 B1 B2 Q1 Q2 Resistance 60 Hz 1 phase 0 327 0 058 2 089 120 240 VAC 0 502 0 112 2 873 50 Hz 1 phase 120 240 VAC 0 246 0 044 2 089 60 Hz 1 phase 100 200 VAC Usethe following table to test the stator resistance ofthe models listed below 71 74 T5 T2 T3 T6 B1 B2 Rotor 10 7 T8 T11 T12 T9 Resistance 60 Hz 3 phase 24 78 Reconnectible 50 Hz 3 phase Reconnectible 120 240 VAC delta A reading less than these values indicates shorted wind ings Replace a shorted stator with a new stator 22 50 22 50 22 50 TESTING VOLTAGE REGULATOR VR1 Confirm that voltage regulator VR1 is faulty before replacing it Use a meter with a diode checking function Fluke Model 73 Multimeter for example to perform the following tests 1 Disconnect the negative battery cable 2 Remove the generator control box cover Figure 8 1 3 Disengage the wiring connector and remove the voltage regulator 4 With the meter on Diode Check test between connector termina
53. Ground Test To test for grounds set the ohmmeter to the highest resistance scale Touch one test prod to the rotor shaftand hold itthere Touch the other test prod to one of the slip rings Figure 8 12 reading less than one megohm indicates that the rotor is grounded Replace a grounded rotor with a new rotor FIGURE 8 10 TESTING ROTOR FOR GROUNDS Open Or Shorted Windings Test To test for open wind ings set the ohmmeter for the highest resistance scale Place test prods on the slip rings as shown in Figure 8 11 Theohmmeter should indicate continuity between slip rings A high resistance reading indicates a poor connection or an open winding Check the connection between the slip rings and rotor lead wires Replace the rotor if the rotor winding is open To test for shorted windings set the ohmmeter for the lowest scale Place the test prods on the slip rings as shown in Figure 8 11 Resistance reading should be 20 25 to 24 75 ohms at 77 F 25 C Replace a rotor with shorted windings with a new rotor 8 11 FIGURE 8 11 TESTING FOR OPENS OR SHORTS Stator Test Thestator may betested for grounded or open windings by using an ohmmeter Testing for shorted windings requires a digital ohmmeter that can read to within 0 01 ohms Figures 8 12 and 8 13 show the stator and transformer removed from the generator for testing However both components may be tested without removing them from the generator Remove
54. IT Bi BUR e E cu eS BREAKER S fy 3 il P i TA Fi 1 CB2 9 e 7 j ai eat 9 _ i f Ly m i oos hd MES DC FUSE F S hf 1 k ff VPS I e I 1 Jew J e 2 i P d VOLTAGE START REGULATOR SOLENOID e VR1 K1 VOLTAGE ADJUST BATTERY STARTER AND GENERATOR WIRING HARNESS CONNECTOR 1 VOLTAGE ADJUST RELAY K5 AND K6 FUEL PUMP FIGURE 7 2 BGD NHD CONTROL COMPONENTS FUSE F1 5A SLO BLO ONLY 585 bud 892 START STOP SWITCH S1 FIGURE 7 3 BGD NHD CONTROL P C B ASSEMBLY A1 7 7 E2 GASOLINE UNITS ONLY CONTROL PRINTED CIRCUIT BOARD ES 1775 5 REMOTE CONTROL WIRING HARNESS CONNECTOR P2 ES 1774 2 Redistribution or publication of this document by any means is strictly prohibited Section 8 Generator GENERATOR CONTROL COMPONENT DESCRIPTIONS The generator and its control components consist of the following elements see Figure 8 1 Control printed circuit board A1 e Brushes Rotor e Stator and housing e Terminal board TB1 voltage regulator VR1 DC voltage regulator VR2 Circuit breaker s CB1 CB2 CB3 e Wiring harness to load Some of these
55. LECTRICAL SYSTEM Hazardous voit ages can ilow from the generator set into ihe utility iine This creates potential for elecirocution or property damage Connect only through an approved device and building main switch is open Consult an electrician in regard to emergency power use GENERAL SAFETY PRECAUTIONS Have afire extinguisher nearby Maintain extinguisher prop erly and become familiar with its use Extinguishers rated ABC by the NFPA are appropriate jor applications Con sult ihe local fire department ier the correct type of extin guisher for various applications e Hoi cccianis under pressure can cause severe personal in jury oper a radiator pressure cap while the engine is running the engine and carefully bleed the system pressure Benzene and lead found in some gasoline have been iden tified by some state and federal agencies as causing cancer or reproductive toxicity When checking draining or adding gasoline take care nct to ingest breathe the fumes con act gasoline Used engine oils have been identified by some state or fed eral agencies as causing cancer or reproductive toxicity _When checking or changing engine oil take care io in gest breathe the fumes or contact used Remove all unnecessary grease and oil from the unit mulated grease and cause overheating and engine damage which presents a potential fire hazard DO
56. NERATOR SET RECEPTACLE M 1604 1 Installation must comply with the applicable codes and standards see the Installation Manual Improper servic ing may create an unsafe installation resulting in dam age to the vehicle and equipment or severe personal injury or death to the user Read all service procedures completely before beginning any repair work and observe all cautions and warnings MODEL IDENTIFICATION When contacting an Onan dealer or distributor supply the complete model number and serial number from the set nameplate This information identifies the set when ordering replacement parts Always use genuine Onan replacement parts obtained from an authorized Onan dealer or distributor Other replacement parts might not perform to Onan specifica tions Incorrect service or repiacement of AWARNING parts can result in severe personal injury and or equipment damage Service personnel must be qualified io perform electrical and or mechan ical service Redistribution or publication of this document by any means is strictly prohibited Section 2 Specifications General Weight Overall Dimensions H x L x W Minimum Free Area for Ventilating Air Minimum Vertical Clearance At Air Discharge Outlet Exhaust Diameter and Material Control Panel Fuse F1 Ignition Choke Fuse F2 Beginning Spec F Engine Displacement Compression Ratio Bore Stroke Cylinder Compression Hot
57. NHD units A front and rear panel assembly serve as sides to complete the housing The generator setis completely suspended underneath the vehicle by the housing assembly To avoid dropping the set during removal follow the recommended remo val procedures AWARNING The generator set is heavy and can cause severe personal injury if dropped during removal Use the recommended remo val techniques and keep hands and feet clear while removing mounting bolts if the generator set will be left in the down tilled position for more than 30 minutes first drain the oil LLLILLLILLLLLLLLLLLLL AL La Ld fp Oil inthe engine cylinders can cause ACAUTION engine damage during starting attempts Oil can enter the engine cylinders when the generator set is in the lowered tilted position Do noi leave the generator set in this position for more than 30 minutes if the oil has not been drained Partial Set Removal Fuel exhaust electrical and control connections must be discon nected as described previously 1 Park the vehicle on a level surface which can sup porithe floor jack wheels Put the transmission in its PARK position lock the brakes and remove the ignition key Make sure no one moves the vehicle while performing this procedure Dropping the generator set can AWARNING cause severe personal injury or death Make sure no one moves the vehicle during this procedure and that the procedure is performed very carefully
58. PTER HOUSING SLIP RINGS The voltage regulator is protected from moisture reduc ing the risk of component failure The printed circuit board control is encased in the regulator housing with a potting compound the ends of the J4 wiring harness are booted covering the terminals of capacitor C5 mounted to the outside of the regulator housing and the wiring harness plug in P4 is treated with a lubricant prior to connection More protection is provided by mounting the voltage regulator assembly inside the generator control housing Voltage Regulator VR2 Voltage regulator VR2 maintains a full charge on the generator setstarting battery 16 21 VAC from generator terminals B1 and B2 and provides a steady 14 2 VDC output VR2 regulates battery charging cur rent to 10 13 amps A 40 amp thermal circuit breaker protects the battery and VR2 from overcurrent conditions BRUSH lt 2 BLOCK ASSEMBLY AD CIRCUIT BREAKER S CB1 CB2 CB3 VOLTAGE REGULATOR 1 TERMINAL BOARD G 1212 1 FIGURE 8 1 GENERATOR CONTROL COMPONENTS Line Circuit Breaker s AC output from the generator is supplied to circuit breakers CB1 and CB2 and CB3 located on the right side of the control housing Ampere rating of these breakers may differ depending on generator set model frequency Refer to the proper Parts Manual when ordering replacement parts Separate circuit breakers are included with genera
59. VT 1023 5 8 16 mm FIGURE 9 9 VALVE GUIDE INSTALLATION 9 5 Valve Seat Inspect the valve seat inserts If the seats are loose cracked or severely pitted new inserts must be installed Remove valve seat inserts using a valve seat removal tool Removal Procedure 1 Remove carbon and combustion deposits from the valve seat 2 Select the proper size puller determined by the inside diameter of the valve seat The puller jaws must expand into the cylinder block at the point where the bottom ofthe valve seat insert rests on the cylinder block Figure 9 10 3 Using the new seat insert as a guide adjust the puller depth Position the puller on the valve seat and tighten its hex nut Clamp the cylinder blockto a solid bench Attach a slide hammer to the puller Between blows with the slide hammer tighten the hex nut PULLER JAWS CT 1104 FIGURE 9 10 VALVE SEAT REMOVAL 1 After the old seat has been removed clean out car bon and metal burrs from the seat insert recess Use a valve seat insert driver and a hammer to install the insert Insertthe pilot ofthe driver intothe valve guide hole in the cylinder block Quickly drive the valve seat insertin so thatthe insert goes evenly to the bottom ofthe recess in the cylinder block Make certain that the valve seat insert rests solidly on the bottom of the recess all the way around its circumference VALVE SEAT INSERT DRIVER US
60. Valve Seat Bore 1 4395 1 4405 1 5645 1 5655 Diameter Intake 36 563 36 588 mm 39 738 39 764 mm Valve Seat Bore 1 189 1 190 1 2510 1 2520 Diameter Exhaust 30 20 30 23 mm 31 775 31 801 mm 3 3 Redistribution or publication of this document by any means is strictly prohibited Section 4 Torque Specifications TORQUE Use engine oil as a lubricant for all threads SPECIFICATIONS EXCEPT the spark plug and rotor through bolt threads FOOT POUNDS NEWTON METRES Cylinder Head Cold 15 17 20 23 Adapter to Engine 25 27 34 37 Mounting Screws Adapter to Generator 5 34 Mounting Screws Rear Vibration Isolator Gearcase Cover Center Screw 30 33 41 45 Flange to Drip 10 12 11 16 Tray Screws Front Vibration lsolator Flange to Oil 19 22 26 30 Base Screws TORQUE Use engine oil as a lubricant for all threads SPECIFICATIONS EXCEPT the spark plug and rotor through bolt threads FOOT POUNDS NEWTON METRES Other 3 8 Cylinder Block 18 23 24 31 Nuts condi e 10 12 do Through Bolt 45 55 61 75 Starter Mounting Screws 30 33 41 45 Stator Clamp Screws 10 12 11 16 Adapter to Engine 25 27 34 37 Mounting Screws Adapter to Generator 49 Mounting Screws Rear Vibration Isolator 30 33 41 45 Center Screw Flange to Drip 10 12 11 16 Tray Screws Front Vibration isolator Flange to Oil 19 22 26 30 T Base Screws 4 2 Section 5 Preparin
61. W 5 0 kW 6 3 kW Ful Load Current 1 Phase Generators At 110 220 Volts 31 8 15 9 amps 45 5 22 7 amps At 120 240 Volts 33 3 16 7 amps 52 5 26 3 amps Propane Consumption Under Full Load 0 98 gph 3 7 L h 1 3 gph 4 9 L h 1 18 gph 4 5 L h 1 7 gph 6 4 L h Under Half Load 0 65 gph 2 5 L h 0 8 gph 3 0 L h 0 78 gph 3 0 L h 1 05 gph 4 0 L h Under No Load 0 4 gph 1 5 L h 0 5 gph 1 9 L h 0 5 gph 1 9 L h 0 65 gph 2 5 L h Section 3 Dimensions and Clearances CYLINDERS AND PISTON ASSEMBLY Values are in inches millimeters unless specified otherwise Cylinder Bore 3 2490 3 2500 3 5625 3 5635 Std size honed 82 52 82 55 mm 90 49 90 51 mm Cylinder Taper 0 005 0 003 0 13 0 08 Cylinder Out Of 0 008 0 003 Round Max 0 08 mm 0 08 mm Clearance In 0 0033 0 0053 0 0070 0 0090 Cylinder 0 084 0 135 mm 0 178 0 229 mm Ring Gap 0 010 0 020 0 010 0 020 0 25 0 50 mm 0 25 0 50 mm Piston Ring 1 top 0 0602 0 0612 0 0602 0 0612 Groove Width 1 53 1 55 mm 1 53 1 55 mm Piston Ring 2 0 0602 0 0612 0 0602 0 0612 Groove Width 1 53 1 55 mm 1 53 1 55 mm Piston Ring 3 0 1193 0 1203 0 1193 0 1203 Groove Width 3 03 3 06 mm 3 03 3 06 mm Piston Ring 1 top 0 080 0 081 0 080 0 081 Groove Width Prior to Spec F 2 03 2 06 mm 2 03 2 06 mm Piston Ring 2 0 080 0 081 0 080 0 081 Groove Width Prior to Spec F 2 03 2 06 mm 2 03 2 06 mm Piston Ring 3 0 188 0 189 0 188 0
62. ach the tailpipe to the outlet end of the muffler Secure it using a 1 3 8 inch U bolt type automotive muffler clamp 8 Support the tailpipe using a shock mounied sup port hanger with clamp Incorrect muffler and tailpipe ACAUTION hanger bracket mounting can result excessive vibration transfer to the vehicle To prevent this mount the muffler and tailpipe hanger brackets directly above the component being supported NOT at an angle Run the generator set for five minutes Check the entire length of the exhaust system for leaks and excessive noise Repair any leaks immediately The muffler and exhaust pipe AWARNING can igniie grass and brush Do not operate the generator set when vehicle is parked in high grass or brush 10 Clean the spark arrester muffler every 100 hours of operation To do this remove the 1 8 inch pipe plug in the bottom of the muffler and run the set for five minutes Then replace the pipe plug inspect the exhaust system for leaks at least every eight hours of running time Underfloor Mount Exhaust System Underfloor mount exhaust systems consist of the exhaust manifold muffler clamps hanger if required and tailpipe When service is required disas semble and reassemble as specified in the following steps Disassembly Procedure 1 Loosen the muffler clamp at the muffler inlet see Figure 6 2 and remove the muffler support bracket screws Remove the two 1 4 20 screws and lock washers
63. acket must point to the generator end when assembled Wiring The ignition system wiring includes Low voltage wiring from B to the ignition module Low voltage wiring from the ignition module to the ignition coil primary winding High voltage wiring from the ignition coil secondary winding to the spark plugs The plugs and coil secondary are grounded to the engine completing a circuit to the battery When the ignition rotor passes the ignition module it causes the module to ground its B connection sending a low voltage pulse through the coil primary A high voltage pulse is induced in the ignition coil secondary firing the spark plug Check all low voltage wiring for loose connections and breaks in the insulation Clean all terminals and connec tions and use an ohmmeter to test them for continuity Use a megger high range ohmmetet to check for breaks in the plug wire insulation Spark Plugs See Spark Plugs under Breaker Point Ignition System BREAKER POINT IGNITION SYSTEM Prior to Spec B for Model BGD and Spec C for Model NHD The ignition system consists of the following elements e Breaker points e Condenser e Ignition coil e Spark plugs e Wiring This section provides service and adjustment proce dures Refer to Specifications section for the correct dimensions for adjustment Breaker Points and Condenser The breaker points and condenser are mounted on the engine biock Asmall plunger rid
64. ading drops slightly each time when the outlet is uncovered the regula tor is not locking off properly To adjust the regulator turn the adjusting screw inward until the manometer fluctuates when the outlet is alter nately covered and uncovered and then back off until the manometer remains steady when the outlet is alter nately covered and uncovered Failure to lock off indi cates either too high an incoming pressure or a dirty regulator valve and seat A soap bubble placed over the ACAUTION lator outlet will not accurately test regulator closing and will cause the very sensitive demand regulator to shut off 6 Close the gas supply shutoff valve at the fuel tank AWARNING LP gas presents the hazard of fire or explosion and it is poi sonous These hazards can result in severe per sonal injury or death Cranking the engine or dis connecting the solenoid valve will create sparks that can ignite accumulated gas vapors Make sure that any gas vapors accidentally released during testing have been safely and completely dissi pated before proceeding ai tte 6 32 7 De energize the solenoid valve and reconnect the solenoid lead to its control lead 8 Connect the gas supply hose to the regulator outlet fitting and secure it with a clamp 9 Remove the manometer and install a 8 inch plug the test hole 10 Verify that the vent hose is properly routed through the opening in the compartment floor then
65. adjust no load speed to 62 51 5 1 hz observe the stability of the set Set the voltage and frequency and adjust the sensitivity of the governor as specified inthe Governor Descriptionin this sec tion Add and remove a half load several times to make certain the set does not bog down or hunt Carburetor Overhaul Carburetor problems which cannot be corrected by mix ture adjustments may be caused by dirtin fuel passages or by worn internal parts Normally the carburetor should seldom require cleaning because LP gas vapo rizes completely before reaching the carburetor leaving no residue However a bad fuel supply or fuel filter may let dirt or oil through to the carburetor This may mean that the carburetor should be cleaned to restore satis factory operation Overhauling the carburetor involves its complete disas sembly thorough cleaning and replacement of worn parts Carburetor repair kits are available that supply new gaskets and replacement parts for the components subject to wear Note the position of all components while removing them for correct reassembly See Figure 6 29 for com ponent designations 6 27 Removal Disassembly Procedures 1 Remove the carburetor from the intake manifold as described in the Carburetor Air Filter and Intake Manifold Assembly section Most parts cleaning solvents are AWARNING flammable and can result in severe personal injury if used improperly Follow
