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1. M AYAN eJ Ls Service Manual BGE BGEL m ai 2 OF UR LN 965 0530 5 86 Spec A C Printed in U S A Safety Precautions Before operating the generator set read the Operators Manual and become familiar with it and the equipment Safe and efficient operation can be achieved only if the unit is properly operated and maintained Many accidents are caused by failure to follow fundamental rules and precautions The following symbols found throughout this manual alert you to potentially dangerous conditions to the operator service per sonnel or the equipment This symbol warns of immediate haz ards which will result In severe personal injury or death This symbol refers to a hazard or unsafe practice which can resuit in severe personal injury or death This symbol refers to a hazard or unsafe practice which can result in personal injury or prod uct or property damage FUEL AND FUMES ARE FLAMMABLE Fire explosion and personal injury can result from improper practices DO NOT fill fuel tanks while engine is running Fuel contact with hot engine or exhaust is a potential fire hazard DO NOT SMOKE OR USE AN OPEN FLAME nearthe gen erator set or fuel tank Fuel lines must be adequately secured and free of leaks Fuel connection at the engine should be made with an ap proved flexible non conductive line Do not use copper pip
2. amp WASHER ROLL PIN ASSEMBLY _ 1 46 INCH WASHER SPRING RETURN COVER RETURN SPRING WASHER SPRING WASHER FLAT WASHER ARMATURE THROUGH BOLT HOUSING m FIGURE 6 44 STARTER ASSEMBLY 14 If Return Spring is Unassembled A Place 1 1 16 inch O D washer over end of shaft With chamfered side of shaft hole up place plas tic retainer on shaft and line up hole with hole in shaft B solid surface Using a 5 32 to 1 8 inch nail set and hammer drive in a new roll pin The pin should be driven in about 1 10th ofan inch 2 5 mm from the edge of the plastic retainer or so it is evenly spaced from each side Support the plastic retainer with a vise or other D Place spring cover over top of plastic retainer then the return spring on top of the retainer E With washer placed over point of plastic retainer push metal retainer into hole of plastic retainer as far as it will go 15 Mount starter on generator stator housing using capscrews lockwashers and nuts Tighten mount ing screws to 30 33 Ib ft 41 45 Nem 16 Connect generator set positive battery cable to starter terminal Connect generator set negative terminal to generator set starting battery 6 33 Redistribution or publication of this document by any means is strictly prohibited Section 7 Control INTRODUCTION The control syste
3. Control Troubleshooting 7 4 BGEL Control Description 7 8 BGEL Control 7 9 Control 7 11 8 GENERATOR eT PP 8 1 nie Pei MEL 8 1 Generator Description seiss cesses ner rr rr rrr mer nnus er d ea eR P ES 8 1 Generator Operation 2 22 8 e s wins ois P EU ee 8 2 Generator Troubleshooting Em 8 2 Generator Service cr 8 8 Brushes and Slip Rings C 8 12 Transformer Voltage Adjustments 8 14 Generator Testing ere 8 14 Table of Contents continues 8 10 ENGINE BLOCK C 9 4 General Mem c ek eee ae 9 1 Oil Filter and Adapter p 52525555 9 1 Cylinder 2 222 22222 7000 40 4 6 9 1 Valve Sytem ened s eus dde re 9 2 Gear eel lei ec su desee qs 9 6 oVemor GUB 9 7 Timing Gears
4. OR OTHER pod SOLID SURFACE USE CARE NOT TO HAVE SPRING RETURN LEG BETWEEN THE PLASTIC RETAINER amp SUPPORT WHEN DRIVING OUT ROLL PIN SUPPORT FIGURE 6 38 DRIVING ROLL PIN OUT 6 29 Testing Armature for Grounds Touch one ohmmeter lead to a commutator bar and then touch the other lead to armature shaft and core laminations A low resistance reading indicates a grounded armature Replace grounded armature with a new part See Figure 6 39 COMMUTATOR BARS ES 1814 FIGURE 6 39 TESTING ARMATURE FOR GROUNDS Testing for Shorts Use growler Figure 6 40 for locat ing shorts in ihe armature Place armature in growler and hold a th n steel blade e g hacksaw blade parallel to the core and just above the armature while slowlv rotating armature in growler A shorted armature will cause the blade to vibrate and be attracted to the core Replace a shorted armature with a new part 23 1615 FIGURE 6 40 TESTING ARMATURE FOR SHORTS Testing for Opens Touch one ohmmeter lead to a commutator bar and then systematically touch the other lead to each of the remaining commutator bars A high resistance reading indicates an open circuit between the commutator bars and armature windings Replace an open armature with a new part Brush Inspection Measure brushes Figure 6 41 and replace if worn less than 0 425 11 mm 0 425 INCH 11 mm WEAR LIMIT NEW 0 570 INCH 14 5
5. adjustment screw inward until vol tage and frequency drops and engine begins to run rough or starts hunting Back out idle adjust ment screw until engine runs smoothly without hunting 6 Pull the governor linkage toward the front of the set so that the throttle lever on the carburetor is resting against the throttle stop screw Adjust the stop screw to obtain a setting of 55 hertz and 100 4 5 volts 7 Release the governor linkage and observe the stability of the set Set the voltage and frequency andadjustthe sensitivity of the governor as speci fied in Governor in this section Add and remove half load several times to make certain the set does not bog down or hunt Carburetor Overhaul Carburetor problems not corrected by mixture adjust ments may be caused by dirt in fuel passages or worn internal parts Under normal conditions the carbur etor should seldom require cleaning since LP gas vaporizes completely before reaching the carburetor and leaves no residue However a bad fuel supply or inoperative fuel filter may allow dirt or oil to collect in the carburetor This may require that the carburetor be cleaned to restore satisfactory operation Overhauling the carburetor includes complete dis assembly 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 re
6. if pressure reading is at zero stop engine crank ing and check electrical connections Press the START switch and recheck pressure reading There are no serviceable components in the fuel pump Replace if defective FUEL SYSTEM LP GAS The fuel system must be in good condition and prop erly maintained for efficient generator set operation The main components of the fuel system are the air cleaner assembly carburetor intake manifold fuel filter solenoid valve vaporizer and two stage regula tor All LP gas generator sets utilize a liquid withdraw wal system and are intended to share the vehicle LP gas fuel supply tanks The LP gas fuel supply tank must be designed with a dip tube to permit liquid fuel withdrawal The following sections provide basic information about LP gas fuel systems and specific service procedures for each fuel system component LP Gas Fuel Systems LP gas liquid withdrawal fuel systems typically operate at pressures that range as high as 200 psi 1379 kPa when the ambient temperature is 110 F 43 3 C Because of the high pressures special pre cautions must be taken to avoid releasing large quan tities of highly flammable LP gas when servicing the fuel system Use the following procedure to purge the fuel system of LP gas before servicing any fuel sys tem components LP Gas Purging Procedure To purge the LP gas from the set fuel system close the shutoff valve at the fuel tank and then s