66. and muffler and tailpipe assembly Completion of the remaining steps requires that the generator set be removed from the vehicle Refer to Preparing to Service section for set removal procedures For LPG sets follow the procedure for purging LPG from the fuel line Remove the cooling system noise shield and scroll see Coolingin this section to provide access to the exhaust manifold Remove the four exhaust manifold screws Lift off the exhaust manifold and the two manifold gaskets Assembly Procedure Exhaust gas can cause severe per AWARNING sonal injury or death To prevent exhaust leaks install all gaskets clamps straps and hardware as specified 1 Install the exhaust manifold using new gaskets and tighten the four manifold screws to the specified torque 2 Replace the noise shield and scroll refer to the Cooling System section If no other service is required install the generator set in the vehicle before completing the remaining steps 3 Place a U bolt type automotive muffler clamp marked 1 1 4 in position on the exhaust manifold near elbow prior to installing muffler 4 Place muffler in position on set making certain that the muffler inlet pipe overlaps exhaust manifold a minimum of 1 1 2 inches 38 mm EXHAUST E ELBOW Pd ao P MUFFLER CLAMP MARKED 1 1 4 BRACKET 1 4 20 SCREWS NOISE SHIELD e SCROLL 5 Install the two 1 4 20 screws and lock washers
67. anging to oversize pistons The following repair data describes the honing procedure BOTTOM OF RING TRAVEL 1090 FIGURE 9 29 METHODS OF MEASURING THE DIAMETER OF A CYLINDER BORE Reboring Cylinder Rebore and hone the engine whenever the cylinder bore is worn damaged out of round or if the cylinder taper exceeds specifications A worn cylinder bore should be resized to the smallest standard oversize diameter at which it can be cleaned up The final finish and bore diameters should then be obtained by honing ACAUTION Operating the boring bar incorrectly may produce a rough cylinder sur face that may not be repairabie even by honing Make certain that only an experienced technician performs this job After boring to the correct oversize there should be no need to adjust or fit pistons and rings cylinder bore dimension and piston and ring clearance should be appropriate When reboring cylinders take these precautions 1 Make sure the cutting tool is properly ground 2 Be sure that the top of the engine block is smooth and free of deposits 3 Cleanthe base ofthe boring bar before the bar is set up Deposits underthe boring bar will cause itto tilt causing the cylinder to be distorted after boring 4 Make an initial rough cut followed by a finish cut Then hone the cylinder bore to the specified oversize Honing Cylinders Using Precision Hones Refer to the hone manufacturer s recommende
68. asurements listed below Plunger Diameter 0 3105 to 0 3125 in 7 89 to 7 94 mm Spring Free Length 1 00 in 25 4 mm 2 6 0 2 Ibs 11 6 0 9 when compressed to 0 5 in 12 7 mm 4 Check the valve seat and clean away accumula tion of metal particles which could cause erratic valve action Verify that the valve seat is concentric with the larger diameter valve bore 5 Clean the plunger and spring in parts cleaning solvent and reinstall PISTON ASSEMBLY The piston assembly consists of e Piston e Piston rings e Piston pin e Connecting rod assembly and bearing After removal from the engine all parts must be carefully inspected for damage and wear before they are replaced Removal and Disassembly Procedure 1 Remove carbon from the top of cylinder bore and check for a ridge Remove this ridge see Figure 9 18 with a ridge reamer before attempting piston removal improper use of a ridge reamer ACAUTION can damage the cylinder bore Use this tool with extreme care CT 1058 FIGURE 9 18 REMOVING WEAR RIDGE Turn the crankshaft until a piston is at the bottom of its stroke Remove the nuts from the connecting rod bolts Liftthe rod bearing cap from the rod and push the rod and piston assembly out the top ofthe cylinder with the handle end of a hammer Be careful not to scratch the crankpin or the cylinder wall when removing these parts
69. ath can if it is accidentally ignited or inhaled Eliminate all possi ble sources of ignition including fire flame spark pilot light arc producing equipment or other igni tion sources before purging LP gas from the fuel system Provide adequate ventilation to dissipate LP gas as it is released Slightly open the fuel line flexible section at the solenoid valve and allow the LP gas to slowly escape Do notopen the fitting widely a large quan tity of gas may be released Disconnect the fuel supply hose from the carbure tor and hold it clear of the set Press in and hold the primer button on the regulator to release LP gas from the set fuel system When gas can no longer be heard escaping from the open end of the fuel supply hose reconnect the hose to the carbureior COMPARTMENT FLOOR MOUNTING HOLES EXS 1121 1 FIGURE 5 1 TYPICAL COMPARTMENT MOUNT INSTALLATION ASSEMBLY REAR PANEL FLOOR OF COACH DOOR SUPPORT TRAY SUPPORT BRACKET EXS 1122 2 FIGURE 5 2 TYPICAL UNDER FLOOR INSTALLATION Disconnecting Set from Vehicle Systems Refer to Figures 5 1 and 5 2 for componentlocations in typical generator set installations 1 Disconnectthe vehicle negative battery cable at the battery terminal Disconnect the generator set negative battery cable at the battery terminal Disconnect the generator set positive battery cable from the start soleno
70. azards that must be considered to service the unit safely Study the safety precautions on the inside front cover of this manual closely and become familiar with the hazards listed in Table 5 1 Approach the job in a safety conscious manner to avoid injury or death Safeguards to Avoid Hazards Use personai protection Wear appropriate protec tive safety equipment such as Safety shoes Gloves Safety glasses Hard hats Do not wear rings or jewelry and do not wear loose clothing that might get caught on equipment TABLE 5 1 HAZARDS AND THEIR SOURCE e Fire and explosions Leaking fuel Hydrogen gas from charging battery Oily rags improperly stored Flammable liquids improperly stored Any fire flame spark pilot light arc producing equipment or other ignition sources Burns Hot exhaust pipes Hot engine and generator surfaces Hot engine oil Electrica short Hot engine coolant Poisonous Gases monoxide from faulty exhaust LP gas leaking into coach interior Operating generator set where exhaust gases can accumulate Reduce the hazard A safe orderly workshop area and well maintained equipment reduce the hazard potential Keep guards and shields in place on machinery and maintain equipment in good work ing condition Store flammable liquids in approved containers away from fire flame spark pilot light arc producing equipment or other igniti
71. bly The air intake assembly Figure 6 16 or 6 17 consists of cleaner housing Air filter Air cleaner adapter Disassembly Procedure 1 Remove the crankcase breather hose and air pre heater hose from the air cleaner housing 2 Remove the air cleaner housing center capscrew and lift off the housing and air filter 3 For sets prior to Spec F remove the choke cover retaining nut and lift off the choke cover 4 For sets prior to Spec disconnect the choke lead wires at the choke terminals 5 Remove the three capscrews that secure the air cleaner adapter to carburetor and lift off the adapter For sets priorto Spec F notethatthe choke linkage must be disengaged from the choke assem bly as the adapter is removed 6 Remove the two capscrews that secure the choke bracket to the adapter Lift off the choke assembly Assembly Procedure Reverse the order of disassem bly Use a new gasket between adapter and carburetor Carburetor and Intake Manifold Assembly Disassembly Procedure 1 Remove the air intake assembly as described in the Air Intake Assembly section 2 Disconnect the fuel line and governor control lin kage from the carburetor 3 Remove the intake manifold capscrews and lift off the carburetor air preheater Lift off the carburetor and intake manifold as an assembly 4 Remove the two intake manifold gaskets and plug the intake ports with a rag to prevent loose parts
72. camshaft and gear assembly remove the cylinder head and valve assemblies then remove the actuating plunger for the breaker points and tappets Installation Each timing gear is stamped with O near its edge The gear teeth must mesh so that these marks exactly coincide when the gears are installed in the engine When installing the camshaft gear and shaft assembly be sure that the thrust washer is properly in place behind the camshaft gear Then install the crankshaft retaining washer and lock ring LUBRICATION SYSTEM All generator set engines use an oil pump to provide constant flow of oil to the engine parts The oil supply collects in the oil base where itis picked up by the oil pump pickup cup bypass valve controls oil pressure Drain the oil before removing the oil base and always use a new gasket when replacing the oil base Oil Pump The oil pump Figure 9 16 is mounted on the front of the crankcase behind the gear cover It is driven by the crank shaft gear The inlet pipe and screen assembly is attached to the pump body A discharge passage in the pump cover is aligned with a passage drilled in the crankcase Other pas sages distribute oil to the front main bearing rear main bearing and pressure control bypass valve OIL PUMP ASSEMBLY CRANKCASE TURNED ON LEFT SIDE LS 1109 FIGURE 9 16 OIL PUMP ASSEMBLY Circumferential grooves in the main bearings supply oil to the connecting rod bearings through
73. connect the negative battery cable 2 Remove the control box cover Figure 7 3 and separate it from control board A1 by removing the four screws on the back of the board 3 With an ohmmeter check for electrical continuity across each P1 J1 and P3 J3 connector on the control board Figure 7 4 Replace the socket por tion of each connector that has a measurable resistance greater than zero ohms or has begun to corrode 4 Reconnect the battery and try to start and run the set 5 If the engine does not crank measure voltage at connector P1 2 while pressing the panel start switch the negative test probe of the voltmeter should be grounded at connector P1 8 If the volt meter indicates zero volts check control board fuse F1 if the fuse is good replace control board A1 If the voltmeter indicates at least 9 volts the problem is not with the control board Go back to the bleshooting Guide 6 If the engine cranks but does not start measure voltage at connectors P3 3 and P3 6 while the engine is cranking the negative test probe of the voltmeter should be grounded at connector P1 8 Replace control board A1 if the voltmeter indicates zero volts at either connector If the voltmeter indi cates at least 9 volts at both conneciors the prob lem is not with the control board Go back to the Troubleshooting Guide 7 If the engine starts but stops when the Start switch is released the problem could be
74. contact the valve face evenly at all points The line of contact should be at the center of the valve face Valve Guide Replacement Worn valve stem guides may be replaced from inside the valve chamber a seal is provided behind the intake valve guides only The smailer diameter of the tapered valve guides must face toward the valve head Tappets are also replaceable from the valve chamber after the valve assemblies are removed first Removal Procedure 1 Before removing the valve guides use an electric drill with a wire brush to remove carbon and other foreign material from the top surface of the guides Failure to do this may result in damage to the guide bores 2 Drive the guides out with a hammer and a valve quide driver Driving out the old valve guides can ACAUTION damage the tappet bores Be careful not to strike the bores with the driver Installation Procedure 1 Runasmall polishing rod with crocus cloth through the valve guide holes to clean out carbon and other foreign materials 2 Place a new gasket on the intake valve guide and coat the outer edge of each new guide with oil 3 Placethe guide notch up in the cylinder block and press it in until the shoulder of the guide rests against the cylinder block A suggested method of installation is shown in Figure 5 16 18 HEX NUT 2 REQUIRED s 178 mm p 7 5 16 FLAT WASHER 2 REQUIRED 5 16 18 THREADED ROD 60 mm
75. crews tightened to the specified torque Make sure the rear thrust washer and shim s did not slip out of place during installation The crankshaft should turn freely by hand Endplay Checking Procedure After tightening two rear bearing plate nuts or cap screws to the specified torque check the crankshaft endplay atthe point shown in Figure 9 28 using a feeler gauge MEASURE ENDPLAY HERE REFER TO DIMENSIONS CT 1068 AND CLEARANCES FIGURE 9 28 CHECKING ENDPLAY 1 Lightly tap the front of the crankshaft with a plastic faced hammer to take up the freeplay Refer to the Dimensions and Clearances section for the recom mended crankshaft endplay 2 If necessary remove the rear bearing end plate and add or remove shims as required 3 Install the end plate and tighten all nuts or cap screws to the specified torque 4 Make sure the shim and thrust washer are in place and recheck crankshaft endplay Verify that the crankshaft turns freely without binding CYLINDER BLOCK The cylinder block is the main support for all other primary engine parts The crankshaft and camshaft are supported by the cylinder block assuring alignment of the crankshaft and cylinder bores Cleaning After removing the pistons crankshaft cylinder heads etc inspect the block for cracks and extreme wear If it is still serviceable prepare it for cleaning as follows 9 14 1 Scrape all old gasket material from the block Remov
76. d adjust the demand regulator inlet pressure and the regulator lockoff as follows 1 Close the gas supply valve at the fuel tank s and remove the 1 8 inch pipe plug from the regulator test hole See Figure 6 36 GAS H ds MANOMETER y A SOLAS OTE ONLI AAAI LPP EH pm OUTLET GAS REGULATOR G SCREW VENT PLUG ed Are 1 8 PIPE PLUG NS FS 1108 1 FIGURE 6 36 MANOMETER TESTING IF REQUIRED 2 Gonnect manometer that reads up to 14 inches 356 mm of water column to the test hole One inch of water equals 0 58 ounce square inch 250 Pa 3 Energize the solenoid shutoff valve by connecting its insulated lead to a battery positive source AWARNING LP gas presents the hazard of fi or explosion and it is poi sonous These hazards can result in severe per sonal injury or death Provide adequate ventilation while adjusting regulator to prevent any possible accumulation of LP gas 4 Remove the gas supply hose from the regulator outlet then open the fuel tank shutoff valve Gas should not come from the regulator outlet during testing because of the closing action of the regula tor valve 5 Alternately block and uncover the regulator outlet while checking the manometer If the regulator closes completely the manometer will hold a steady reading If the manometer re
77. d follow the head torque tightening sequence shown in Figure 9 2 Start by tightening all bolts to 5 ft lbs 7 N m then 10 ft ibs 14 N m etc until all bolts or stud nuts are tightened to the specified torque see Torque Speci fication section 5 Retorque before engine has run a total of 25 hours BGD VALVE STEM SEAL a XN ST ay a TH eid VALVE SEAT NHD LE VALVE m E VALVE einen _INSERT Mw VALVE GUIDE d sd m ar m E eas 4 ONLY VALVE SPRING VALVE VALVE INSERT GUIDE KEEPERS VALVE CLEARANCE VALVE ADJUSTING SCREW a lt NN ee VALVE INTAKE VALVE STEM SEAL OPTIONAL VALVE SYSTEM properly functioning valve system is essential for the engine to perform well Onan generator sets use an L head valve design as shown in Figure 9 3 The valve system may be accessed by removing the cylinder heads and valve covers on top of the engine A valve spring compressor must be used to remove the valves see Figure 9 4 from the cylinder block Use the proce dures described below to inspect and service the valve system VALVE CLEARANCE VALVE ADJUSTING SCREW TAPPET VALVE VALVE CAP RETAINER VT 1034 Sho VALVE SPRING WASHER LOCK EXHAUST ONLY VT 1005 FIGURE 9 3 VALVE SYSTEM A VT 1018 FIGURE 9 4
78. d grit size to produce the specified surface finish of 20 to 40 RMS Too rough a finish will wear out the piston rings and too smooth a finish can retard piston ring seating 1 Position the block solidly for either vertical or horiz honing Use either a drill press or a heavy duty drill which operates at approximately 250 to 450 rpm 2 Follow the hone manufacturer s instructions for the use of oil or lubricant on the stones Do not use lubricants with a dry hone 3 Insertthe hone in the bore and adjustthe stone to fit snugly to the narrowest section When adjusted cor rectly the hone should not shake or chatter in the cylinder bore but will drag freely up and down when hone is not running 4 Connect the drill to hone and start the drill Note that high spots in the bore cause an increased drag on the stones Move the hone up and down in bore with short overlapping strokes about 40 times per minute Usually the bottom of the cylinder must be honed first because it is smaller As the cylinder takes a uniform diameter move the hone up and down through the length of the cylinder bore 9 Checkthe diameter of the cylinder regularly during honing at six places in the bore measure twice at top middle and bottom at 90 degree angles A dial bore gauge is the easiest method but atelescoping gauge can be used 6 The crosshatch formed by the stones should form an included angle of 23 degrees This can be achieved
79. d install the throttle plate 6 28 using new screws if furnished in the repair kit Center the plate in the throttle bore before tighten ing the screws To do this move the throttle lever to the completely closed position Seat the plate by gently tapping on it with a small screwdriver then tighten the screws Install the seal the throttle stop lever and the collar on the throttle shaft 2 Install the idle main adjustment screws and turn A regulator that has been operated then stored for any them in until lightly seated For preliminary settings length of time may require rebuilding or replacement turn the idle screw out 1 1 4 turn and the main Diaphragms and gaskets tend to dry shrink and harden screw out 2 1 2 1 4 turns with time Use the test procedure specified in the Regu lator Test section to check regulator operation then ACAUTION Forcing the mixture adjusiment rebuild or replace as required Repair kits include screws light will damage the detailed and illustrated installation instructions needle and seat Turn these screws in only until light tension is felt 3 Jointhe upper and lower sections ofthe carburetor and install the bowl plug and washer 4 When the carburetor is installed on the set make final adjustments to mixture screws as specified in the Carburetor Mixture Screw Adjustments section Regulator A two stage regulator see Figure 6 31 delivers DIAPHRAGM rized LPG fuel to th