7. 3 TO ADJUST mena MEASURE THIS DISTANCE 4 BOWL FLANGE GASKET TAB CONTACTING HEAD OF PIN WITH FULL WEIGHT OF FLOAT COMPRESSING INLET VALVE SPRING FS 1611 FIGURE 6 18 FLOAT LEVEL 5 Install float bowl and main mixture screw assem bly Turn screw in until lightly seated and then turn out the number of turns specified in Table 6 2 Forcing the mixture adjustment A CAUTION screws light will damage the needle and seat Turn in only until light tension can be felt 6 When carburetor is installed on set make final adjustments to mixture screws as described in Carburetor Mixture Screw Adjustments section Choke The choke consists of a bi metal spiral strip electric heating element and choke pulloff diaphragm The bi metal coil is connected to the choke shaft and holds the choke plate nearly closed when the engine is cold When the engine starts vacuum from the intake mani fold causes the pulloff diaphragm to pull in and par tially open the choke As the engine continues to run electric current is supplied to the heating element Heat from the element causes the bi metal strip to coil The coiling action of the bi metal strip turns the choke shaft and gradually opens the choke plate Heat from the element keeps the choke open while the engine is running The choke gets very hot during WARNING normal operation and can result in severe burns if touched Do not remove choke cover while the set is ope
8. terminal on the coil The resistance should be between 3 87 and 4 73 ohms A high resistance value indi cates an open circuit or poor connection inside the coil Replace the coil if not within specifi cations 4 To measure resistance in the secondary circuit connect the ohmmeter leads to the two high ten sion terminals see Figure 6 8 The resistance measured should be between 12 600 and 15 400 ohms A fower resistance value indicates a shorted secondary winding A higher resistance value indicates the coil has excessive internal resistance or an open circuit Replace coil if not within specifications OHMMETER 5 1373 FIGURE 6 8 TESTING COIL SECONDARY Spark Plugs Remove and inspect the spark plugs at the intervals recommended in the operators manual A careful examination of the plug can often pinpoint the source of an engine problem The following covers some common spark plug conditions and the probable cause One Plug Carbon Fouled Check for an open ignition cable or low compression Black Soot Deposits Check for faulty choke operation 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 plug is not in wrong heat range e Chipped Insulator Check for advanced timing Be
9. FIGURE 8 14 TESTING STATOR AND TRANSFORMER FOR GROUNDS TABLE 8 3 GROUND TEST FOR STATORS AND TRANSFORMERS LOCATION T1 T3 Bi Stator Stator Transformer Ifthe T1 lead is grounded the source of the ground could be either the stator windings or the transformer primary windings To isolate disconnect the trans former primary leads from the stator leads T2 from H2 and T4 from H4 Touch the test prod to T1 T3 H2 and H4 to identify the grounded component Replace a grounded stator or transformer with a new part Open Or Shorted Windings Test To test for opens disconnectthe transformer and stator leads as speci fied inthe Ground Testsection Set the ohmmeter for the highest resistance scale and then connect the test prods see Figure 8 15 to the leads specified in Table 8 4 The ohmmeter should indicate continuity between lead ends A high resistance reading indi cates an open winding If the open circuit is between T1 and one of the transformer primary lead wires H1 or H3 the source of the open could be either the stator windings or the transformer primary windings To isolate disconnect the transformer primary leads from the stator leads T2 from H2 or T4 from H4 Test each winding separately as specified in Table 8 4 to locate the source of the open Replace the stator or transformer if test indicates an open winding To test for shorted windings use a digital type ohm meter th
10. flexible lines as copper will work harden and become Be sure all fuel supplies have a positive shutoff valve GASOLINE AND LPG FUEL MAY BE ACCIDENTALLY IG NITED BY ELECTRICAL SPARKS prosenting thehazardof fire or explosion which can result in severe personal in jury or death When installing the generator set Do not tie electrical wiring to fuel lines Do not run electrical lines and fuel lines through the same compartment openings Keep electrical and fuel lines as far apart as possible Place a physical barrier between fuel lines and electrical lines wherever possible If electrical and fuel lines must pass through the same com partment opening make certain that they are physically separated by running them through individual channels or by passing each line through a separate piece of tubing DO NOT SMOKE while servicing batteries Lead acid bat teries emit a highly explosive hydrogen gas that can be ig nited by electrical arcing or by smoking EXHAUST GASES ARE DEADLY Never sleepin the vehicle with the generator set running un less vehicle is equipped with an operating carbon monoxide detector Provide an adequate exhaust system to properly expel dis charged gases Inspect exhaust system daily for leaks per the maintenance schedule Be sure that exhaust manifolds are secure and not warped Do not use exhaust gases to heat a compartment Be sure the unit is well ventilated MOVING PARTS CA
11. 11 Use a brush or low pressure compressed air to remove any dirt or debris that may be lodged on the engine cooling fins Assembly Cooling system assembly is the reverse of disassembly When installing the flywheel align the keyway in the flywheel with the woodruff key on the crankshaft Use non hardening sealer on the fly wheel capscrew threads and tighten to the specified torque Refer to Exhaust System when installing the exhaust manifold muffler and tailpipe ELYWHEEL FLYWHEEL PULLER JACK SCREW A FLYWHEEL CAP SCREW CS 1000 FIGURE 6 5 FLYWHEEL PULLER Overheating can result engine ACAUTION damage To avoid overheating never operate the generator set with any of the cool ing system components removed IGNITION SYSTEM The ignition system consists of the breaker points condenser ignition coil spark plugs and wiring For reliable generator set operation the complete igni tion system must be in good working order and prop erly adjusted Many generator set problems can be traced to an improperly maintained ignition system Refer to the following paragraphs when servicing or making adjustments and the SPECIFICATIONS Section 2 for recommended dimensions Breaker Points and Condenser The breaker points and condenser mount on top of the engine block A small plunger rides on an ignition cam at the end of the camshaft The plunger actuates the points which open and close twice w
12. FIGURE 6 41 BRUSH INSPECTION 6 30 TORQUE TO 5 10 1 1 8 57 1 13 Nem POSITIVE BRUSH STUD TORQUE TO 25 30 IN LBS 2 83 3 39 Nem IMPORTANT THIS INSULATED SHUNT MUST BE ROUTED THRU UNINSULATED NEGATIVE BRUSH TERMINAL NEGATIVE BRUSH TERMINAL BRUSH SPRING CONTACT LOOP SHUNT AS SHOWN TO PREVENT CONTACT WITH COMMUTATOR IN FINAL ASSEMBLY IMPORTANT SPRING MUST BE ASSEMBLED ON MOUNTING TAB AS SHOWN ES 1612 1 FIGURE 6 42 BRUSH ENDCAP Assembly 1 Wipe off dirt and from starter components using a clean cloth or blow off dirt with filtered low pressure compressed air Oil on armature will damage ACAUTION Starter Do not immerse bear ings in cleaning fluid Use a brush dipped in clean engine oil for removing dirt from bearings Avoid getting on brushes or commutator 6 31 Mount brush springs on tabs as shown in Figure 6 42 Using a small screwdriver turn spring coun terclockwise to torque so contact loop is inside of brush holder Spring should be pushed down to mounting tab shoulder Push negative brush terminals over through bolt holes on brush endcap Insert positive brush stud into hole and torque to 25 30 Ib in 2 83 3 39 Nem Using a small screwdriver inserted into brush spring contact loop bend the spring back to allow each brush to be inserted into holder Be sure all brush wires are facing up ifthe brushes are atleast 0 43
13. making adjustments to the transformer 2 With the unit operating at no load adjust the speed adjustment nut to achieve the following frequency and voltage Mode ajust speed Nut To 60 Hz 120 Volts 50 Hz 110 220 Volts 50 Hz 120 240 Volts 62 Hz 127 5 4 5 Volts 52 Hz 233 9 Volts 52 Hz 225 9 Volts 3 Stop the setand adjust the transformer tap connec tions as shown in TABLE 8 1 to increase or decrease the voltage as required 4 Repeat the voltage check and continue to make adjustments until voltage is within range specified 5 Check the no load and full load voltage and fre quency as specified in Section 6 for the Governor Voltage and frequency should stay within the limits shown inTable 6 1 TABLE 8 1 TRANSFORMER TAP CONNECTIONS VOLTAGE ADJUSTMENT To Increase Voltage Standard Setting To Decrease Voltage GENERATOR TESTING This section covers the test procedures for the stator rotor transformer and CR4 bridge rectifier Field Voltage Test To check the field voltage remove the brush block cover and connect a DC voltmeter to the brush block terminals Connectthe positive lead to the B outboard terminal and the negative lead to the B inboard terminal Start the generator set and allow it to stabilize Measure the field voltage with no load applied and then with full load applied Both readings should fall within a range of 1810 60 volts DC Remove test leads and replace br
14. sure no one moves the vehicle during this procedure and that the procedure is performed very carefully and only as instructed Dropping the generator set can Use a forklift truck to support the generator set tray at the points shown in Figure 5 4 Place a wooden block on one fork so the set will remain level Lift the forklift just so it makes contact with the drip tray then put a little upward pressure under the tray Verify the weight of the generator set is supported by the forks before proceeding Remove the bolts that secure the side support to the drip tray and the underfloor bracket Lift generator up slightly until safety catch on result in severe personal injury side support is clear of tray Pull support forward and upward until disengaged from tray and underfloor bracket 5 6 6 Remove the side support to provide the clearance needed for lowering the set Remove the safety catch from the center of each hinge assembly and then remove the U shaped hinge pin Slowly lower the generator set untilit is clear of ail obstructions and can be moved out from under the recreational vehicle FORK LIFT M 1601 FIGURE 5 4 COMPLETE SET REMOVAL Section 6 Engine Primary Systems The engine primary systems include the following e Exhaust System Cooling System e Fuel System Gasoline INTRODUCTION Ignition System Electric Starter Crankcase Ventilation Sy
15. 25 in 82 55 mm 2 87 72 90 Oil Capacity With Filter ox DE PU E ia 4 Qt 8 8 L Ventilation Free Area 2 85 in 584 4 cm FUCK Lead Free or Regular PP LPG Propane Liquid Withdrawal GENERATOR DETAILS 50 Hz 60 Hz Watts 3500 ves 4000 rera DER PET 110 220 or 120 240 120 Amps lee eoe ria 31 8 15 9 29 2 14 6 33 3 PRASC lt 1 WIES P 2 Battery 1 1 TUNE UP SPECS Spark Plug Gaps 0 025 in 0 64 mm Ec 0 016 0 41 XII 16 Valve Lash Intake 0 005 in 0 127 mm Exhaust n RM 0 013 in 0 330 mm Redistribution or publication of this document by any means is strictly prohibited MODELS CYLINDERS AND PISTON ASSEMBLY Cylinder Bore Std size honed Cylinder Taper Max Cylinder Out Of Round Max Clearance Cylinder Ring Gap Piston Ring 1 top Groove Width Piston Ring 2 Groove Width Piston Ring 3 Groove Width Piston Ring 1 Top Side Clearance Piston Pin Diameter Piston Pin Fit in Rod Connecting Rod Side Clearance Con
16. 68 75 Oil Base 18 23 24 31 Gearcase Cover 8 10 11 14 Spark Plug 7 9 9 12 Exhaust Manifold 9 11 12 15 Intake Manifold 6 10 8 14 Rotor 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 25 34 Mounting Screws Rear Vibration Isolator Center Screw 30 33 41 45 Flange To Drip 10 12 11 15 Tray Screws Front Vibration isolator Flange to Oil 19 22 26 30 Base Screws 4 1 Redistribution or publication of this document by any means is strictly prohibited Section 5 Preparing to Service TROUBLESHOOTING Before starting to service the generator set follow a systematic troubleshooting procedure to locate and isolate the problem For servicing purposes the generator set can be divided into the following e Engine Primary Systems e Control e Generator e Engine Block Assembly separate section is contained in this manual that covers each area Several troubleshooting guides are included in this manual to help the serviceperson locate the cause of various malfunctions It should be noted that some malfunctions might have several possible causes For this reason the serviceperson may have to investi gate several likely problem areas in order to isolate the source of the malfunction Because of the com plexity of the product atroubleshooting chart can
17. BORE If boring baris operated incorrectly ACAUTION it will produce a rough cylinder sur face that may not clean up even when honed Boring should be done only by qualified service personnel who are careful in their work After boring to the correct oversize cylinder bore dimension piston and ring clearance should be appropriate There is no need to adjust or fit pistons and rings When reboring cylinders take the following pre cautions 1 Make sure cutting tool is properly ground before using it 2 Besuretop of engine block is smooth and deposit free 9 14 Clean base of boring bar before bar is set up Deposits under boring bar will cause it to tilt and the cylinder will be distorted after boring Make an initial rough cut followed by a finish cut Then hone cylinder bore to the specified over size Honing Cylinders Using Precision Hones Refer to hone manufacturer s recommended grit size to produce specified surface finish of 20 to 40 RMS Too rough of a finish will wear out the rings and too smooth of a finish can retard piston ring seating Position block solidly for either vertical or horiz ontal honing Use either a drill press or heavy duty drill which operates at approximately 250 to 450 rpm Follow hone manufacturer s instructions for the use of oil or lubricant on stones Do not use lubri cants with a dry hone Insert hone in bore and adjust stone to fit snugly to the narrowes