80. does not equal battery voltage minus 10 volts zener diode is defective Meters and switch function properly but 5 run lamp does not illuminate Lamp internal to switch is burned out If remote switch functions properly 6 starting and stopping generator set but meters and run lamp do not operate Current sensing resistor R4 on control board A1 has opened caused by a short in the remote control wiring between control board P2 J2 terminal 6 5 and remote control time meter run lamp battery condition meter Corrective Action Check fuel and oil levels and refill as necessary Clean fuel filter Refer to Fuel System Section 6 for test and service procedures Replace breaker points Refill tank with fresh fuel Check for continuity and correct if circuit is open Check for continuity and correct if circuit is open Replace time meter Replace battery condition meter Replace zener diode Replace remote start stop switch 92 Check for continuity of remote wiring harness and wiring on remote control in series with terminals 6 and 5 Replace wiring of shorted circuit VOLTAGE REGULATOR VR2 E e NM if a FUEL SOLENOID 2 R e LPG UNITS ONLY gt 47 1 fet Ins XS r set n 2 2 fund MEC ONE AA od I9 i Weg Me 1 AP 4 5 NW be M ye N MU VOU e CIRCU
81. e and the crankcase 2 Remove the filter see Figure 9 1 by turning it coun CYLINDER HEADS terclockwise with a filter wrench Remove the cylinder heads for cleaning when poor 3 Loosen the two capscrews that secure the adapter engine performance is noticed to the engine block and remove the adapter and gasket The low oil pressure cutoff switch is dar Hand Sanico Procedures installed in a threaded hole in the filter adapter Cylinder Head Se 1 Remove the cylinder head capscrews by using a To assemble the oil filter and adapter perform these 1 2 inch socket wrench Lift off the cylinder head steps in reverse order Install a new adapter gasket so that the two small oil holes are aligned with the oil holes in the block This gasket should be installed dry Coat the threads of each capscrew with non hardening sealer and tighten to the recommended torque The heads may warp if they are ACAUTION removed while hot Wait until the engine has cooled before removing the heads 2 After removing the heads clean outall carbon dep osits Be careful not to damage the outer sealing edges where the gaskets fit The heads are made of aluminum and may be damaged by careless handling 3 Use new head gaskets and clean both the heads and the cylinder block thoroughly where the gaskets rest 9 1 BGD C 1002 NHD M 1871c FIGURE 9 2 CYLINDER HEAD TIGHTENING SEQUENCE 4 Place the heads in position an
82. e carburetor The primary stage of the regulator receives LP gas at container pressure and reduces itto the low pressure required for set operation The secondary stage of the regulator restricts fuel flow through the regulator until the vacuum from the engine creates a demand for fuel Fuel flows through the regula tor only when the engine is cranking or operating it stops flowing when the engine is stopped The regulator should require little attention if the set Is ee used on a regular basis and operated on clean high PRIMARY quality fuel Most regulator malfunctions can be traced VALVE to two sources 572 Hardened diaphragms and seats due to extended periods of non use e Dirtorforeign matter embedded in valves and valve seats PRIMARY DIAPHRAGM XFS 1600 FIGURE 6 32 REGULATOR DISASSEMBLY FS 1596 1 FIGURE 6 31 LP GAS REGULATOR 6 29 A regulator with granules of foreign matter embedded in the secondary seat may cause inconsistent starting or idling Foreign matter dissolved in the LPG can form granules as the fuel is vaporized Remove the regulator front cover and diaphragm assembly see Figure 6 32 to check for dirt or oil deposits If granules are imbedded in the rubber ofthe secondary valve wash the valve and seat clean Regulator Test Procedure Use compressed air and an automobile fuel pressure gauge to test the regulator 1 Attach the pressure gauge to the test port on
83. e oil bypass to allow cleaning solution to contact inside of oil passages 2 Remove grease and scale from the cylinder block by agitating in a bath of commercial cleaning solu tion or hot soapy washing solution 3 Rinsethe block in clean hot water to remove clean ing solution Inspection When rebuilding the engine thoroughly inspect the block for any condition that would make it unfit for further use This 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 Minute cracks may be detected by coating the suspected area with a mixture of 25 percent kerosene and 75 percent light motor oil Wipe the part dry and immediately apply a coating of zinc oxide white lead dissolved in wood alcohol If cracks are present the white coating will become discolored at the defective area Remove this coating after the test and before Always replace a cracked cylinder block 2 Inspect all machined surfaces and threaded holes Carefully remove any nicks or burrs from machined surfaces Clean out tapped holes and clean up any damaged threads 3 Check the top of the block for flatness with a straight edge and a feeler gauge Cylinder Bore Inspection Inspectthe cylinder bores for scuffing scratches wear and scoring If these condi tions exist they must be rebored and honed for the next oversize piston When the appea
84. e reconnectible units voltage is sensed through isolation transformer T2 The sensing leads provide reference voltage to the vol tage regulator depending on load The voltage regula tor increases DC excitation voltage to the rotating field proportionate to the load continuously adjusting the field current as the load changes Efficient generator set performance depends on voltage and frequency engine speed regulation Output load changes can significantly decrease or increase engine speed If the governor does not maintain proper engine speed too large a burden may be imposed on the voltage regulator for proper current to be supplied to the load Governor adjustmentand troubleshooting is discussed in Section 6 of this manual GENERATOR TROUBLESHOOTING This troubleshooting guide provides solutions to many common generator problems Figure 8 1 shows the location of the generator components Referto the appropriate wiring diagram to locate terminal connections Ifthese suggestions do not help contact an authorized Onan service representative A WARNING Untrained personnel should not attempt repair due to hazards which can result personal injury or death Troubleshooting information is provided for qualified repair personnel only Trouble No AC Voltage Note This condition may cause the generator set to stop when start switch 1 is released AC Output Voltage Too Low or Too High Possible Cause
85. earings are free Rod Bearing Clearance Procedure 1 Mark all parts so they can be installed in their origi nal positions and wipe all parts clean of oil and grease 2 Place a piece of the correct size Plasti gage across the full width of the bearing cap about inch 6 mm off center 3 Install the bearing cap and tighten to the specified torque Do not rotate the crankshaft after the cap is in place 4 Remove the bearing cap and leave the flattened Plasti gage on the part to which it adheres Com pare the widest point of ihe flattened Plasti gage with the graduations on the envelope see Figure 9 27 to determine the bearing clearance S Si S DII UN IND 1424 ES 2 r r SS i E FIGURE 9 27 MEASURING BEARING CLEARANCE 9 13 Removal Procedure 1 Loosen the rear bearing plate screws and remove the bearing plate gasket thrust washer and shims 2 Turn the crankshaft so the crankthrow is aligned with the notch in the rear opening ofthe crankcase 3 Carefully slide the crankshaft out of the crankcase Inspection Inspect the rod and main bearing journals If they are worn or scored and cannot be smoothed by polishing either the journals should be reground to fit one of the standard undersize bearings or the crankshaft should be replaced Remove only enough metal to restore the
86. ecause generator set installations vary it is not possi ble to describe a specific removal procedure If an acceptable method cannot be determined contact the vehicle manufacturer or the generator set installer for the preferred method Special fuel handling procedures are required to remove an LPG powered set The fuel system must be purged of LP gas before the set can be removed safely from the vehicle The generator set is heavy and can AWARNING cause severe personal injury if dropped during removal Use adequate lifting devices to provide sufficient support for the set Keep hands and feet clear while lifting 5 2 LPG Purging Procedure 1 Open the set mounted AC circuit breakers and close the shutoff valve at the fuel tank 2 Start and run the generator set until it is out of fuel 3 Crank the set a few times after it stops to make certain that it is purged of fuel Ifthe generator set cannot be operated do the following 1 BARRIER Move the vehicle to a well ventilated outdoor loca tion far from fire flame spark pilot light arc producing equipment or other ignition sources Disconnect the vehicle negative battery cable and the generator set negative battery cable from their respective batteries Close the generator set fuel system shutoff valves and all other shutoff valves at the fuel tank LP gas Propane is extremel Dig pni Severe personal injury or de
87. eed AC output voltage from the generator energizes the generator relay 2 Energizing K2 opens a set of contacts to de energize K4 and closes another set of contacts to connect B to the run relay Relay continues to keep the fuel and ignition circuits energized De energizing K4 disconnects the battery from the generator field and drops out relay K1 which discon nects the starter motor When start stop switch S1 is released it returns to cen ter run position and the engine continues to run Relays K2 generator relay run relay and K5 stop relay are energized while relays K1 startsolenoid and start relay are de energized Stopping Moving the start stop switch 61 to the STOP position grounds resistors R1 and R2 to de energize run relay This opens its contacts to disconnect from igni tion coil T1 stop relay K5 and fuel pump fuel solenoid E2 The relay K5 contacts close grounding resistors R1 and R2 This prevents from being energized and the set from restarting when switch 1 is released from the STOP position Without ignition or fuel the engine stops As the genera tor output voltage drops generator relay K2 aiso de energizes All components return to their de energized position following set shutdown TESTING CONTROL BOARD A1 Confirm that control board A1 is faulty before replacing it Use a DC voltmeter and an ohmmeter to perform the following tests 1 Dis
88. er ies This will prevent accidental arcing Fuel lines must be adequately secured and free of leaks Place a physical barrier between lines and electrical Keep your hands away from moving paris Make sure that tasteners on the generaior set are secure Tighten supporis and clamps xeep guards in position over fans drive etc Do not wear loose clothing or jewelry while working on gen eraior seis Loose clothing and jewelry can become caught in moving paris Jewelry can short out electrical contacts and cause shock or buming if adjustment musi be made while the unit is running use ex treme caution around hot manifolds moving paris ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Disconnect staring battery before removing protective shields or touching electrical equipment Use rubber insula ve mats placed dry wood platforms over floors that are metal or concrete when around electrical equipment Do not wear damp clothing particulariy wet shoes or allow skin sur faces tc be damp when electrical equipment e Use exireme caution when working on electrical compo nents High voltages can cause injury or death Follow all siate and local eleciricai codes Have ail electrical installations periormed by a qualified licensed electrician Tag open switches avoid accidental closure DO NC GENERATOR SET DIRECTLY ANY BUILDING E
89. er cover and air cleaner filter element Remove the brush block cover from the stator housing Disconnectthe F1 outboard and F2 inboard lead wires from the brush block terminals Remove the brush block mounting screws and lift out the brush block Removebrushes and brush springs from holder and replace with new parts Pull and hold both brush lead wires outward from brush holder Place brush block assembly into mounting position inside stator housing While continuing to hold the brushes away from slip rings insert the brush retainer wire from outside stator housing hole through brush block assembly Release both brush lead wires See Figure 8 9 Install brush block mounting screws and tighten only enough to hold brush block assembly in posi tion Liftboth brush lead wires and remove brush retain ing wire completely from stator housing 8 10 11 12 13 14 15 FIGURE 8 9 BRUSH REPLACEMENT Adjust brush block assembly so that brushes are aligned on slip rings and tighten brush block mounting screws Connectthe voltage regulator and brush lead wires to brush block terminals F1 with outboard brush lead and F2 with inboard brush lead Install brush block cover onto stator housing Install air filter element and air cleaner cover Connect negative battery cable to battery terminal Slip Ring Inspection and Maintenance Remove the brush bl
90. er ends butttogether Locate the expander gap 180 degrees from the ring gap The rings for newer replacement pistons and Spec F pistons are packaged with instructions Follow the instructions exactly Note especially which ring goes in which groove and which side of the ring is up Also note that the oil control ring is an assem bly of three pieces COMPRESSION RINGS EXPANDER CT 1047 FIGURE 9 25 PISTON RINGS 9 12 Piston Installation Procedure 1 Turn the crankshaft to position the 1 rod bearing journal at the bottom of its stroke 2 Lubricate the 1 piston assembly and the inside of the cylinder Compress the rings with a ring com pressor as shown in Figure 9 26 instali the bearing insert in rod NOTCH TOWARD CAMSHAFT CT 1048 CT 1066 FIGURE 9 26 INSTALLING PISTON AND CONNECTING ROD 3 Position the piston and rod assembly inthe cylinder block with the connecting rod oil hole toward the camshaft 4 Tap the piston down into the bore with the handle end of the hammer until the connecting rod is seated on the journal Check the bearing clearance before proceeding to step 5 see Rod Bearing Clearance section 5 Install the bearing cap on the rod Install one fas tener and tighten to 5 ft Ibs 7 Nem Repeatthis for the other fastener Tighten both fasteners to 14 ft lbs 19 Nem 6 Install the remaining piston and rod in the same way Crank the engine by hand to see that all b
91. er ignition sources before purging LP gas from the fuel system Pro vide adequate ventilation to dissipate LP gas as it is released 4 Slightly open the fuel line flexible section at the solenoid valve and allow the LP gas to slowly escape Do not open the fitting widely a large quan tity of gas may be released 5 Disconnect the fuel supply hose from the carbure tor and hold it clear of the set 6 Press in and hold the primer button on the regulator to release LP gas from the set fuel system 7 When gas can no longer be heard escaping from the open end of the fuel supply hose reconnect the hose to the carburetor 6 25 Carburetor Air Filter and intake Manifold Assembly The carburetor air filter and intake manifold assembly Figure 6 27 consists of Air cleaner housing e Air filter Air cleaner adapter e K5 relay assembly Carburetor e Intake Manifold Prior to Spec B for Model BGD and Spec C for Model NHD Disassembly Procedure 1 Remove the crankcase breather hose from the air cleaner housing 2 Remove the air cleaner housing center capscrew and lift off the housing and air filter 3 Disconnect the lead wires from the K5 relay terminals 4 Remove the three capscrews that secure the air cleaner adapter to the carburetor and lift off the adapter 5 Remove the two capscrews that secure the K5 relay bracket to the adapter and lift off the relay assembly 6 Disconnect the f
92. ere is no pressure on the valve lifters 4 Clearances are listed in the Specifications section For each vaive the gauge should just pass between the valve stem and valve tappet see Figure 9 12 VT 1026 FIGURE 9 12 VALVE CLEARANCE ADJUSTMENT 5 To correct the valve clearance turn the adjusting screw as needed The screw is self locking 6 adjust the valves on the right cylinder turn the engine one complete revolution and line up the mark on the flywheel and the TC mark on the gear cover again Then follow the adj nee procedure given for the left cylinder 7 Replace all parts removed Tighten all screws securely Torque manifold bolts 2 Turn the governor cup so the nylon lined hole is at the three o clock position Use a small amount of grease to help hold the cup position The rounded Removal Procedure side of the governor yoke must ride against the Remove the flywheel key and gear cover mounting governor cup Screws Turn the governor arm and shaft clockwise as far as Gently tap the gear cover with a plastic faced hammer possible and hold in this position until the gear to loosen it see Figure 9 13 cover is installed flush against the crankcase Be careful not to damage the gear cover oil seal Installation Procedure Refer to the Oil Seals section if replacing the gear cover 1 When installing the gear cover make sure thatthe 01 Seal pin in the gear cover engages the nyl
93. es on an ignition cam at the end of the camshaft This plunger actuates the points which open and close twice with every revolu tion of the camshaft Point gap setting determines when the points will open and consequently ignition timing If the timing is retarded too far efficiency is reduced Ifitis advanced too much overheating results The condenser prevents arcing across the opening breaker points to extend point life An open condenser causes a weak spark and rapid point wear and must be replaced A shorted condenser allows no spark Anew condenser is supplied with the engine tune up kit Replace the condenser when replacing the points Breaker Point Replacement Adjustment Procedure Make ignition adjustments with the engine cold and at rest Do not file the points 1 Disconnect the negative battery cable at the bat tery terminal 2 Remove the breaker box cover clip and lift off the breaker box cover 3 Remove the spark plugs to permit easy rotation of the engine and generator assembly Use a socket wrench to turn the rotor through bolt clockwise until the breaker point gap is open as far as possible 4 Disconnectthe ignition lead wireatscrew A Figure gt 6 9 5 Remove the breaker points mounting screws B and lift out the point assembly 6 Replace the breaker point assembly 7 Useanallen wrench to adjustsetscrew C to the gap listed in the Specifications section Measure the point gap with a