18. FIGURE 8 10 CHECKING BRUSH WEAR 8 12 Remove brushes and brush springs from holder and replace with new parts Pull each brush outward from the brush holder and at the same time insert see Figure 8 11 a stiff wire through the small holes in the base of the hoider The wire holds the brushes off the slip rings during disassembly Install brush block in housing but do not tighten mounting screws Removethe wirethatis holding the brushes off the slip rings by pushing it out through the hole in the end of the stator housing Adjust brush block so that brushes are centered on the slip rings and then tighten mounting screws Connect the B lead wire to the outboard brush terminal and the B lead wire to the inboard brush terminal BRUSH SPRING Ca dT W 422 122 10 Install brush block cover and tighten mounting screws 11 Install air filter element and air cleaner cover 12 Connect negative battery cable to battery terminal Slip Ring Service Remove the brush block cover and inspect the slip tings for grooves pits or other damage If the slip rings are not in good condition they may be refin ished using a commutator stone Use the following procedure to 1 2 G 1179 FIGURE 8 11 BRUSH REPLACEMENT 8 13 Remove the air cleaner cover and air cleaner filter Disconnect the lead wires from the brush block terminals and then insulate
19. June 1986 and before Service of the fuel pump is limited to the bottom cover plunger tube and plunger assembly All parts of the electric system are hermetically sealed in a gas atmosphere and are not serviceable If electrical failure occurs replace the pump Do not tamper with the seal at the ACAUTION center of the mounting bracket on the side of the pump as it retains the dry gas which surrounds the elecirical system Electrical system componenis are not serviceable Use the following procedure for servicing the pump 1 Using a5 8 inch wrench loosen the pump cover then remove by hand 2 Remove the filter magnet and cover gasket Figure 6 22 Later models do not have a filter assembly PUMP ASSEMBLY FILTER FS 1487 FIGURE 6 22 FUEL PUMP ASSEMBLY June 1988 and before 6 19 Using nose pliers remove the retainer spring from the plunger tube Remove the washer ring seal cup valve plunger spring and plunger from tube see Figure 6 23 PUMP ASSEMBLY PLUNGER RETURN SPRING TUBE CUP VALVE O RING SEAL WASHER RETAINER FS 1486 FIGURE 6 23 PLUNGER ASSEMBLY Wash all parts except gasket and seal in parts cleaning solvent Blow out solvent and dirt with low pressure compressed air Slosh the pump assembly in cleaning solvent blow dry and swab the inside of the plunger tube with a cloth wrapped around astick If the plunger does not wash clean or has rough sp
20. Remove the two 1 4 20 screws and lock washers and muffler and tailpipe assembly Completion of the remaining steps requires that the generator set be partially removed from the vehicle Refer to the PRE PARING TO SERVICE Section 5 for the set removal procedures 3 Remove the cooling system scroll and noise shield see Cooling System in this section to provide access to the exhaust manifold Removethe four exhaust manifold screws and lift off the exhaust manifold and the two manifold gaskets If set is LP gas fueled the fuel regulator vaporizer must be removed along with the exhaust manifold Refer to the Fuel System LP gas in this section for the vaporizer regulator removal and replacement procedures Assembly Exhaust gas can result in severe AWARNING personal 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 speci fied torque Replace the noise shield and scroll refer to the Cooling System section if no other service is required install the generator set in the vehicle before completing the remaining steps Place a U bolt type automotive muffler clamp marked 1 1 4 in position on the exhaust manifold near elbow prior to installing muffler Place muffler in position on set making certain that muffler inlet pipe overlaps exhaust manifold a minimum of
21. WASHER SHIM BEARING 1475 PRECISION DO NOT LINE BORE OR REAM FIGURE 9 31 REAR BEARING Front Bearing Locktite 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 Locktite Bearing Mount to the mating surfaces of the bearing and bearing bore Allow three to four minutes for drying AWARNING Breathing vapor from towelette and prolonged contact with skin can be harmful Be sure area is well ventilated Use the combination main and cam bearing driver and a press to install the front bearing Push the bearing in to the depth allowed by the flange on the driver Wipe off any excess Locktite and allow one hour for hardening at room temperature Engines shipped from the factory have separate thrust washers and main bearings for both front and rear of engine Front bearing replacement part is one piece bearing with attached thrust washer as shown in Figure 9 32 Do not add an additional thrust washer to this front bearing NOTE DO NOT ADD ADITIONAL THRUST WASHER WHEN REPLACING FRONT BEARING FRONT MAIN BEARING BORE T LOCK PIN S ALIGN BEARING NOTCHES WITH l LOCK PINS AND MATCH OIL HOLES FRONT MAIN BEARING PRECISION TYPE DO NOT LINE BORE OR REAM OR ORE M 1476 FIGURE 9 32 FRONT BEARING OIL SEALS Remove the rear bearing plate to replace
22. ali internal passages Locate leak and correct as required Drain fuel tank and refill with fresh fuel in cold weather place air preheater in winter position Adjust breaker point gap Reset spark plug gap Adjust carburetor main and idle adjustment screws Adjust carburetor float level Disassemble carburetor and clean ail internal passages See Engine Block Assembly section TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Possible Cause Faulty ignition due to incorrect ignition timing incorrect spark plug gap Dirty air cleaner Restricted fuel flow due to plugged fuel filter or faulty fuel pump Incorrect fuel mixture due to incorrectly adjusted fuel mixture screws incorrect float level or dirt in carburetor Exhaust system blocked or restricted Incorrect valve tappet clearance Excessive engine wear or damage to engine Carburetor air preheater set incorrectly Gasoline sets only Trouble Engine Lacks Power a b a b a b C Engine Overheats 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 b c Black Exhaust 1 Smoke b d incorrectly adjusted fuel mixture screws incorrect float level or dirt in carburetor Gasoline sets only Rich fuel mixture due to dirty air cleaner choke sticking
23. battery cable at the battery terminal 2 Disconnect the generator set negative battery cable at the battery terminal 3 Disconnect the generator set positive battery cable from the start solenoid 4 Disconnect the remote control wire plug from the generator set control 5 Disconnect the generator load wires at the RV electrical system junction box Tag the RV circuit wires if necessary for positive identification when reconnecting 6 Loosen the conduit connector and pull the load wires and flexible conduit free of the junction box 7 Disconnect the muffler from the exhaust mani fold at the flange connection and disconnect any support brackets or hangers that connect the muffler to the set 8 On gasoline fueled sets turn off the fuel shutoff valvein the compartment and disconnect the fuel lineatthe fuel pump Securely plug the end ofthe fuel line to prevent fuel leakage or an accumula tion of explosive gasoline vapor Gasoline vapor is extremely flam AWARNING mable and can result in severe per sonal injury or death if ignited Make certain all fue line openings are plugged to prevent gasoline vapor from accumulating On LP gas propane fueled sets disconnect the fuel line after purging at the solenoid valve and plug the end of the fuel line to prevent entrance of dirt Removing Conventional Compartment Mounted Set From RV When the generator set has been disconnected from the electrica
24. bores Drive the guides out with a hammer and vaive guide driver Driving out old guides can damage the tappet bores Be careful not to strike bores with driver Installation Run small polishing rod with crocus cloth through valve guide holes to clean out carbon and other foreign materials Place a new gasket on the intake valve guide and coat the outer edge of each new guide with oil Place guide notch up in cylinder block and press in until shoulder of guide rests against the cylinder block A suggested method of installation is shown in Figure 9 8 5 16 18 HEX NUT 2 REQUIRED 178 122 uem T Z ex 5 16 FLAT WASHER 2 REQUIRED 5 16 18 THREADED ROD 60 mm 5 8 16 mm NS FIGURE 9 8 VALVE GUIDE INSTALLATION Valve Seat Inspect valve seat inserts If seats are loose cracked or severely pitted new inserts must be installed Remove valve seat inserts using a valve seat removal tool Removal Remove carbon and combustion deposits from valve seat Select the proper size puller deter mined by the inside diameter of the valve seat The puller jaws must expand into the cylinder block at the point where the bottom of the valve seat insert rests on the cylinder block Figure 9 9 Using the new seat insert as a guide adjust the puller depth Posi tion the puller on the valve seat and tighten hex nut Clamp cylinder block to a solid bench Attach slide hammer to puller Between b
25. cable from the starter lug terminal 3 Remove the starter mounting screws and then carefully disengage the starter from the stator housing 4 Remove starter through bolts and carefully separate the brush end cap housing and arma ture assembly See Figure 6 33 5 Use an impact wrench to remove the pinion gear stop nut from the armature assembly Carefully separate the pinion gear assembly and drive end cap from the armature PINION GEAR THROUGH BOLT SEAL ARMATURE BRUSH SCREWS INPUT STUD NUT END CAP ES 1334 FIGURE 6 33 STARTER MOTOR HOUSING Testing Armaiure For Grounds Touch an ohmmeter lead to a commutator bar and then touch the other lead to the armature shaft and core laminations Alow resistance reading indicates a grounded armature Replace grounded armature with new part See Fig ure 6 34 1001 FIGURE 6 34 TESTING ARMATURE FOR GROUNDS Testing For Shorts Use a growler see Figure 6 35 for locating shorts in the armature Place armature in growler and hold a thin steel blade e g hacksaw blade parallel to the core and just above the armature while slowly rotating armature in growler A shorted armature will cause the blade to vibrate and be attracted to the core Replace shorted armature ES 1002 FIGURE 6 35 TESYING ARMATURE FOR SHORTS 6 27 Testing For Opens Touch an ohmmeter lead to commutator bar and then systematically touch the other lead to each of the rem
26. can be tested for grounded open or shorted windings using an ohmmeter Figures 8 12 and 8 13 show the rotor removed from the generator for testing However it is possible to test the rotor without removing it from the generator To obtain access to the slip rings remove the brush block cover Use a stiff wire to hold the brushes off the slip rings during testing Refer to the Brushes And Slip Rings section for procedures to use for inserting the wire Ground Test To test for grounds set the ohmmeter jor the highest resistance scale Touch one test prod to the rotor shaft and hold it there Touch the other test prod to one of the slip rings A reading less than one megohm indicates the rotor is grounded Replace a grounded rotor with a new rotor 8 14 Open Or Shorted Windings Test To test for open windings set the ohmmeter for the highest resistance scale Piace test prods on the slip rings as shown in Figure 8 12 Ohmmeter should indicate continuity between slip rings A high resistance reading indi cates a poor connection or an open winding Check the connection between the slip rings and rotor lead wires Replace rotor if rotor winding is open FIGURE 8 12 TESTING ROTOR FOR GROUNDS Totestfor shorted windings set the ohmmeter forthe lowest scale Place the test prods on the slip rings as shown in Figure 8 13 A reading less than the value shown in Table 8 2 indicates shorted windings Replace a rotor with shorted wi
27. circuit open or defective K5 relay Output voltage from generator not being suppled to control due to defective charge resistor open circuit in wiring between generator and control or defective bridge rectifier or output voltage from generator Defective control PC board Cil level is low Dirty fuel filter restricting fuel filter causing filter to freeze up Breaker points sticking Contaminated fuel Weak or discharged battery Generator set charger will not recharge a battery that is in a very low state of charge Load connected to battery while set is turned off 7 13 Corrective Action 1a Check oil level and add oil if low 1b Check for continuity and correct if circuit is open ic Replace low oil pressure switch 14 Refer to Lubrication system section for test and service procedures 2a Check for continuity and correct if circuit is open 2b Replace K5 relay 3a Test R6 charge resistor 2 5 ohm and replace if defective 3b Check for continuity and Correct if circuit is open 3c d Refer to Generator section for test and service procedures 4 Replace control PC board 1 Cheek fuel and oil levels and refill as necessary 2 Clean fuel filter Refer to Fuel System section for Service procedures 3 Replace breaker points 4 Refill tank with fresh fuel 1 Connecta separate battery charger to bring battery up to fuil charge 2 Turn off load
28. due to a incorrectly adjusted fuel mixture screws b incorrect fioat level or c dirt in carburetor Governor mechanism worn excessively Carburetor icing Gasoline sets only viscosity too light or oil is diluted Crankcase breather valve is dirty or defective leaks Excessive engine wear Light loading Cil viscosity too light or oil is diluted Low oil level Low oil pressure switch defective Faulty oil bypass valve 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 Engine Block Assembly section In cold weather place air preheater in winter position 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 Engine 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 The condition of the exhau
29. follows 1 Remove 3 8 24 x 1 in capscrew located behind gear cover and under governor arm 2 Remove spring and plunger with a magnetic tool 9 8 HEX CAP SCREW FLAT WASHER 15 1110 FIGURE 9 16 OIL BY PASS VALVE 3 Determine proper valve operation by checking the spring and plunger acording to the following measurements Plunger Diameter 0 3105 to 0 3125 in 7 89 to 7 94 mm Spring Free Length gt 1 00 in 25 4 mm ee sees 2 6 0 2 Ibs 11 6 0 9N when compressed to 0 500 in 12 7 mm Check the valve seat and clean away any accumu lation of metal particles which could cause erratic valve action Verify that the valve seat is concentric with the larger diameter valve bore Clean plungerand spring in parts cleaning and install PISTON ASSEMBLY The piston assembly consists of the piston piston rings piston pin connecting rod assembly and bear ing After removal from the engine all parts must be carefully inspected for damage and wear before replacing Removal and Disassembly Remove carbon from top of cylinder bore and for a ridge Remove ridge see Figure 9 17 with ridge reamer before attempting piston removal Improper use of a ridge reamer can damage the cylinder bore ACAUTION To remove the piston and connecting rod assemblies turn the crankshaft until a piston is at the bottom of the stroke Remove the nuts from th