94. et and install a pressure gauge 2 Press the Start switch and hold it for several seconds until the pressure reading is constant 3 The pressure reading for a good pump will fall between 4 and 5 psi 27 5 to 34 4 kPa Pressure should stay constant or drop off very slowly pressure reading is below 3 1 2 psi 17 2 kPa replace fue pump f pressure reading is at zero stop engine cranking and check electrical connections Press the START switch and recheck pressure reading There are no serviceable components in the fuel pump Refer to the generator set Parts Manuals Onan publications 965 0228 BGD and 940 0229 and replace pump with Onan supplied pump only ACAUTION Do not tamper with the seal at the center of the mounting bracket on the side of the pump because it retains the dry gas which surrounds the electrical system Electrical system components are not serviceable FUEL SYSTEM LPG LIQUID WITHDRAWAL The fuel system must be properly adjusted and in good condition Components of the fuel system are Air cleaner assembly Carburetor Intake manifold Fuel filter Solenoid valve Vaporizer Two stage regulator LPG generator sets which use a liquid withdrawal sys tem are intended to share the vehicle LPG fuel tank The LPG fuel tank must be designed with a dip tube to permit liquid fuel withdrawal This manual section provides basic information about LPG fuel sy
95. flange on the driver Wipe off any excess Loctite and allow one hour for hardening at room temperature Engines shipped from the factory have separate thrust washers and main bearings for both front and rear of engine The front bearing replacement part is a one piece bearing with attached thrust washer as shown in Figure 9 33 Do not add an additional thrust washer to this front bearing NOTE DO NOT ADD ADDITIONAL THRUST WASHER WHEN diet REPLACING FRONT BEARING BORE e e Q LOCK PIN ne el LOCK PIN ALIGN BEARING NOTCHES WITH PER LOCK PINS AND MATCH OIL HOLES FRONT MAIN BEARING PRECISION TYPE DO NOT LINE BORE OR REAM OR BORE M 1476 FIGURE 9 33 FRONT BEARING USE GREASE IN SPACE BETWEEN SEALS TO IMPROVE SEAL OIL SEALS Replacement Procedures Remove the rear bearing plate to replace the rear oil seal Remove the gear cover to replace the front oil seal Use an oil seal remover to pry out the front or rear oil seal Usean oil seal guide and driverto press or drivethe rear seal into the rear bearing plate until it bottoms against the shoulder of the plate see Figure 9 34 Press or drive the front oil seal into the gear cover until itis 0 97 0 002 inch 24 6 0 5 mm from the mounting face of the cover Place a light coating of grease on the lips of the replacement seal before installing the rear bearing p
96. flat thickness gauge 8 Replace the point box cover spark plugs and spark plug leads 9 Connect the negative battery cable to the nega tive battery terminal SEE SPECIFICATIONS SECTION FOR GAP SCREW ES 1592 2 SCREWS Bp FIGURE 6 9 BREAKER POINTS ignition Coil The ignition coil Figure 6 10 is a transformer that steps up the battery voltage to approximately 20 000 volts to fire the spark plug Keep all ignition coil terminals and connections clean and secure Check for loose seams dents punctures and other mechanical damage If ignition is poor and other ignition components are not at fault testthe coil as described below Make certain of coil polarity the nega tive terminal connects to the breaker points and the positive terminal connects to a battery positive source within the control HIGH VOLTAGE TERMINALS LOW VOLTAGE TERMINAL E SECONDARY WINDING PRIMARY WINDING IRON CORE ES 1666 FIGURE 6 10 IGNITION 6 11 Ignition Coil Testing Procedures Quick AWARNING Gasoline vapor is extremely flam mabie and can result in severe sonal injury or death if ignited certain that no gasoline or other flammable fumes are present Park the vehicle in a well ventilated area and leave the generator set compartment door open for several min utes before performing the test 1 Remove a spark plug 2 Reco
97. from accidentally entering the ports 5 Unbolt the carburetor from the intake manifold For sets prior to Spec F disengage the choke pull off linkage from the carburetor Assembly Procedure Reverse the order of the disas sembly steps Use new gaskets between the intake manifold and the engine and between the intake mani fold and the carburetor Do not use sealer on the gaskets Tighten the intake manifold capscrews to the specified torque 6 16 O RING SUP OVER THE END OF THE PREHEATER HOSE AND INSERT IT me di INTO THE COLLAR FUEL INLET THE FUEL LINE FROM A REMOTE OR MOUNTED PUMP IS CONNECTED HERE THROUGH AN ELBOW FITTING FS1607 1 FIGURE 6 16 GASOLINE FUEL SYSTEM SPEC 6 17 CRANKCASE BREATHER TUBE AIR PREHEATER AIR PREHEATER CHOKE PULL OFF SE HOSE gt as AIR CLEANER N HOUSING INTAKE MANIFOLD COTTERPIN gt WASHERS GOVERNOR ROD CHOKE SPRING FUEL LINE THROTTLE LEVER FS 1879 SEE DETAIL A FIGURE 6 17 GASOLINE FUEL SYSTEM PRIOR TO SPEC F 6 18 Carburetor Mixture Screw Adjustments The most common cause of poor carburetion is incor rect adjustment of the idle or main mixture adjustment screws Variation from the correct settings may resultin serious engine trouble Too rich a mixture wastes fuel and increases engine wear by washing the lubricant from the cylinder walls and diluting the crankcase oil Too lean a mixture results in a loss of
98. ft coupling and through bolt The outer end of the rotor is sup ported by a single bearing that is pressed onto the rotor shaft The bearing fits inside the generator housing Cooling airflow for the generator is provided by a cen irifugal fan that mounts on the inner end of the rotor shaft The fan also serves as a mount for the starier ring gear Stator and Housing During generator set operation AC current 1 produced in the windings of the stator Stator winding leads are routed into the generator set control housing compart ment for control component connection as follows Leads T1 2 and T4 to Terminal Board TB1 for supplying power to load Leads B1 and B2 to Control Board A1 wiring har ness J1 for supplying power to generator relay K2 and for battery charging Leads Q1 and Q2 to Voltage Regulator VR1 wiring harness J4 for excitation voltage of rotor AC vol tage from stator is rectified to DC voltage VR1 The stator mounts inside the generator housing and is held in position with clamps and capscrews A series of air intake openings in the end of the housing allow cool air to be drawn inside the housing for generator cooling The housing also provides a mounting for the engine starter 8 voltage regulator VR2 rear rotor bearing exciter brush block control components and fuel pump or solenoid The complete stator and housing assembly bolts to the engine to generator adapter
99. g to Service TROUBLESHOOTING The generator set can be divided into four areas for servicing e Engine Primary Systems e Control Generator e Engine Block Assembly A separate section in this manual covers each area Troubleshooting charts define the causes of various malfunctions SPECIAL TOOLS The tools listed below are necessary to service the generator set Some of these are available through an authorized Onan service center consult the Onan tool catalog publication 4900 0019 Engine Tools Torque wrench 0 75 ft lbs or 0 100 Nem Feeler gauge Pressure gauge Spark plug gap gauge Cylinder compression tester Flywheel puller Snap ring pliers Gear puller with puller ring Cylinder ridge reamer Combination main and cam bearing remover Combination main and cam bearing driver Oil seal loader and driver Piston ring Compressor Piston ring spreader Cylinder hone Valve seat cutter Valve spring compressor Vaive lock replacer Valve seat driver Valve guide driver Slide hammer Piston groove cleaner Outside micrometer set 0 to 4 in Telescoping gauge set 1 2 in to 4 in Hole gauge 0 300 in to 0 400 in Plasti Gage bearing clearance guide Generator and Control Lead or dead blow hammer Battery hydrometer VOM multi tester insulation resistance tester Megger Frequency meter Armature growler Load test panel and leads SAFETY CONSIDERATIONS Generator sets present several h
100. gine may be tilted up to install the cup and flyballs 1 Put the fiyballs between the spacer arms and install the cup on the center pin 2 Lock the cup in place with the snap ring 9 8 Camshaft Center Pin installation 1 The camshaft center pin extends 3 4 inch 19 mm from the end of the camshaft This distance provides 7 32 inch 5 6 mm travel for the governor cup as illustrated in Figure 9 14 Measure this distance while holding the cup against the flyballs If the distance is less the engine may race especially at no load 2 Remove the center pin and press in a new pin the specified amount Do not hammer the new pin into place or it will be damaged The camshaft center pin cannot be pulled outward or removed without damage If the center pin extends too far the cup will not hold the flyballs properly TIMING GEARS AND CAMSHAFT if either the crankshaft gear or the camshaft gear needs replacement both gears should be replaced Removal Procedure 1 Remove the snap ring and retainer washer 2 Attach the gear pulling ring using two 10 32 screws Figure 9 15 Tighten the screws alternately until both are tight CRANKSHAFT TIMING GEARS f ZA FIGURE 9 15 TIMING GEAR REMOVAL AND INSTALLATION 1029 THESE MARKS MUST SOE ALIGN WHEN INSTALLING 3 Attach a gear puller to the puller ring and remove the crankshaft gear The camshaft and gear are removed as an assembly 4 Before removing the
101. h of these connections 9 Load wires e Control wires e Ground strap e Battery cables INITIAL START ADJUSTMENTS Adiust the carburetor idle and main adjustment screws as specified in the Fuel System section Start the set then immediately adjust the governor speed adjustment nut for a safe no load operating speed With no load applied listen for unusua sounds or vibrations When the choke is completely open adjust the carburetor and governor as specified in the Fuel System section of this manual OUTPUT CHECK Apply a full load to make sure the set can produce its full rated output Use a load test panel to apply a progres sively greater load until full load is reached EXHAUST SYSTEM With the generator set operating inspect the entire exhaust system including the exhaust manifold and exhaust pipe Visually and audibly check for leaks at all connections weids gaskets and joints Also make sure that exhaust pipes do not heat surrounding areas excessively If leaks are detected correct immediately Inhalation of exhausi gases can AWARNING result in severe personal injury or death Inspect exhaust system audibly and visually for leaks daily Repair leaks immediately FUEL SYSTEM With the generator set operating inspectthe fuel supply lines return lines filters and fittings for leaks Check any flexible sections for cuts cracks and abrasions and make sure they are not rubbing against anything that c
102. he frequency to 55 Hz 45 Hz for 50 Hz sets 6 Turn the speed nut in until the no load frequency is 62 63 Hz 51 5 52 5 Hz for 50 Hz sets Some wandering through the no load range is normal 6 14 7 Gonnect rated load For single phase output Load Watts Volts x Amperes For three phase output Load Watts 1 73 x Volts x Amperes average for the three phases These load calculations assume a 1 0 power factor obtainable by using a resistance load bank True rated oulput may not obtained if appliances are used as part the load 8 Check output voltage Service the generator Sec tion 8 Generator before proceeding if voltage cannot be adjusted within the following limits by means ofthe control panel voltage adjusting rheostat Rated Phases Max Voltage Min Voltage Voltage No No Load Rated Load 79 120 1 132 108 120 240 7 264 216 120 240 3 252 220 220 380 3 417 364 127 220 3 232 202 277 480 3 504 440 GOVERNOR SPRING 006 5 SITIVITY RE OP Uff Ag f gt BALL AND SOCKET ins CARBURETOR THROTTLE LEVER GOVERNOR ROD 9 Check frequency with rated load connected If droop from no load is more than 3 Hz 2 5 Hz for 50 Hz sets turn the sensitivity adjustment screw one to two turns counterclockwise Read just no load frequency to 62 63 Hz 51 5 52 5 Hz for 50 Hz sets and check droop again B Ifdroop from no load
103. id Disconnect the remote control wire plug from the generator set control Disconnect the generator load wires at the vehicle electrical system junction box Tag the vehicle cir cuit wires for positive identification when recon necting Loosen the conduit connector and pull the load wires and flexible conduit free of the junction box Extended shaft units oniy Disconnect any cou plings adapters or power takeoff related attach ments from the extended shaft of the unit Disconnectthe muffler from the exhaust manifold at the flange connection Disconnect any support brackets or hangers that connect the muffler to the set 9 4 9 Gasoline sets Turn off the fuel shutoff valve in the compartment and disconnectthe fuel line at the fuel pump Securely plug the end of the fuel line to pre vent fuel leakage or an accumulation of explosive gasoline vapor Gasoline vapor is extremely flam AWARNING mable and can result in severe personal injury or death if ignited Make certain all fuel line openings are plugged io prevent gasoline vapor from accumulating Eliminate all possible sources of ignition including fire flame spark pilot light arc producing equipment or other igni tion sources before working in this area LPG sets After purging the system disconnect the fuel line at the solenoid valve and plug the end of the fuel line to prevent contamination Removing Above Floor Mounted Set
104. inals 7 Pull each brush outward from the holder and at the same time insert a piece of stiff wire into the small hole in the end of the stator housing see Figure 8 2 Carefully guide the wire through the brush block then release each brush Verify that each brush is held off the slip rings by the wire The brushes will be damaged A CAUTION during disassembly if not held off the slip rings Make ceriain wire is in place before removing stator assembly 6 6 BRUSH BLOCK G 1178 FIGURE 8 2 BRUSH BLOCK ASSEMBLY 8 Remove the two control panel screws from the housing lift off the control panel and disconnect plug jack connections P1 J1 and P3 J3 of the con trol printed circuit board 9 LPG units Disconnect the fuel line at the vaporizer coupling 10 Place a 3 8 inch allen wrench in the head of the rotor through bolt Use a rubber mallet and sharply strike the allen wrench so the through boltis driven in a counterclockwise viewed from generator end direction Several sharp taps should break loose the through bolt 11 Remove the rotor through bolt and thread the spe cial lifting eye 9 16 12 into the end of the housing Refer to Figure 8 3 LIFTING EYE BOLT 9 16 12 G 1176 2 FIGURE 8 3 GENERATOR LIFT 12 13 14 15 16 17 18 Place pad in front of the engine to cushion and protect the scroll Attach a hoist or other suitable lifting device to the lifting eye Tip up the
105. ine oil to remove dirt from bearings Avoid get ting oil on brushes or commutator 2 Mountthe brush springs on tabs as shown in Figure 6 42 Using a small screwdriver turn the spring counterclockwise to torque so the contact loop is inside the brush holder The spring should be pushed down to the mounting tab shoulder 3 Push the negative brush terminals over the through bolt holes on the brush endcap TORQUE 5 10 IN LBS 57 1 13 Nem POSITIVE BRUSH STUD TORQUE TO 25 30 IN LBS 2 83 3 39 Nem IMPORTANT THIS INSULATED SHUNT NEGATIVE BRUSH NEGATIVE BRUSH TERMINAL BRUSH SPRING CONTACT LOOP MUST BE ROUTED THRU UNINSULATED SHUNT AS SHOWN TO PREVENT CONTACT WITH COMMUTATOR IN FINAL ASSEMBLY TERMINAL IMPORTANT SPRING MUST BE ASSEMBLED ON MOUNTING TAB AS SHOWN ES 1612 1 FIGURE 6 42 BRUSH ENDCAP Inserta positive brush stud into the hole and torque to 25 30 Ib in 2 83 3 39 N m Using a small screwdriver inserted into the brush spring contact loop bend the spring back so that each brush can be inserted into the holder Be sure that all brush wires are facing up Ifthe brushes are at least 0 430 inch 10 9 mm long rest the brush springs against the sides of the brushes to keep them clear during armature instal lation See Figure 6 43 Place a washer on the commutator end of the shaft and put the armature into the brush endcap Push the four brushes toward the commutato
106. ions and altitude These pressures are for a warm engine at cranking speed about 300 r min If further inspection is neces sary refer to Engine Block Assembly section GOVERNOR The governor controls engine speed directly affecting the voltage output and frequency of the generator Fas ter engine speed increases generator voltage and fre quency Slower engine speed decreases generator volt age and frequency The governor maintains a constant engine speed under changing load conditions so that generator voltage and frequency do not vary Voliage frequency sensitive equip A CAUTION ment such as VCRs televisions com puters eic may be damaged by power line frequency variations Some solid state devices are powered whenever connected to an AC output even if ihe device is not in actual operation For this reason disconnect all devices which are voltage or frequency sensitive before attempting any carburetor governor adjust ments If disconnecting the devices is not possible open the circuit breaker s at the distribution panel or at the generator set if so equipped Governor Adjustment Recommended equipment e Digital frequency voltmeter with 0 3 frequency accu racy 0 5 voltage accuracy Fluke 8060A or 85 series Digital ammeter Beckman 4410 Load bank with 8 kW minimum capacity variable 600 watt section Preliminary adjustment Before adjusting the governor system make certain that the length of the