30. high ambient air temperatures b faulty fuel pump Breaker points sticking Contaminated fuel Weak or discharged battery Generator set charger will not recharge a battery that is in a very low state of charge Load connected to battery while set is turned off 7 6 1a 1b 1c 1d 2a 2b 3a 3b Corrective Action Check oil level and add oil if low Check for continuity and correct if circuit is open Replace low oil pressure switch Refer to Lubrication system section for test and service procedures Test R6 charge resistor 2 5 ohm and replace if defective Check for continuity and correct if circuit is open 2c d Refer to Generator section for test and service procedures Replace control PC board Check fuel and oil levels and refill as necessary Refer to Fuel System section for testing and service procedures Remove any objects or debris that may restrict airflow to and from the set Refer to Fuel System section for test and service procedures Replace breaker points Refill tank with fresh fuel Connect a separate battery charger to bring battery up to full charge Turn off load Trouble Low Battery Continued Run Lamp Time Meter or Battery Condition Meter Does Not Operate TROUBLESHOOTING THE BGE CONTROL Possible Cause Disconnect the negative battery cable at the battery and remove conirol lead P1 6 from the battery
31. in generator voltage and fre quency A decrease in engine speed will cause a corresponding decrease in generator voltage and frequency The governor maintains a constant engine speed under changing load conditions so that generator voltage and frequency do not vary Governor Adjustments Before mak ng governor adjustments run the unit about 10 minutes under light load to reach normal operating temperature If governor is completely out of adjustment make a preliminary adjustment at no load to first attain a safe voltage and speed operating range An accurate voltmeter and frequency meter should be connected to the generator in order to correctly adjust the governor A small speed drop not noticea ble without instruments will result in an objectionable voltage drop A binding in the bearings of the governor shaft in the ball joint or in the carburetor throttle assembly will cause erratic governor action or alternate increase and decrease in speed hunting A lean carburetor adjustment can also cause hunting Springs tend to lose their calibrated tension through fatigue after long usage If the governor action is erratic after all adjustments are made replace the spring If this does not improve operation the problem is probably within the gover nor mechanism Refer to the Governor Cup in this section for service procedures Adjustments to the governor should be made in the following sequence 1 The carburetor fuel mixture
32. intake manifotd must be removed to provide clearance for lifting the generator stator assembly Disconnect the choke heater lead wires throttle linkage fuel line crankcase breather hose and preheater tube Remove the intake manifold screws and lift off the carburetor and intake manifold as an assembly Refer to Fuel System Section 6 for detailed removal procedures Disconnect the lead wires from the charge resis tor quick disconnect type connections the low oil pressure cutoff switch and the terminal on the ignition coil Remove the brush block cover and disconnect the B outboard and B inboard lead wires from the brush block terminals 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 5 Carefully guide the wire through the brush block and then release each brush Verify that each brush is held off the slip rings by the wire 10 11 12 G 1175 FIGURE 8 5 BRUSH BLOCK The brushes will be damaged ACAUTION during disassembly if not held off the slip rings Make certain wire is in place before removing stator assembly Remove the transformer cover and if the set is LP gas fueled disconnect the fuel line at the vap orizer coupling Attach the special lifting plate see Figure 8 6 to the end ofthe stator housing using four 5 16 18 X 1 capscrews Place a p
33. jack until itjust makes contact with the drip tray then put a little upward pressure under the drip tray BOLTS 4 SUPPORT BRACKET DRIP TRAY PLACE FLOOR JACK UNDER DRIP TRAY REINFORCEMENT RIBS 1600 FIGURE 5 3 PARTIAL SET REMOVAL 5 5 4 Remove the four bolts from the front support bracket and remove the support bracket itself This might require slight adjustment either slight raising or lowering the floor jack Once the support bracket is removed all the weight of the generator set on that side is on the floor jack Slowly lower the floor jack being care ful to allow the floor jack to roli as the generator set swings downward Onan suggests wood blocks be placed under the drip tray assembly so the floor jack can be removed This will allow more access room for the maintenance or service procedure Make sure generator is resting AWARNING d securely before removing floor jack Otherwise the generator set can swing downward causing severe personal injury Complete Set Removal Park the recreational vehicle on as level a surface as possible Then follow these Steps very carefully It is assumed that disconnecting the fuel exhaust etc has already been performed as described previously 1 Put the vehicle in its park position lock the brakes and remove the ignition key Make sure no one moves the vehicle while performing this procedure AWARNING or death Make
34. leaks high oil consumption rough idle reduced engine power a rapid formation of sludge and varnish within the engine or oil in the breaker point box i Crankcase Breather Service If the crankcase becomes pressurized as evidenced by oil leaks at theseals use the following procedures to service Remove the breather tube from the valve cover see Figure 6 10 Remove the valve cover pack spring washer reed valve and breather baffle Clean all parts in parts cleaning solvent Most parts cleaning solvents are flammable and can result in severe personal injury if used improperly Follow the manu facturers recommendations when cleaning parts BREATHER HOSE HEAD CAPSCREW WASHER FLAT lt bs HOSE CLAMP PACK GASKET FLAT 7 WASHER REED gt BREATHER BAFFLE C 1101 FIGURE 6 10 CRANKCASE BREATHER The reed valve must be flat with no sign of a crease Assemble using a new gasket Do not overtighten valve cover capscrew Reed vaive must be assembled as shown with washer on top and breather baffle on the bottom Over tightening the valve cover ACAUTION can cause an air leak and allow dirt to enter the engine Be careful not to distort the valve cover when tightening GOVERNOR The governor controls engine speed which directly affects the voltage output and frequency of the generator An increase in engine speed will cause a corresponding increase
35. or gas cans oily rags chains wooden blocks portable propane cylinders etc A fire could result or the generator set operation cooling noise and vibration may be ad versely affected Keep the compartment floor clean and dry Do not work on this equipment when mentally or physically fatigued or after consumirig any drug that makes the operation of equipment unsafe RV 9 Supplement 55 103 Date 11 86 Insert with Title BGE BGEL Service Manual Number 965 0530 PURPOSE This supplement reflects the following manual updates Page 1 for units equipped with a Nikki carburetor New throttle stop mixture adjustment and float setting in refer ence to like information found on pages 6 14 6 15 and 6 17 Section 8 Generator Pages 8 3 and 8 4 Changes made to transformer tap connections and added point to point lead checking note Page 8 11 Text changes made to assembly procedure transformer tap connections 2 B Page 8 14 Change made to Table 8 1 Transformer Tap Connections SUPPLEMENT USE Refer to the corresponding pages of your manual and write Refer to Supplement on them This supplement should not be used without reference to the appropriate Service Manual The Service Manual should not be used without this supplement Please file or otherwise keep the two together Maintenance of generator sets involves AWARNING the risk of properly damage or severe personal injury
36. positive terminal on the K1 start solenoid Connect a DC ammeter and 5 ampere fuse in series between the P1 6 lead wire and the stud terminal on the K1 solenoid With set running the ammeter should read between 0 and 1 ampere If meter shows baitery is discharging fault is due to a defective generator charge winding b power rectifier open Open circuit between terminal 6 or remote connector plug and terminal 6 on Start Run Stop switch Open circuit between ground terminals on lamp or meters and terminal 1 on remote Start Run Stop switch If battery condition meter works but time meter does not operate time meter is defective If time meter works but battery condition meter does not operate verify that jumper wire is connected between terminals 5 and 6 on remote start stop switch If jumper is in place connect a voltmeter between the positive terminal on battery charge meter and ground Use the following to determine fault a If reading equals battery voltage minus 10 volts battery meter is defective If reading does not equal battery voltage minus 10 volts zener diode is defective 7 7 Corrective Action Refer to Generator section for testing and service procedures Replace control PC board 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 d
37. procedure to remove the stator from the stator housing a Remove stator lead wires from the trans former primary leads and secondary taps as described in steps 20a through 20c b Cut off the wire ties that secure the stator lead wires to the inside of the housing Cut only wire ties not the tie supports c Remove the four stator clamps and capscrews d Carefully lift the stator straight up until it clears the stator housing Careless handling of the sta ACAUTION tor can damage the insula tion on the stator windings Do not brush the windings against the housing as it is lifted clear Generator Assembly Use the following procedures to assemble the generator 1 If the stator was removed from the housing during disassembly use the following procedures to install the stator in the housing a Position the stator so the output leads are oriented as shown in Figure 8 3 then carefully lower the stator into the stator housing Careless handling of the sta ACAUTION tor can result in damage to the stator windings Do not brush the stator windings against the housing as it is lowered into position b Install the four clamps and capscrews that secure the stator to the housing Tighten cap screws to specified torque c Route stator lead wires through holes in sta tor housing as specified in Figure 8 3 Fasten wiring harness to inside of housing using wire ties d If transformer was not removed during di
38. screws must be cor rectly adjusted before governor adjustments are made if the carburetor needs adjusting refer to the Mixture Screw Adjustments in this section before making any adjustments to the governor 6 11 SPEED ADJUSTMENT NUT SENSITIVITY ADJUSTMENT SCREW FS 1613 FIGURE 6 11 GOVERNOR ADJUSTMENT Touching hot exhaust pipes or LAWARNING moving parts can result severe personal injury Use extreme caution when making adjustments while the engine is running 2 Adjust the length of the governor linkage and check for binding or excessive looseness The length of the linkage connecting the governor arm to the throttle shaft assembly is adjusted by loosening the lock nut and rotating the ball joint see Figure 6 11 Adjust this length so that with the engine stopped and tension on the governor spring the stop on the throttle shaft assembly almost touches the stop on the side of the car buretor One more turn of the governor ball joint would allow the throttle shaft stop to touch the carburetor Tighten lock nut 3 With the unit operating at no load adjust the speed adjustment nut to achieve the following frequency and voltage 60 Hz 120 Volts 62 Hz 127 5 4 5 Volts 50 Hz 110 220 Volts 52 Hz 233 9 Volts 50 Hz 120 240 Volts 52 Hz 255 9 Volts 4 Check the frequency and voltage first with a load applied and then with no load applied The fre quency and voltage should stay within the limi
39. sections for cuts cracks and abra sions and make sure they are not rubbing against anything that could cause breakage ACAUTION Leaking fuel will createa fire hazard which might result in severe per sonal injury or death if ignited by a spark If leaks are detected correct immediately 10 2 CONTROL Stop and start the generator set several times at the set control and remote control to verify the control functions properly MECHANICAL Stop the generator set and inspect for leaking gaskets loose fasteners damaged components or interference problems Repair as required Inspect the generator set compartment and verify there are no breaks or openings in the vapor proof wall that separates the compartment from the coach interior Seal openings as required Make sure all soundproof ing material is in place Redistribution or publication of this document by any means is strictly prohibited Onon Cummins Power Generation 1400 73rd Avenue Minneapolis MN 55432 763 574 5000 Fax 763 574 8087 Cummins and Onan are registered trademarks of Cummins Inc
40. specified in Carburetor Mixture Screw Adjustments section Regulator Atwo stage Impco regulator see Figure 6 28 is used to deliver vaporized LP gas fuel to the carburetor The primary stage of the regulator receives LP gas at container pressure and reduces it to the low pressure required for set operation The secondary stage of the regulator restricts fuel flow through the regulator until vacuum from the engine creates a demand for fuel Fuel flows through the regulator only when the engine is cranking or operating and stops flowing when the engine is stopped Theregulator will normally require very little attention if the set is used on a regular basis and operated on clean high quality fuel Most regulator malfunctions can be traced to the following two sources Hardened diaphragms and seats due to extended periods of non operation Dirt or foreign matter embedded on valves and valve seats FS 1598 FIGURE 6 28 LP GAS REGULATOR A regulator that has been operated and then stored for any length of time may require rebuilding or replacement Diaphragms and gaskets tend to dry shrink and harden as the lighter petroleum ends evaporate Use the test procedure specified in the Regulator Test section to check regulator operation and then rebuild or replace as required Repair kits include detailed and illustrated installation instruc tions A regulator that has granules of foreign matter embedded on the secondary