107. is less than 2 Hz 1 5 Hz for 50 Hz sets turn the sensitivity adjustment screw one to two turns clockwise Readjust no load frequency and check droop again 10 Check governor response under no load 1 4 load 1 2 load 3 4 load and rated load If the governor hunts increase droop up to a maximum of 4 Hz Go to the Troubleshooting Guide if the governor still hunts SPEED ADJUSTMENT NUT GOVERNOR SPRING 2 GOVERNOR ROD 25 1613 SENSITIVITY ADJUSTMENT SCREW FIGURE 6 15 GOVERNOR ADJUSTMENT Prior to Spec B for Model BGD Spec C for Model NHD GOVERNOR SPEED ADJUSTMENT THROTTLE LEVER SEE DETAIL FIGURE 6 14 GOVERNOR ADJUSTMENT Becin Spec B for Model BGD Spec C for Model NHD 6 15 FUEL SYSTEM GASOLINE The fuel system must be properly adjusted and in good condition for efficient generator set operation Main components of the fuel system include Air filter assembly Carburetor e Choke e Intake manifold e Fuel filter Fuel pump Air preheater See Figure 6 16 or 6 17 as appropriate Gasoline vapor is extremely flam A WARNING mable and can result in severe per sonal injury or death if ignited Make certain all fuel line openings are plugged to prevent gasoline vapor from accumulating Eliminate all possible sources of igni tion including fire flame spark pilot light arc producing equipment or other ignition sources before working in this area Air Intake Assem
108. ively Clean or replace slip rings Check for good wiring connections and correct as required Check for continuity and correct if circuit is open Test voltage regulator and replace if faulty Test each component for open grounded or shorted windings and replace if defective Readjust output voltage pot Check for good wiring connections and correct as required Check for continuity and correct if circuit is open A WARNING Untrained personnel should not atiempt repair due to hazards which can resultin personal injury or death Troubleshooting information is provided for qualified repair personnel only Trouble Noisy Generator Generator Overheats Possibile Cause Loose brush holder Worn generator end bearing Rotor and stator rubbing together due to a Varnish lumps b Rotor misaligned with crankshaft Generator overloaded due to defective circuit breaker Airflow restricted due to dirt or debris covering vent openings in stator housing Stator windings covered with oil or dirt Open grounded or short circuit in rotor or stator Defective voltage regulator 8 5 Corrective Action Tighten brush holder Replace end bearing Check for varnish lumps between rotor and stator remove as required Follow specified assembly procedures to correct rotor to crankshaft alignment Remove part of load and replace circuit breaker
109. k Plugs Remove and inspect the spark plugs at the intervals listed in the operator s manual A careful examination of the plug can often determine the source of an engine problem Figure 6 12 Spark Plug problems include e One plug carbon fouled Check an open ignition cable or low compression e Black soot deposits Check for faulty choke opera tion overly rich fuel mixture or dirty air filter Oil fouled Check for faulty crankcase breather worn rings or worn valve guides e Burned or overheated Check for leaking intake manifold gaskets lean fuel mixture or incorrect ignition timing Be sure that the wrong heat range plug is not being used Chipped insulator Check for advanced timing Bend only the side electrode when setting the gap Splash fouled Check for accumulated combustion chamber deposits Refer to the tion of this manual Light tan or grey deposits Normal plug color 5 1374 FIGURE 6 12 CHECKING PLUG GAP Wiring The ignition system wiring includes One positive B wire which conducts low voltage from the battery to the primary winding of the coil One negative wire which conducts low voltage to the points and condenser Two wires which carry the high voltage from the secondary coil winding to the spark plugs The plugs and coil secondary are grounded to the engine making a complete circuitto the battery The ignition coil primar
110. kage 2 Incorrect governor adjustment 3 Faulty governor spring 4 Incorrect fuel mixture due to a incorrectly adjusted fuel mixture screws b incorrect float level or c dirt in carburetor Governor mechanism worn excessively Carburetor icing Faulty ignition condenser Gasoline sets only Oil viscosity too light or oil is diluted Crankcase breather valve is dirty or defective Oil leaks Excessive engine wear Light loading 1 viscosity too light or oi is diluted 2 Low oil level 3 Low oil pressure switch defective 4 Faulty oil bypass valve 5 Excessive engine wear or defective oil pump 6 3 Corrective Action Clean and lubricate governor linkage Adjust governor speed and sensitivity Replace governor spring Adjust carburetor main and idle adjustment screws Adjust carburetor float level Disassemble carburetor and clean all internal passages See Engine Block Assembly section In cold weather place air preheater in winter position Replace condenser Drain oil and refill with correct viscosity oil Clean crankcase breather and replace if defective Locate source of leak and repair as required See Engine Block Assembly section Don t run set at no load for long periods of time Drain oil and refill with correct viscosity oil Add oil as required Replace oil pressure switch see E
111. l pairs 5 9 7 9 10 9 11 9 12 9 10 5 5 11 5 12 and 5 3 Figure 8 16 It is impor tantthatthe positive lead ofthe meter be connected tothe firstterminal of each pair Replace the voltage regulator if any reading indicates short or open except for pair 10 5 which should indicate open Short is indicated by zero or a number very nearly zero Meters of a different type may indicate open differently Read the meter instructions If in doubt compare with readings of a regulator of the same part number known to be good FIGURE 8 14 VOLTAGE REGULATOR CONNECTOR TERMINALS 8 13 Redistribution or publication of this document by any means is strictly prohibited Section 9 Engine Block Assembly GENERAL The engine block assembly includes LOW OIL PRESSURE S e Pistons and connecting rods e Crankshaft e Camshaft e Valves and lifters Cylinder heads e Lubrication system e Timing gears e Governor mechanism e Bearings e Cylinder block Performing major service on the block assembly requires that the generator set be removed from the vehicle see Set Removal section The control genera tor and all primary engine systems must also be removed for complete access to the block assembly Refer to the previous sections for disassembly and rem oval procedures DRIP SHIELD OIL FILTER LS 1175 OIL FILTER AND ADAPTER SERVICE FIGURE 9 1 OIL FILTER AND ADAPTER 1 Opentheoildrain valv
112. late or gear cover This provides initial lubrication until engine oil reaches the seal Refer to the Crankshaft section for the rear bearing plate installation proce dures Refer to the Gear Coversection for the gear cover installation procedures Ch mp KH GEAR COVER MOUNTING FACE THIS SURFACE SHOULD BE OF GEAR COVER CLEANED OF ALL OLD SEALING COMPOUND BEFORE INSTALLING OIL SEAL SEAL 0 97 0 02 INCH 24 6 0 5 mm THIS SURFACE SHOULD BE CLEANED OF ALL OLD SEALING DRIVE OR PRESS OIL SEAL TO SHOULDER g INSTALLING SEAL OF THE PLATE BORE GEAR COVER OIL SEAL REAR BEARING PLATE SEAL 1477 FIGURE 9 34 OIL SEALS 9 18 Section 10 Service Checklist After servicing inspect and test the installation to con firm that the generator set will operate to its rated capac ity Check each of the areas described below before putting the set into service MOUNTING Examine all mounting bolts and supporting members to verify that the generator set is properly mounted All fasteners should betightened securely to preventthem from working loose when subjected to vibration LUBRICATION Ifthe engine oil was drained fill the crankcase with oil of the recommended classification and viscosity Refer to the appropriate operators manual for the specific recommendations and procedures WIRING Verify that all wiring connections are tight and installed properly Check eac
113. maged by power line frequency variations Some solid state devices are powered whenever connected to an AC output even if the device is not in actual operation For this reason sensitive before attempting any carburetor governor adjust ments If disconnecting the devices is not possible open the circuit breaker s at the distribution panel or at the generator set if so equipped LPG carburetors have three adjustment screws e Thethrottle stop screw sets the width of the throttle plate opening when the throttle is pulled back to the closed position e The idle adjustment screw controls the fuel mixture when the set is operating at no load e The main adjustment screw controls the fuel mix ture when the set is operating at full load No other adjustments are necessary with an LPG car buretor because there are no float or choke adjustments Do not make these adjustments until the ignition system governor and other fuel system components have been checked for correct operation If the carburetor is grossly out of adjustment turn the mixture screws in until they are lightly seated then turn the main adjust ment screw out 2 1 2 1 4 turns and the idle adjust ment screw out 1 1 4 turn This provides a rough preliminary adjustment ACAUTION Forcing the mixture adjustment screws tight will damage the needle and seat Turn in only until light tension can be felt Start the engine and allow itto run for 10 minutes a
114. material from ends of voltage regulator lead wires F1 and F2 and then install brush block assembly Follow steps 9 through 14 in the Brush Replacement section GENERATOR TESTING This section describes test procedures for checking field voltage rotor and stator Field Voltage Test To check the field voltage remove the brush block cover and connect a DC voltmeter to the brush block terminals Connect the positive lead to the B outboard terminal and the negative lead to the B inboard terminal Start the genset and allow it to stabilize Measure the field voltage with no load applied and then with full load applied Both readings should fall between 18 and 60 volts DC and be stable at constant load If field voltage fluctuates at constant load refer to Troubleshooting in this section a possible governor or voltage regulator problem exists Stop the genset remove the test leads and replace the brush block cover when the test is complete Rotor Test The rotor may be tested for grounded open or shorted windings using an ohmmeter Figures 8 10 and 8 11 show the rotor removed from the generator for testing However itis possible to testthe rotor without removing it from the generator To obtain access to the slip rings remove the brush block cover Lift the brush lead wires and insert a brush retaining wire from outside stator housing through brush block assembly to hold the brushes off the slip rings during testing
115. n result if itis accidentally ignited Eliminate all possible sources of ignition including fire flame spark pilot light arc producing equipment or other ignition sour ces before performing this procedure Remove the carburetor and intake manifold assembly as specified in the Carburetor and Intake Manifold Assembly description in this section Remove the car buretor from the intake manifold Disassemble it using the following procedure Carburetor Disassembly Procedure 1 Remove the air cleaner adapter and the automatic choke assembly 2 Remove the throttle and choke plate retaining screws then remove the throttle and choke plates Pull outthe throttle and choke shafts being careful not to damage the Teflon coating applied to some throttle shafts 3 Remove the main and idle mixture screw assemblies 4 Separate the lower section of the carburetor fuel bowl from the upper section fuel bowl cover ofthe carburetor 5 Carefully note the position of the float assembly parts then slide outthe retaining pin and removethe float assembly springs or clips and the needle valve 6 Unscrew and remove the needle valve seat Carburetor Cleaning and Repair Procedure 1 Soak all metal components not replaced by the repair kit in carburetor cleaner Do not soak any rubber or plastic parts Follow the cleaner manufac turer s recommendations Most parts cleaning solvents are LAWARNING famsable and can result in seve
116. nd bearing surfaces of all lubricated parts For this reason do not use gaso line or commercial solvents to clean the cylinder bores after deglazing or honing These solvents cannot remove abrasives from the cylinder walls 4 Clean the cylinder bore thoroughly with soap water and clean rags until a clean white rag shows discoloring when wiped through the cylinder bore BEARINGS To remove the camshaft or crankshaft bearings the engine must be completely disassembled Drive out the bearings by using a combination main and cam bearing removal tool and a press Support the casting to avoid distorting or damaging the bearing bores Camshaft Bearing Replacement Procedure Precision replacement camshaft bearings do not require line reaming or line boring after installation 1 Coat the bearing with lubricating oil 2 Position the front bearing so that the oil hole in the bearing is aligned with the oil hole see Figure 9 31 in the block ALIGN HOLE IN BEARING wo 7 32 OUTSIDE WITH HOLE IN BEARING FIGURE 9 31 CAMSHAFT BEARING 3 Position the rear bearing so that the elongated slot is aligned with the breaker point plunger hole in the top of the block 4 Use the combination main and cam bearing driver with a press to install the front and rear cam bear ings Push in the bearings to the depth allowed by the flange on the driver Crankshaft Bearings Precision re
117. ngine Block Assembly section Inspect oil bypass valve and clean or replace as required see Engine Block Assembly section See Engine Block Assembly section EXHAUST SYSTEM Exhaust system condition is extremely critical because ofthe possibility of exhaust gases entering the vehicle The exhaust system must be serviced immediately if inspection reveals leaking joints or connections loose fasteners or broken or damaged components Always replace worn components with new Onan replacement parts Do not attempt to repair a broken exhaust pipe or manifold by welding Do not replace worn components with parts that do not meet Onan specifications Contact an authorized Onan service center for exhaust kit parts and installation instructions Inhalation of exhaust gases can AWARNING result in severe personal injury or death Modifying the exhaust system other than shor tening the downpipe may allow poisonous exhaust gases to enter the vehicle Use only Onan replacement paris to service the exhaust system Unauthorized modifications will void the Onan warranty Liability for injury or damages due to unauthorized modifications becomes the responsibility of the person making the change L BRACKET SCROLL _ FLANGE LOCK AN Dg SCREW MUFFLER INLET Figure 6 1 shows a typical exhaust system for a com partment mount generator set Figure 6 2 illustrates a typical exhaust system for an underfl
118. ning the connecting rods in solvent make certain to include the rod bore Blow out all passages with low pressure compressed air Piston and Connecting Rod Inspection Procedure Piston Inspection inspect the pistons for fractures at the ring lands skirts and pin bosses Check for wear atthe ring lands using a new ring and feeler gauge as shown in Figure 9 21 Replace the piston if the side clearance of the top compression ring is as much as 0 008 inch 0 20 mm CT 1061 FIGURE 9 21 CHECKING RING LAND 9 11 Improper ring width or excessive ring side clearance can result in ring breakage New rings in worn ring grooves do not make adequate contact with the cylinder wall Figure 9 22 SS 55 PISTON CYLINDER WALL IMPROPER RING CONTACT CT 1062 FIGURE 9 22 NEW RING IN WORN RING GROOVE Replace pistons showing signs of scuffing scoring worn ring lands fractures or damage from pre ignition Connecting Rod Inspection Replace connecting rod bolts and nuts with damaged threads Replace connect ing rods with deep nicks signs of fractures scored bores or bores out of round more than 0 002 inch 0 05 mm Use a new piston pin to check the connecting rod for wear A push fit clearance is required this varies from engine to engine new piston pin falls through a dry rod pin bore as a result of its own weight replace the rod or bushing as required Piston Pin Inspection Replace pist
119. nk to the generator output leads 2 Start the generator set and apply a full load Adjust the governor speed adjustment nutto obtain 59 49 2 hertz 6 19 IDLE MIXTURE ADJUSTING SCREW CAP THROTTLE LEVER ALTITUDE MAIN JET ADJUSTING SCALE SCREW CAP FS 1871 FIGURE 6 18 CARBURETOR ADJUSTMENTS 3 Remove the plastic cap over the main adjustment screw Turn the adjustment screw inward until the voltage or frequency drops Then turn it outward until the voltage or frequency drops again Locate the point where voltage and frequency are highest Replace the plastic cap The tang on the cap should point to the altitude scale on the float bowl where these adjustments were made Remove the load and adjust the governor speed adjustment nut to within 62 51 5 1 hertz Remove idle adjustment screw cap limiter Turn the idle adjustment screw inward until the voltage and frequency drop and the engine runs rough or starts hunting Back out the idle adjustment screw as required for smooth operation without hunting Replace the idle adjustment screw cap limiter with its lever located at mid position Detween stops Or for a more accurate setting with CO meter if available after setting idle and main adjustment screws but before installation of plastic limiter cap settothefollowing with engine running no load 6 to 896 CO rated load 7 to 1096 CO install limiter caps as instructed above Remove the
120. nnect the spark plug wire to the spark plug 3 Ground the spark plug to bare engine metal 4 Crank the engine A strong spark should appear between the plug center electrode and the side electrode A weak spark means that the coil points and condenser or wiring may be defective Direct Testing With Ohmmeter 1 Remove all wires attached to the coil 2 Remove the coil from the engine 3 Inspect terminals for corrosion looseness cracks denis or other damage Look for carbon runners around high tension terminals these indicate elec trical leakage Replace a damaged or leaking coil 4 Clean the outside of the coil with a cloth dampened in parts cleaning solvent 5 Measure resistance in the primary circuit connect the ohmmeter leads to the positive and negative terminals on the coil This resistance should be between 3 and 5 ohms Replace the coil if the resistance is higher high resistance indicates an open circuit or a poor connection inside the coil 6 Measure resistance in the secondary circuit con nect the ohmmeter leads to the two high voltage terminals see Figure 6 11 Fhis resistance should be between 10 and 40 kilohms Replace the coil if it is not within this specification lower resistance indicates a shorted Secondary winding and higher resistance indicates the coil has excessive internal resistance or an opep circuit 6 12 5 1373 FIGURE 6 11 TESTING COIL SECONDARY Spar
121. o a Open circuit in wiring between generator and control b No output voltage from generator Weak or discharged battery due to a Low electrolyte level in battery b Long periods of non use Load connected to battery while set is turned off Weak or discharged battery due to a Faulty VR2 battery charge regulator b Open 2 circuit breaker 3a 3b 3c 3d 1a 1b TG 1d 2a 2b 3a 3b 1a 1b 3a Corrective Action Refer to gnition System Section 6 for test and service procedures Refer to Fuel System Section 6 for test and service procedures Check for continuity and correct if circuit 15 open See Testing of Control Board 1 Replace the fuse Replace Relay if there is cranking voltage at terminals 87 and 85 but not at terminal 30 when cranking Check oil level and add oil if low Check for continuity and correct if circuit is open Replace low oil pressure switch Refer to Section 6 Troubleshooting for procedures to follow Check for continuity and correct if circuit 1 open Replace 5 relay Check for continuity and correct if circuit is open Refer to Generator section for test and service procedures See Testing of Control Board Replenish electrolyte and recharge battery Connect a separate battery charger to bring battery up to full charge Turn off disconnect load and recharge battery Check
122. ock cover and inspectthe slip rings for grooves pits or other damage If the slip rings are not in good condition they may be refinished using a com mutator stone Slip Ring Service Procedure 1 2 3 Remove the air cleaner cover and air cleaner filter Disconnect the lead wires from the brush block terminals and then insulate the lead wire ends Tie the lead wires to one side to allow clear access to the slip rings Remove the brush block mounting screws and lift out the brush block assembly 4 3 8 inch allen wrench into the rotor through bolt and rotate the engine and generator one full turn While rotating inspect condition of slip rings If the slip rings need refinishing continueto next step if slip rings do not need refinishing follow steps 6 through 14 in the Brush Replacement section 5 Move the Start Stop switch to START position to crank the engine During this step crank the engine for 3 to 6 second cranking periods with a rest period between so the starter will not overheat During engine Cranking hold a commutator stone Onan tool 420 0259 against rotating slip rings Remove the commutator stone after each cranking period and check that carbon is being removed and all roughness and grooves are smoothed out AWARNING Contact with rotating machinery can cause severe personal in jury Keep hands fingers clothing and jewelry clear while servicing slip rings 6 Remove insulating
123. on lined smooth hole in the governor cup GOVERNOR GOVERNOR CUP GOVERNOR ARM ROLL PIN GOVERNOR SHAFT ROTATE GOVERNOR CUP GOVERNAR SO THAT ROLL PIN SHAFT VOKE FITS INTO THE SMOOTH SIDE IF FEELER WILL TOWARD CUP METAL LINED ENTER HOLE 1 2 IN 13 mm HOLE OR PLASTIC IDEEN BALL HAS FALLEN OUT BUSHING IN THE CUP VT 1027 FIGURE 9 13 GEAR COVER ASSEMBLY 9 7 GOVERNSA Removal Procedure 1 Remove the gear cover as described above 2 Remove the snap ring from the camshaft center pin see Figure 9 14 WHEN GOVERNOR IS PROPERLY ASSEMBLED THE CAMSHAFT DIMENSION SHOWN GEAR ON DRAWING WILL BEASINDICATED 7 52 V come SNAP RING GOVERNOR CUP GOVERNOR FLYBALL VT 1028 FIGURE 9 14 GOVERNOR CUP 3 Slide the governor cup off making certain to catch the flyballs Replace any flybali that is grooved or has a flat spot 4 Examine the ball spacer If the arms of the ball spacer are worn or otherwise damaged remove the spacer by splitting it with a chisel Use a press to install a new spacer on the camshaft gear 5 The governor cup must spin freely on the camshaft center pin without excessive looseness or wobble If the race surface of the cup is grooved or rough replace it with a new one Installation Procedure The governor cup and flyballs are easily installed when the camshaft assembly is removed from the engine necessary the en
124. on pins that are cracked scored or out of round more than 0 002 inch 0 05 mm Bearing Inspection inspect bearings for burrs breaks pitting and wear Replace bearing inserts which are scored have their overlay wiped out show fatigue fail ure or are badly scratched If the bearings appear to be serviceable check them for proper clearance CT 1063 FIGURE 9 23 PISTON CLEARANCE MEASUREMENT Piston Clearance Correct piston tolerances must be maintained Use a micrometer to measure the piston diameter at the point shown in Figure 9 23 When the cylinder bore is mea sured see Cylinder Block section subtract the piston diameter from the cylinder bore diameter to obtain the piston to cylinder wall clearance Refer to the Dimen sions and Clearances section for the recommended piston clearance Fitting Piston Rings Before installing new rings on the piston check the ring gap by placing each ring squarely in its cylinder at a position corresponding to the bottom of its travel Figure 9 24 The gap between the ends of the ring is given in Dimensions and Clearances section M PISTON RING IN CYLINDER BORE FEELER GAGE tJ FIGURE 9 24 CHECKING RING GAP CT 1064 Do not file the ring ends to increase the end gap If the ring end gap does not meetthe specifications checkthe correctness of ring and bore sizes A cylinder bore that is 0 001 inch 0 03 mm undersize will reduce the end gap 0 003 0 08 m Rings
125. on sources Keep the workshop clean and well lighted and provide adequate ventilation Keep fire extin guishers and safety equipment nearby and be pre pared to respond to an emergency Develop safe work habits Unsafe actions cause accidents with tools and machines Be familiar with the equipment and know how 10 use it safely Use the correct tool for the job and check its condition before starting Comply with the warnings in this manual and take special precautions when work ing around electrical equipment Do not work alone if possible and take no risks Be prepared to respond to an accident Agencies such as the Red Cross and public safety depart ments offer courses in firstaid CPR and fire control Take advantage of this information to be ready to respond to an accident Learn to be safety conscious and make safety procedures part of the work routine Electrical Shock AC generator set load connections Faulty wiring Faulty electrical load wiring Faulty generator set wiring Rotating Machinery Flywheel fan guard not in place Slippery Surfaces Leaking or spilled oil Heavy Objects Removing generator set from vehicle Removing heavy components SET REMOVAL GUIDELINES Certain service procedures require that the generator set be removed from the vehicle The generator set is normally mounted in a special compartment on the vehicle bed or below the vehicle floor B
126. ontacts close Run relay on 1 continues to keep the ignition coil energized when K4 drops out Fuel Pump E2 gasoline units The fuel pump is energized in the same manner as the ignition coil Fuel Solenoid E2 LPG units Thesolenoid valve provides a positive fuel shutoff when ever the generator set is stopped The solenoid must be energized before fuel will flow to the regulator It is energized in the same manner as the fuel pump is ener gized in gasoline units Remote Start Control optional The remote start control is an optional accessory that enables the generator set to be operated from a remote location The deluxe control includes a running time meter and battery condition meter Line Circuit Breaker s CB1 CB2 CB3 AC output from the generator is supplied through the circuit breakers located on the right side of the control housing Ampere rating of these breakers may differ depending on generator set model frequency Refer to the proper Parts Manual when ordering replacement parts Separate circuit breakers are included when output is 3 phase or greater than 240 VAC Voltage Regulator VR1 The voltage regulator helps provide stable output volt age under varying loads During initial start of the set the voltage regulator receives DC currentfrom the start ing battery and begins excitation of the rotor through leads J4 9 F1 and J4 10 F2 After the generator set starts and runs it provides
127. oor mount genera tor set Separate service procedures cover each type of exhaust system Also refer to the exhaust kit installation instructions Compartment Mount Exhaust System The exhaust system consists of Exhaust manifold Muffler Muffler strap Hanger Clamps Tailpipe Disassembly Procedure 1 Loosen the front muffler clamp muffler strap and tailpipe hanger Remove the muffler and tailpipe assembly Figure 6 1 2 Remove the screws that secure the exhaust tube to the exhaust manifold Remove the exhaust tube and exhaust gasket MUFFLER STRAP CUTOUT HANGER BRACKET FOOT 1 METRE MINIMUM FROM DOWNPIPE OR AT PERIMETER OF VEHICLE CLAMP MARKED 1 3 8 FRONT SET VIEW CLAMP MARKED 1 1 2 EXS 1147 3 FIGURE 6 1 CONVENTICNAL COMPARTMENT MOUNT EXHAUST SYSTEM 6 4 Completion the remaining steps requires that the generator set be removed from the vehicle Refer to the Preparing to Service section for set removal procedures For LPG sels follow the procedure for purging LPG from the fuel line 3 Remove the cooling system noise shield and scroll see Coolingin this section to provide access to the exhaust manifold 4 Remove the screw that secures the exhaust mani fold outlet flange to the exhaust manifold support bracket 5 Remove the four exhaust manifold screws Lift off the exhaust manifold and the two manifold gaskets A WARNING Exhaust gas can produce severe
128. or as illustrated in Figure 6 6 It is an elec tronic switch in the primary circuit ofthe ignition coil It is switched on and off once each revolution by the rotor Theignition module contains no user serviceable parts problems within the module mean that it must be replaced SECTION A A BRACKET ENGINE TO GENERATOR ADAPTOR N IGNITION MODULE IGNITION ROTOR CRANKSHAFT FIGURE 6 6 IGNITION MODULE AND ROTOR ignition Coil The ignition Figure 6 7 1 a transformer that fires the spark plugs at about 20 000 volts each revolution when the ignition module opens the primary circuit causing the coil field to collapse Keep all ignition coil terminals and connections clean and secure Check for loose seams dents punctures and mechanical damage If ignition is poor and the other ignition components are not at fault test the coil as described below Make certain of coil polarity the nega tive terminal connects to the ignition module black lead and the positive terminal connects to a battery positive source within the control the ignition module red lead and the filter capacitor C4 HIGH VOLTAGE TERMINALS LOW VOLTAGE TERMINALS PRIMARY WINDING SECONDARY WINDING ES 1863 FIGURE 6 7 IGNITION COIL Quick Ignition Test Gasoline vapor is extremely flamma AWARNING ble and can result severe personal injury or deaih if ignited Make certain that no gasoline o
129. osi tion Tighten the center screws to the specified torque Secure the ground strap to the drip tray using a capscrew and two EIT locking washers Note that the ground strap is installed between the locking washers to ensure a good electrical connection Attach the lifting plate Figure 8 3 to the end of the stator housing using four 5 16 18 x 1 capscrews 12 13 14 15 16 17 18 19 20 21 Attach a hoist or other lifting device to the lifting plate Carefully tilt the set back until it rests cn the drip tray Remove the lifting plate when compiete LPG units Connect the fuel line at the vaporizer housing Connect plug jack connections P1 J1 and P3 J3 of the control printed circuit board Install the con trol panel assembly on generator housing Tighten the mounting screws Pull the brush leads outward and remove the wire holding the brushes off the rings Make certain thatthe brushes are centered on the slip rings If the brushes are not centered loosen the brush block mounting screws and adjust Retighten the mount ing screws when complete Connect the lead to the outboard brush terminal and the B lead to the inboard brush terminal Install the brush block cover and tighten the cover mount ing screws Connect the leads to the charge resistor low pressure cut off switch and ignition coil B terminal Place new intake manifold gaskets on the engine block and ins
130. ould cause breakage Leaking fue creates a fire hazard AWARNING which can result in severe personal injury or death if fire flame spark pilot lighi arc producing equipment or other ignition sources are present If fuel leaks are deiected shut off the genera tor set and correct immediately CONTROL Stop and start the generator set several times atthe set control and remote control to verify that it functions properly MECHANICAL Stop the generator set and inspectitfor leaking gaskets loose fasteners damaged components or interference problems Repair as required Inspect the generator set compartment and verify that there are no breaks or openings in the vapor proof that separates the compartment from the vehicie interior Seal openings as required Make sure thataill soundproofing material is in place 10 1 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 e Throbbing in Temples e Nausea e Muscular Twitching Headache e Vomiting Weakness and Sleepiness Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist seek medical atten tion Shut down the unit and do not operate until it has been inspected and repaired Protection against
131. paris are used on selected models the following discussion is general Control Printed Circuit Board A1 The starting battery supplies initial excitation voltage to the generator rotor While the engine cranks battery DC voltage is supplied through the N C contacts of genera tor relay K2 on control board A1 through voltage regu lator VR1 to the brushes and slip rings of the rotor When the engine starts and generator voltage builds up generator relay K2 is energized opening the N C con tacts in the battery B circuittothe voltage regulator and closing a set of N O contacts in the start dis connect run relay K3 circuit of board A1 This circuit keeps relay K3 energized while the set is in operation If relay K2 becomes de energized the set shuts down Brushes DC excitation voltage is induced through the brushes and rotor slip rings to the rotor windings The brush block assembly consists of a single brush block with two brushes The brush block mounts directly over the rotor slip rings inside the generator housing and may be accessed by removing the small plate at the rear of the housing Rotor The 4 pole rotor provides the rotating magnetic field that is required to generate an AC voltage potential in the stator windings The DC current required for field excitation is supplied through two slip rings on the rotor shaft The inner end of the rotor is connected directly to the engine crankshaft with a tapered seat sha
132. passages from each main journal A passage connects the front main bearing oil supply to the front camshaft bearing The oil overflow from the bypass valve lubricates the camshaft drive gears Normal oil pressure is at least 18 psi 90 kPa for Model BGD andatleast20 psi 138 kPa for Model NHD genera tor sets when the engine is at normal operating tempera ture If pressure drops below this value at governed speed inspect the oil system for faulty components Checkthe oil pump thoroughly for worn parts Oil the pump to pr me it before reinstalling it Except for the gaskets and pick up cup the component parts of the pump are not individually available Install a new pump assembly if any parts are worn Oil Bypass Valve The bypass valve located to the right and behind the gear cover Figure 9 17 controls oil pressure by allow ing excess oil to flow directly back to the crankcase Normally the valve begins to open at 13 14 psi 89 6 96 5 kPa HEX CAP SCREW FLAT WASHER LS 1110 FIGURE 9 17 BYPASS VALVE The bypass valve is non adjustable and normally needs maintenance To determine if abnormal high or low oil pressure is caused by improper valve operation inspect as follows 1 Removethe 3 8 in capscrew behind the gear cover and under the governor arm 2 Remove the spring and plunger with a magnetic tool 3 Determine the proper valve operation by checking the spring and plunger against the me
133. placement crankshaft main bearings do not require line reaming or line boring after installation They are available in standard size 0 002 0 010 0 020 or 0 030 inch undersize When installing either the front or rear main bearing always align the oil hole s in the bearing with the oil hole s in the bearing bore The oil passage must be at least 1 2 open Rear Bearing Use the combination main and cam bear ing driver and a press to install the rear main bearing Push the bearing into the bearing plate from the inner side see Figure 9 32 to the depth allowed by the flange on the driver REAR BEARING END PLATE LOCK PIN ALIGN BEARING OIL HOLES WITH OIL HOLES IN BEARING BORE THRUST WASHER SHIM BEARING M 1475 PRECISION TYPE DO NOT LINE BORE OR REAM FIGURE 9 32 REAR BEARING Front Bearing Loctite brand Bearing Mount is used when installing the front bearing Use the towelette fur nished with the bearing kit to clean the outside of the bearing and the bearing bore in the block Apply the Loctite to the mating surfaces ofthe bearing and bearing bore Allow three to four minutes for drying Breathing the vapor from the towelette provided with the Loctite or prolonged contact with skin can be harmful Be sure ihe area is well ventilated 9 17 Usethe combination main cam bearing driver and a press to install the front bearing Push the bearing in to the depth allowed by the
134. r making sure that the springs are properly positioned on the brushes Recheck to be certain that the spring is pushed all the way down on the mounting tab Make sure thatall brush wires are clear of the com mutator and that uninsulated portions of insulated wires do not touch the inside diameter of the hous ing Uninsulated portions of wires must also not touch adjacent brush boxes 6 35 5 1611 FIGURE 6 43 RESTING BRUSH SPRING ON BRUSH SIDE 9 Place the magnetic housing ever the armature Use b With the chamfered side of the shaft hole facing a nut driver over the end of the shaft to hold down place a plastic retainer on the shaft and line the armature and the endczz up the hole with a hole in the shaft 10 Place a spring washer and a fiat washer on the Support the plastic retainer with a vise or other shaft as shown in Figure 8 44 solid surface Using a 5 32 or 1 8 inch nail set and hammer drive in a new roll pin The pin 11 Place the mounting bracket on the motor with the should be driven about 1 10th of an inch 2 5 exposed end of the sieeve bearing and through bolt mm from the edge of the plastic retainer or in lead ins facing the inside of ihe motor The flat near such a way that it is evenly spaced from each one mounting hole should line up with the positive side stud on end cap so the through bolts will line up d Place the spring cover over the top of the plastic 12 Insert the through bol
135. r other flammable fumes are present Park the vehicle in a well ventilated area and leave the generator set compartment door open for several minutes before performing ihe test 1 Make certain that no gasoline fumes or other flam mable fumes are present Park the vehicle in a well ventilated area and leave the generator set com partment door open for several minutes before per forming this test Remove a spark plug Reconnect the spark plug wire to the spark plug 0 N Ground the spark plug to bare engine metal 5 Crank the engine Use extreme care when performing A WARNING this test procedure To avoid shock do not hold the plug without adequate insulation strong spark should appear between the plug center electrode and the side electrode A weak spark means that the coil or wiring may be defective Testing Ignition Coil 1 Remove all wires attached to the ignition coil 2 Remove the coil from the engine Inspect terminals for corrosion looseness cracks dents or other damage Look for carbon runners around high tension terminals these indicate elec trical leakage Replace a damaged or leaking coil Clean the outside of the coil with a cloth dampened in parts cleaning solvent Measure resistance in the primary circuit connect the ohmmeter leads to the positive and negative terminals on the coil This resistance should be between 5 ohms Replace the coil if the resi
136. rance of cylinder bores is acceptable and there are no scuff marks check the bores for wear or out of roundness as follows 1 Check cylinder bore for taper out of round and wear with a cylinder bore gauge telescope gauge or inside micrometer These measurements should be taken atfour places the top and bottom of piston ring travel and parallel and perpendicular to axis of the crankshaft 2 Record the measurements taken at the top and bot tom ofthe piston travel as follows see Figure 9 29 A Measure and record as the cylinder bore diameter parallel to crankshaft near the top of cylinder bore where the greatest amount of wear OCCUIS 9 15 B Measure and record as 8B the cylinder bore diameter parallel to crankshaft at the bottom of piston travel C Measure and record as C the cylinder bore diameter perpendicular to crankshaft near the top of cylinder bore where the greatest amount of wear occurs D Measure and record as D the cylinder bore diameter perpendicular to crankshaft at the bottom of piston travel E Reading A subtracted from reading and read ing C subtracted from reading D indicates the cylinder taper F Reading A compared to reading C and reading B compared to reading D indicates whether or not the cylinder is out of round If the out of round exceeds 0 003 inches 0 08 mm the cylinders mustbe rebored and honedto the next oversize A reboring machine is used when ch
137. re personal injury if used improperly Follow the manufacturer s recommendations when clean ing parts 2 Clean carbon from the carburetor bore espe cially where the throttle and choke plates seat Be careful not to plug the idle or main fuel ports 3 Blow out all passages with compressed air Do not use wire or other objects for cleaning that might increase the size of critical passages 6 20 4 Check the condition of any needle valve not included in the repair kit and replace it if damaged Figure 6 20 Replace the float if it is damaged or loaded with fuel 5 Check the choke and throttle shafts for excessive play in their bore Replace them if necessary 6 Replace old components with the new parts included in the repair kit L DAMAGE AND WEAR OCCUR HERE im FS 1483 3 FIGURE 6 20 MIXTURE NEEDLE INSPECTION Reassembly and Installation Procedure 1 Slideinthethrottle shaftand install the throttle plate using new screws if they are furnished in the repair kit Before tightening the screws the plate must be centered in the bore To do this back off the throttle stop screw as necessary and completely close the throttle lever Seat the plate by gently tapping it with a small screwdriver then tighten the screws Install the choke shaft and plate in the same manner Install the idle mixture screw assembly Turn in the screw until lightly seated then turn it out one turn Forcing the mixture adj
138. rk pilot light arc producing equipment or other ignition Sources before performing this procedure 1 Remove the four capscrews and lock washer that hold the filter pow to the filter body 2 Separate the filter bowt from the filter body and discard the O ring seal E 4 3 Bembie the nut and washer from the center stud and pull out the filter element 4 Ifthe filter elementi is clogged wash the element in kerosene Blow it dry with low pressure 30 psi 207 kPa compressed air Replace the filter element if damaged 6 30 5 Wipe the center stud magnet clean of any rust scale particles that have collected 6 Install a clean filter element using two new gaskets and securely tighten the center stud nut 7 Place anew O ring in the filter bowl sealing groove 8 Align the reference mark on the filter bowl with the reference mark on the filter body Install cap screws 4 and lock washers 4 Tighten the cap screws to 56 to 74 165 6 5 to 8 3 N m torque When the fuel system is pressurized check the filter for leaks Solenoid Valve The solenoid valve see Figure 6 35 provides a positive fuel shutoff when the generator set is stopped The solenoid must be energized for fuel to flow to the regula tor faulty valve must be replaced To bench test the valve connect battery positive B to the top terminal and battery negative B to the grounded terminal The plunger assembly sho
139. rmature shaft and the core laminations A low resistance reading indicates a grounded armature Replace a grounded armature with a new one See Figure 6 39 FIGURE 6 39 TESTING ARMATURE FOR GROUNDS Testing for Shorts Use a growler Figure 6 40 to locate shorts in the armature Place armature in growler and hold a thin steel blade hacksaw blade parallel to the core and just above the armature while slowly rotating the armature the growler Turn off the growler before rotating the armature A shorted armature will cause the blade to vibrate and be attracted to the core Replace a shorted armature with a new one HACK SAW ES 1615 FIGURE 6 40 TESTING ARMATURE FOR SHORTS 6 34 Testing for Opens Touch one ohmmeter lead to a commutator bar then systematically touch the other lead to each of the remaining commutator bars A high resistance indicates an open circuit between the com mutator bars and armature windings Replace an open armature with a new one Brush Inspection Measure brushes Figure 6 41 and replace them if worn less than 0 425 11 mm 0 425 INCH 11 mm WEAR LIMIT NEW 0 570 INCH 14 5 mm ES 1610 FIGURE 6 41 BRUSH INSPECTION 1 Wipe off dirt and oil from starter components using a clean cloth or blow off dirt with filtered low pres sure compressed air Oil on armature will damage ACAUTION starter Do not immerse bear ings in cleaning fluid Use a brush dipped in clean eng
140. section 11 Remove the capscrews that hold the backpiate to the engine Lift off the backplate 12 Use a brush or low pressure compressed air to remove any dirtor debris lodged in the engine cool ing fins Cooling System Assembly Procedure Reassembly is the reverse of dissassembly When installing the flywheel align its keyway with the wood ruff key on the crankshaft Use non hardening sealer on the flywheel capscrew threads and tighten them to the specified torque Refer to the Exhaust System section of this manual when installing the exhaust manifold muffler and tailpipe Generator set overheating can result engine damage To avoid this never operate the generator set with any of the cooling system components removed 6 8 ELECTRONIC IGNITION SYSTEM Beginning Spec B for Model BGD and Spec C for Model NHD The electronic ignition system consists of the following elements ignition rotor e Ignition module e ignition coil Spark plugs e Wiring Ignition Rotor The ignition rotor is keyed to the engine crankshaft Figure 6 6 The ends have opposite magnetic polarity north and south One pole switches on the ignition module and the other pole switches it off once each revolution of the crankshaft The ignition rotor normally should not require replacement during the life of the generator set Ignition Module The ignition module is mounted to the generator en gine adapt
141. set as shown in Figure 8 3 until it is completely vertical and resting on the scroll housing end Careless handling can damage A CAUTION the rotor Do not lift the entire generator set by this method Remove the capscrew and two EIT lock washers that secure the ground strap to the drip pan Remove the three vibration isolator center screws from the underside of the drip pan and lift drip pan away from engine generator Disconnect lead wires attached to the starter motor Loosen the fasteners that mount the starter to the stator housing and remove starter Remove the four capscrews lock washers and nuts that secure the stator housing to the engine to generator adapter Remove the lifting eye bolt Figure 8 4 Carefully lift the stator assembly straight up until it clears the rotor Set stator assembly to rest on smooth clean surface G 1175 1 FIGURE 8 4 REMOVE LIFTING EYE BOLT 8 7 19 CAUTION Careless handling of ihe stator assembly can damage the insu lation on the siator windings Do not brush the stator windings against the rotor as itis lifted clear Install the tool shown in Figure 8 5 Use a screw driver to turn the rotor tool in a clockwise direction until it bottoms Install 9 16 12 x 2 capscrew in the end of the rotor shaft and tighten until rotor breaks loose from crankshaft Remove capscrew from end of rotor when complete CAPSCREW ROTOR TOOL 10 IN 254 mm G 1175
142. shaft mating surfaces 2 Apply Loctite 680 adhesive to the mating surface on the shaft 3 Apply Loctite 747 activator to the mating surface on the bearing 4 Install the bearing and allow ten minutes curing time before handling the assembly Generator Assembly Procedure 1 Install the stator in its housing asfollows see Figure 8 6 a Position the stator so the output leads align with the access hole to control housing Carefully lower the stator straight down into the stator housing Careless handling of the sta A CAUTION tor can damage the insulation on the stator windings Do not brush the wind ings against the housing as it is lowered into housing and take care not to drop or drag the stator on work area outside of stator housing b Install the three stator clamps and capscrews C Pull the stator leads into control box d Connect stator leads e T1 T2 T3 and T4 to terminal board TB1 Qi 02 F1 and F2 from voltage regulator VR1 harness J4 e B1 and B2 io control printed circuit board harness J1 10 11 e Rotate stator housing assembly onto smooth clean surface resting on the bell shape of the housing end bearing face up Install the brush block assembly in the stator hous ing Lift the brush wires and install the brush holding wire in the housing The wire holds the brushes off the slip rings during assembly see Figure 8 2 Carefully placethe rotor assembly on the end
143. st ance is higher high resistance indicates an open circuit or a poor connection inside the coil Measure resistance in the secondary circuit con nect the ohmmeter leads to the two high voltage terminals see Figure 6 8 This resistance should be between 10 and 40 kilohms Replace the coil if it is not within this specification lower resistance indicates a shorted secondary winding and higher resistance indicates the coil has excessive internal resistance or an open circuit FIGURE 6 8 TESTING IGNITION COIL SECONDARY 6 10 Testing Ignition Module e Remove the spark plugs and fan scroll Figure 6 4 so that the engine can be turned by hand Connect the positive side of a voltmeter to the negative terminal of the ignition coil larger ofthe two screw terminals and the negative side of the voltmeter to engine ground e Remove ail leads from the positive terminal of the coil Use a jumper to connect the ignition module lead the one just removed from the coil to the battery positive positive terminal e Roiate the flywheel clockwise hand Replace the ignition module if voltage does not jump from about 1 volt to about 12 volts and then back again each turn of the crank To replace the module remove the bracket mounting screws Figure 6 6 and lift out the bracket module assembly Be sure to assemble the new module to the bracket as shown by Section A A Figure 6 6 The studs on the br
144. stems and service procedures for each fuel system component LPG Liquid Withdrawal Fuel Systems LPG liquid withdrawal fuel systems typically operate at pressures as high as 200 psi 1379 kPa when the ambient temperature is 110 F 43 3 C Because of the high pressure special precautions must be taken to avoid releasing large quantities of highly fiammable LP gas when servicing the fuel system Use the procedure described below to purge the fuel system of LP gas before servicing any fuel system components LPG Purging Procedure 1 Open the AC load circuit breaker and close the shutoff valve at the fuel tank 2 Startthe generator set and run it until itstops for lack of fuel Crank the set a few times after it stops to make sure the fuel system is purged of fuel Ifthe generator set cannot be operated do the following 1 Move the vehicle to a well ventilated outdoor loca tion far from fire or flame 2 Disconnect the vehicle negative battery cable and the generator set negative battery cable from their battery terminals 3 Close fuel shutoff valves at the fuel tank for the generator set fuel supply system and any other fuel supply system Close the fuel shutoff valves for any auxiliary equipment LP gas Propane is extremely AWARNING flammable Severe personal in jury or death can result if it is accidentally ignited Eliminate all fire spark pilot light arc producing equipment or oth
145. t exhaust gases 6 7 down and away from the vehicle and away from windows doors or compartment openings e Do not connect the generator set exhausttailpipe to vehicle exhaust system Exhaust gases will be forced into the non running engine and might be released through the carburetor air inlet Water vapor from the exhaust might also damage the non running engine COOLING SYSTEM These are air cooled sets A flywheel fan draws cool air in from the generator end of the compartment See Fig ure 6 3 This cool air passes over the cooling fins on the engine absorbing the heat The heated air is then dis charged through the opening in the bottom of the fan housing inhalation of carbon monoxide can AWARNING result in severe personal injury or death Never use discharged cooling air for heating the vehicle interior because discharged cooling air can contain poisonous gases See Specifications regarding the minimum free area of the compartmentair inletand minimum clearance atthe air discharge opening The air inletand discharge open ings must remain free of any obstructions to avoid res tricting airflow Regularly remove any dirt dust or debris clogging the duct openings Remove any dirt lodged between the cooling fins on the engine block and cylinder heads If the fins are dirty heat transfer is greatly reduced and overheating can occur M 1604 15 FIGURE 6 3 COOLING AIRFLOW The cooling system consists of
146. t light load Figure 6 28 illustrates the location of the adjust ment screws IDLE ADJUSTMENT SCREW THROTTLE STOP FIGURE 6 28 MIXTURE SCREW ADJUSTMENTS Adjustment Procedure 1 Stop the set and connect a voltmeter frequency meter and load bank to the generator output leads 2 Start the generator set and apply a full load Adjust the governor speed adjustment nut if necessary to obtain 59 2 hertz 3 Turn the main adjustment screw inward until the voltage or frequency drops then outward until the voltage or frequency drops again Set the main adjustment screw atthe point where the voltage and frequency are highest 4 Remove the load Adjust the governor speed adjustment nut if necessary to obtain 62 1 hz 5 Turnthe idle adjustment screw inward uniil the vol tage and frequency drop and the engine begins to run rough or starts hunting Sack out the idle adjustment screw until the engine runs smoothly without hunting Or for a more accurate setting with CO meter if available after setting idle and main adjustment screws but before installation of plastic limiter cap set to the following with engine running no load 6 to 8 CO rated load 7 to 10 CO Install limiter caps as instructed above 6 With unitat no load adjust governor speed 50 2 hz 50 hz sets 40 2 hz With the throttle lever againstthe idle stop screw adjust idle stop screw to 55 1 hz 50 hz sets 45 1 hz 7 Re
147. tall the carburetor and intake manifold assembly Tighten the intake manifold screws to the specified torque Connect the preheater tube crankcase breather hose fuel lines throttle linkage and choke heater wires gasoline units Refer to Fuel System Section 6 for detailed assembly procedures Install the flywheel guard scroll opening and the noise shield Install the set in the vehicle and securely fasten all mounting screws and hardware Connect the fuel exhaust and electrical systems in reverse order of disassembly Refer to the Sef Removal section for more information Fill crankcase with oil of the recommended classifi cation and viscosity BRUSHES AND SLIP RINGS Brush Inspection Remove the brush block cover and inspect the brushes and brush holder for burns or other damage If the brushes appear to be in good condition use a piece of wire modified as shown in Figure 8 8 to check for excessive brush wear Insert the wire through the hole above each brush Make sure the wire 1 resting on the brush and not on part of the spring lf the painted part of the wire is not visible the brush is excessively worn and must be replaced 8 9 FIGURE 8 8 CHECKING BRUSH WEAR Always replace the brush springs when installing new brushes to insure that proper tension is maintained Brush Replacement Procedure 1 1 e Disconnect the negative battery cable at the bat tery terminal Remove the air clean
148. ter Crankcase ventilation system Governor Fuel system Gasoline Fuel system LPG liquid withdrawal Fuel system LPG vapor withdrawal Electric starter The primary engine systems can often be serviced with out removing the generator set from the vehicle and without major disassembly Use the following trouble shooting guide to help locate problems related to the engine primary systems Refer to the Troubleshooting Generator Set Control section for genset starting problems Before considering major inspection of the engine due to abnormal engine performance engine knocks power loss etc refer to the Operator s Manual publi cation 965 0129 Periodic Maintenance Schedule for the procedure to clean the carburetor and combustion chamber with Onan 4C TROUBLESHOOTING ENGINE PRIMARY SYSTEMS A WARNING Untrained personnel should not attempt repair due to hazards which can result in personal injury or death Troubleshooting information is provided for qualified repair personnel only Trouble Possible Cause Corrective Action Engine 1 Faulty ignition due to Misfires a worn or fouled spark plugs 1a Replace spark plugs b worn breaker points b Replace breaker points c incorrect ignition timing c Set breaker point gap d faulty ignition coil or d Test coil and replace if necessary e faulty plug wires e Test spark plug wires and f faulty condenser replace if faulty g faulty igni
149. that are 0 010 0 020 0 030 and 0 040 inch 0 25 0 51 0 76 and 1 02 mm oversize should be used on corresponding oversize pistons Tapered piston rings are usually marked TOP on one side or identified in some other manner Instali these rings with the identifi cation mark toward the closed end of the piston Piston Assembly Procedure 1 Lubricate all parts with clean engine oil 2 Position the piston on connecting rod Install the piston pin The piston pin is a full floating type and must be kept in place in the piston with two lock rings one at each side Install the lock rings and ensure they are properly in place before installing the piston and connecting rod in the engine Newer replacement pistons and Spec F pistons have round wire piston pin lock rings These can be pushed in by thumb pressure or pried in with a small screwdriver Wear safety glasses and hold ACAUTION your thumb over the ring to keep the ring from flying out and getting lost or causing personal injury Install the rings on the piston beginning with the oil control ring Figure 9 25 Use a piston ring spreader to prevent twisting or excessive expan sion of the ring Compression rings are marked with a dot or the word top on one side of the ring to indicate which side faces the top of the piston Unmarked piston rings can be installed either way The oil control ring has an expander Install the expander first then close until the expand
150. the back of the regulator as shown in Figure 6 33 2 Attach a pressure hose to the inlet opening and open the air pressure valve 3 If the primary seal is sound the gauge should read approximately 1 1 2 psi 10 3 kPa and the pres sure should remain constant A fluctuating pressure reading indicates a bad primary seat 4 Close the air pressure valve and observe the pres sure gauge The pressure should remain constant If the pressure reading drops the secondary seat is leaking If the regulator does not pass either test it must be rebuilt or replaced INLET OPENING 4i 4 TEST PORT IAL FIGURE 6 33 REGULATOR TEST iN FS 1599 Fuel Filter The fuel filter see Figure 6 34 removes solid impurities such as rust and scale from the LP gas before they can clog the regulator and carburetor A magnet within the filter housing traps iron and rust particles and a filter element traps non magnetic particles The fuel filter operates at container pressure it must be carefully assembled to prevent leakage FILTER ELEMENT FILTER GASKETS XP BODY N MAGNET 1 O RING SEAL lt 2 FILTER BOWL FS 1614 FIGURE 6 34 FUEL FILTER Disassembly and Cleaning Procedure LPG is extremely flammable Severe AWARNING personal injury d death can result if itis accidentally ignited Eliminate all possible sources of ignition including fire flame spa
151. the components are located and basic troubleshooting procedures CONTROL DESCRIPTION The generator set control consists of the components listed below see Figure 7 1 Control panel assembly e Printed circuit board A1 e Start Run Stop switch 51 e Fuse F1 Start solenoid K1 e Stop relay K5 Ignition coil T1 Fuel pump E2 gasoline units Fuel solenoid E2 LPG units Remote start control optional Circuit breaker s CB1 CB2 regulator VR1 Voltage regulator VR2 e Terminal board TB1 Ignition relay DC FUSE F1 CONTROL BOARD A1 INSIDE START STOP SWITCH S1 START SOLENOID K1 The following sections describe each component and how it functions This description is generalized features and components may differ between models of the generator set The control panel assembly consists Printed circuit board A1 Start Run Stop switch 51 Fuse F1 Printed Circuit Board A1 The printed circuit board controls the engine start start disconnect run and stop functions mounted to the rear of the control panel contains wiring harness connections to the engine generator and optional remote start control the start stop switch 81 and the control fuse F1 Start Run Stop Switch 1 1 is a SPDT rocker switch which starts and stops the generator set The switch returns to the
152. tion module f Replace condenser electronic ignition g See Testing Ignition Module 2 Lean fuel mixture due to 2a Adjust carburetor main a incorrectly adjusted and idle adjustment screws fuel mixture screws b Adjust carburetor float level b incorrect float level c Disassemble carburetor c dirt in carburetor and clean all internal passages d vacuum leak d Locate leak and correct as required 3 Contaminated fuel 3 Drain fuel tank and refill with fresh fuel 4 Carburetor icing 4 In cold weather place air Gasoline sets only preheater in winter position Prior to Spec B for Model BGD and Spec C for Model NHD Engine 1 Faulty ignition due to Backfires a incorrect ignition timing 1a Adjust breaker point gap b incorrect spark plug gap b Reset spark plug gap c faulty condenser c Replace condenser 2 Lean fuel mixture due to 2a Adjust carburetor main and a incorrectly adjusted idle adjustment screws fuel mixture screws b Adjust carburetor float b incorrect float level level c dirt in carburetor 3 Mechanical damage to engine Gasoline sets only c Disassemble carburetor and clean all internal passages 3 See Engine Block Assembly section Prior to Spec B for Model BGD and Spec C for Model NHD 6 1 TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Continued RNING Untrained personnel should not attempt repair due to hazards which can result in personal Trouble Engine
153. tor sets whose output exceeds 240 VAC Consult the Installation manual for more information Wiring Harness to Load s A wiring harness is provided to connect the generator set to the electrical system All leads are stranded copper wire to withstand vibration The leads mustbe protected with flexible conduit from the generator set control housing to the switching disconnect device which must be provided by the vehicle manufacturer The lead wires exit the control housing behind the fuel pump solenoid Load conductors are black neutral conduc tors are white and the ground conductor is green GENERATOR OPERATION See the appropriate wiring diagram in Section 11 Wir ing Diagrams when troubleshooting problems When the start stop switch is moved to START the rotating field rotor is momentarily connected to battery 8 3 positive B to provide magnetism for voltage build up As the engine starts and speed increases the roiat ing field induces an AC voltage in the stator windings AC voltage from the quadrature winding 1 Q2 is rectified for field excitation voltage AC voltage output stabilizes at approximately 128 volts when the engine reaches governed speed Voltage regulator VR1 enables the generator to provide a stable AC output voltage under varying load condi tions Leads from VR1 wire harness J4 2 and 3 are connected to terminal board TB1 these leads sense voltage changes of the load on the generator 3 phas
154. ts and torque to 35 45 Ib in retainer then place the return spring on top of 3 96 5 09 N m the retainer 13 Wipe dust from the helix and gear and apply a light e With a washer placed overthe point of the plas coat of GE Versilube 322 L on the outside diameter tic retainer push the metal retainer into the hole of the helix the inside diameter of the gear and the of the plastic retainer as far as it will go unchamfered end of the gear Place the clutch and helix assemblies on the motor shaft with flats 15 Mount the starter on the generator stator housing engaged in clutch hole using capscrews lockwashers and nuts Tighten the mounting screws to 30 33 Ib ft 41 45 N m 14 If the return spring is unassembled 16 Connect generator set positive battery cable to a Place a1 1 16inch O D washer over the end of starter terminal Connect generator set negative the shaft terminal to generator set starting battery WASHER METAL SPRING SPRING WASHER eae CLUTCH amp SPLINE FLAT WASHER WASHER ASSEMBLY 1 16 INCH WASHER SPRING RETURN COVER RETURN SPRING N THROUGH BOLT MAGNETIC HOUSING ES 1613 ce ie oe m m a FIGURE 6 44 STARTER ASSEMBLY 6 36 Section 7 Control INTRODUCTION The control system governs the following functions e Starting e Monitoring for fault conditions e Instrumentation e Battery charging e Stopping This section covers how the control operates where
155. ue roiation until tapping the choke lever no longer makes it bounce This is the fully closed position and becomes the reference position 4 Refer to Table 6 1 to determine the number of degrees the element cover must be rotated clock wise from the reference position The marks on the choke housing are spaced at 5 intervals 5 Rotate the element cover as specified then tighten the cover mounting screws 6 Move the choke lever back and forth to check for smooth operation The lever should return automat ically to the free position when released from the open position without sticking or binding 7 instali plastic choke cover and tighten center mounting unit TABLE 6 1 CHOKE ADJUSTMENTS Ambient Air Rotation From Temperature Reference Mark 40 F 4 C 45 F 7 C 50 F 10 C 60 F 16 C 65 F 18 C 70 F 21 C 75 F 24 C 80 F 27 C 85 F 29 C 90 F 32 C 95 F 35 C 100 38 C Each mark on choke housing equals 5 angular rotation PLASTIC COVER FS 1605 3 Choke Replacement Prior to Spec If the choke fails to open remove the protective plastic cover and checkto see if the heating elementis operat ing The heating element cover should become hotafter afew minutes of operation Ifthe element cover does not get hot start the set then use an AC voltmeter to check for voltage approximately 20 VAC at the element cover terminals If voltage is
156. uel hose and governor control lin kage from the carburetor INTAKE MANIFOLD CARBURETOR 7 Remove the two capscrews that secure the carbure tor to the intake manifold Lift off the carburetor 8 Remove the intake manifold as follows a Disconnectthe flexible fuel supply line from the fuel vaporizer b Remove the exhaust manifold as described in this section to provide clearance to lift off the intake manifold ACAUTION Bending the fuel vaporizer tubing weakens the metal enabling cracks to form Do not bend the vapo rizer tubing to remove the intake manifold c Remove the intake manifold capscrews and lift off the intake manifold d Remove the two intake manifold gaskets from the block and plug the intake ports with clean rags to prevent loose parts from accidentally entering the ports Assembly Reverse order of disassembly steps Use new gaskets betweenthe exhaust manifold and engine the intake manifold and engine and the carburetor and intake manifold Tighten the exhaust and intake mani fold capscrews to the specified torque Tighten the fuel vaporizer fittings and check for leaks CRANKCASE BREATHER HOSE AIR CLEANER HOUSING AIR FILTER FS 1512 1 AIR CLEANER ADAPTER FIGURE 6 27 CARBURETOR AIR FILTER AND INTAKE MANIFOLD ASSEMBLY 6 26 Carburetor Mixture Screw Adjustments Voltage frequency sensitive equip ACAUTION ment such as VCRs televisions com puters eic may be da
157. uidelines listed below and in the Installation Manual to select and locate the tailpipe Inhalation of exhaust gases can AWARNING resull in severe personal injury or death Exhaust gases can enter the vehicle interior if the tailpipe is damaged missing or improperly installed Follow the recommended exhaust system replacement procedures for safe operation Use 1 3 8 inch I D 18 gauge rigid steel tubing for tailpipe Do not use flexible exhaust tailpipe because itis vulnerable to road shock and vibration Install an exhaust tailpipe at least 3 inches 76 mm away from the fuel tank and from any combustible material If 3 inches clearance cannot be main tained install heat shielding between the tailpipe and the fuel tank or any combustible material to prevent excessive heating Do NOT terminate the exhaust tailpipe in these positions A Under a window door or any opening that might allow exhaust gases to enter the vehicle interior Ahead of underneath the generator com partment air intake which might recirculate exhaust gases Terminate the tailpipe at the rear of the compartment air intake if possible Under the fuel tank fill spout so spilled fuel cannot be ignited by a hot tailpipe Under the vehicle so exhaust gases cannot enter the vehicle interior through small open ings in the underside of the vehicle Extend the tailpipe atleast one inch 25 mm beyond the perimeter of the vehicle Direc
158. uld with draw and open the valve when the solenoid is ener gized Replace the solenoid valve if it does not operate properly FIGURE 6 35 SOLENOID VALVE FUEL SYSTEM LPG VAPOR WITHDRAWAL The LPG vapor withdrawal fuel system is very similar to the liquid withdrawal system Main components of the LPG vapor withdrawal fuel system are Air cleaner assembly Carburetor intake manifold e Solenoid valve Demand regulator externally mounted 6 31 ADJUSTING Special precautions must be taken to avoid releasing large quantities of highly flammable LP gas when servic ing the fuel system Use the LPG Purging Procedure described in the LPG Liquid Withdrawal Fuel System section to purge the fuel system of LP gas before servic ing any fuel system components Service procedures for the air cleaner assembly car buretor intake manifold and solenoid valve are des cribed in the previous sections The following service procedure applies to the LPG vapor withdrawal demand regulator which is unique to the vapor withdrawal system Demand Regulator Adjustment Procedure Difficult starting may be caused by slow cranking due to a weak battery Temperatures below 32 0 increase the load on the battery at cranking speed Low cranking speed in turn inhibits proper intake vacuum for starting If the generator set fails to start or operate properly and the starting or ignition systems are not at fault check an
159. ump and repair or replace if faulty Adjust carburetor main and and idle adjustment screws Adjust carburetor float level Disassemble carburetor and clean internal passages Repair vacuum leak Locate and remove cause of blockage Adjust valve tappets see Engine Block Assembly section See Engine Block Assembly section In hot weather place air preheater in summer position Dissassemble and scrape carbon Adjust governor Clear away any debris that may restrict airflow to set Do not use compartment for storage area Clean away ali dirt and oil from engine cooling fins Adjust breaker point gap Adjust carburetor main and idle adjustment screws Adjust carburetor float level Disassemble carburetor and clean all internal passages Replace air cleaner Clean choke and choke linkage Adjust carburetor idle and main adjustment screws Disassemble carburetor and clean all internal passages Trouble Engine Hunts or Surges High Oil Consumption Note New engines sometimes have high oil consumption during break in Low Cil Pressure TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Continued AWARNING Untrained personnel should not attempt repair due to hazards which can result in personal injury or death Troubleshooting information is provided for qualified repair personnel only Possible Cause 1 Sticking or binding governor lin
160. ustment ACAUTION screws tight will damage the needie and seat Turn in only until light tension is felt Install the needle valve and seat fuel bow gasket and float assembly Make sure all clips and springs are properly placed and thatthe float moves freely without binding see Figure 6 21 6 21 Sy FLOAT AXLE up BUOYANCY X SPRING 1 POSITION HOOK UNDER TANG ON FLOAT POSITION OF SPRING AFTER INSTALLATION FS 1610 FIGURE 6 21 FLOAT INSTALLATION 4 Invert the float and needle valve assembly and check the float level by measuring from the carbure tor housing to the far side bottom of the float see Figure 6 22 The full weight of the float should be resting on the needle valve and spring If the setting is incorrect remove the float and bend the tab to adjust Bend the float only at the point indicated BEND TAB TO ADJUST MEASURE THIS DISTANCE m 4 A BOWL FLANGE GASKET TAB CONTACTING HEAD OF PIN WITH FULL WEIGHT OF FLOAT COMPRESSING INLET VALVE SPRING FIGURE 6 22 FLOAT LEVEL Attempting adjustments with the ACAUTION float assembly installed can damage the inlet needle and seat Remove the float assembly before making adjustments Install the float bow and the main mixture screw assembly Make sure the index line on the float bowl altitude scale lines up with the arrow head cast in the mating flange of the carburetor Turn the screw in until lightly seated
161. y low voltage side is grounded when the breaker points close Check all low voltage wiring for loose connections and breaks the insulation Clean all terminals and connec tions and use an ohmmeter to test them for continuity Use a megger high range ohmmeter to check for breaks in the plug wire insulation CRANKCASE VENTILATION SYSTEM The crankcase breather prevents pressure from build ing up in the crankcase it also prevents oil contamina by removing moisture gasoline vapors and other harmful blow by materials from the crankcase These vapors are routed to the outside of the generator set A sticky crankcase breather can cause oil leaks high oil consumption rough idle reduced engine power rapid formation of sludge and varnish within the engine and oil in the breaker point box Crankcase breaiher vapor contains AWARNING poisonous carbon monoxide Do not run the generator set while parked unless the under carriage is exposed io a steady airflow Crankcase Breather Service Procedure Oil leaks at the seals may mean that the crankcase is pressurized Use the following procedure to eliminate this condition 6 13 HEX HEAD CAPSCREW 1 Remove the breather tube from the valve cover see Figure 6 13 2 Removethe valve Cover pack spring washer reed valve and breather baffle 3 Clean all parts in solvent BREATHER HOSE J FLAT WASHER VALVE HOSE CLAMP PACK SPRING

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