41. the AC output windings are wired in parallel T1 connected inter nally to T3 to produce 120 volts only Ail stators aiso havetwo lead wires 1 S2 thatare used with the voltage regulating transformer The stator mounts inside the generator housing and is held in position with four clamps and four cap Screws series of air intake openings in the end of the housing allow air to be drawn inside the housing for generator cooling The housing also pro vides a mounting point for the starter rear bearing brushes control fuel pump and voltage regulating transformer The complete stator and housing assembly boits to the engine to generator adapter 8 1 Rotor The 4 pole rotor provides the rotating magnetic field that is required for generating an AC voltage poten tial in the stator windings The DC current required for field excitation is supplied through two slip rings that mount on the rotor shaft The inner end of the rotor is connected directly to the engine crankshaft using tapered seat shaft cou pling and through bolt The outer end of the rotor is supported by a single bearing that is pressed onto the rotor shaft The bearing fits inside the generator housing bearing Cooling airflow for the generator s provided by a centrifugal fan that mounts on the inner end of the rotor shaft The fan also serves as a mount for the starter ring gear Voltage Regulating Transformer The voltage regulating transfo
42. 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 Use an oil seal guide and driver to press or drive the rear seal into the rear bearing plate until it bottoms against the shoulder of the plate see Figure 9 33 Press or drive the front oil seal into the gear cover until it is 0 97 0 02 inch 24 6 0 5 mm from the mounting face of the cover 9 16 Lubricate the lips of the replacement seal with a light coating of grease before installing the rear bearing plate or gear cover This provides initial lubrication until engine reaches the seal Refer to the Crank USE GREASE IN SPACE BETWEEN SEALS TO IMPROVE SEAL shaft section for the rear bearing plate installation procedures Refer to the Gear Cover section for the gear cover installation procedures THIS SURFACE SHOULD BE GEAR COVER MOUNTING FACE 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 DRIVE OR PRESS OIL CLEANED OF ALL OLD SEALING SEAL TO SHOULDER COMPOUND BEFORE OF THE PLATE BORE INSTALLING SEAL GEAR COVER OIL SEAL REAR BEARING PLATE OIL SEAL M 1477 FIGURE 9 33 OIL SEALS 9 17 Redistribution or publication of this document by any means is strictly prohibited Section 10 Service Checklist After servicing inspect and test the complete instal
43. to obtain their recommendations before attempting to remove the set from the coach Generator sets are heavy and can AWARNING result in severe personal injury if dropped during removal Use adequate lifting devi ces to provide sufficient support for the set Keep hands and feet clear while lifting Special fuel handling procedures are required when removing an LP gas propane powered set The fuel system must be purged of LP gas before the set can be safely removed from the coach Follow the purg ing procedure following before attempting to remove an LP gas powered set If the generator setis powered by gasoline proceed to the appropriate set removal section BARRIER MOUNTING COMPARTMENT FLOOR HOLES EXS 1121 FIGURE 5 1 TYPICAL COMPARTMENT MOUNT INSTALLATION FLOOR OF REAR PANEL ASSEMBLY SUPPORT TRAY SUPPORT BRACKET 4 EXS 1122 FIGURE 5 2 TYPICAL UNDER THE FLOOR INSTALLATION 5 3 LP Gas Propane Purging Procedure To purge the LP gas from the set fuel system close the shut off valve at the fuel tank and then start the generator set Allow the generator set to operate until it runs out of fuel Crank the set a few times after it Stops to make sure the fuel system is completely purged of all LP gas fuel If the generator set cannot be operated move the RV coach to an outdoor location that is well ventilated and is away from fire or flame Disconn
44. used on corresponding oversize pistons Rings of the tapered type are usually marked one side or identified in some other manner Install these rings with the identification mark toward the closed end of the piston 9 10 Installing Piston Cylinder When installing the piston assembly the raised lines witness marks on the rods and caps must be aligned see Figure 9 24 Also note that the connecting rod bolt is offset to one side of the cap When assembled on the crankshaft the thin side of the cap should be nextto the cylinder block The rod and cap stamped 2 should be installed next to the bearing plate PISTON RING IN CYLINDER BORE 1 Turncrankshaftto position rod bearing journal at bottom of its stroke 2 Lubricate piston assembly and inside of cylinder Compress rings with a ring compressor as shown in Figure 9 25 install bearing insert in rod CT 1064 FIGURE 9 23 CHECKING RING GAP Piston Assembly Installation Lubricate all parts with clean engine oil Position the piston on the connecting rod Install the pis ton 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 Install the rings on the piston beginning with the oil control ring Use a piston ring spreader to prevent twisting or excessive expans
45. 0 inch 10 9 mm long rest the brush springs against the sides of brushes to keep them clear during armature installation See Figure 6 43 Place washer on commutator end of shaft and put armature into brush endcap Push the four brushes toward commutator making sure springs are prop erly positioned on brushes Recheck to be sure spring is pushed all the way down on mounting tab Make sure all brush wires are clear of commutator and that uninsulated portions of insulated wires do not touch inside diameter of housing Uninsulated portions of wires must also not touch adjacent brush boxes 10 11 12 13 magnetic housing over armature Use nut driver over the end of shaft to hold down armature and endcap Place spring washer and flat washer on shaft as shown in Figure 6 44 Place mounting bracket on motor with exposed end of sieeve bearing and through bolt Jead ins tothe inside of motor The flat near one mounting hole should line up with the positive stud on end cap so through bolts will line up Insert the through bolts and torque to 35 45 Ib in 3 96 509 Nem Wipe dust from helix and gear and apply alight coat of GE Versilube 322 L on outside diameter of helix inside diameter of gear and unchamfered end of gear Place clutch and helix assembly on motor shaft with flats engaged in clutch hole FIGURE 6 43 RESTING BRUSH SPRING GN BRUSH SIDE 6 32 METAL SPRING RETAINER
46. 1 1 2 inches 38 mm EXHAUST ELBOW MUFFLER CLAMP MARKED 1 1 4 E 1 4 20 SCREWS EXS 1120 FIGURE 6 2 UNDERFLOOR MOUNT EXHAUST SYSTEM 5 Install the two 1 4 20 screws lock washers that secure the muffler support bracket to the set and tighten muffler clamp A CAUTION Prevent excessive vibration transfer to the vehicle mount muffler and tailpipe hanger brackets directly above the component being supported and NOT at an angle 6 Run the generator set for five minutes and check entire exhaust system visually and audibly for leaks or excessive noise 7 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 visu ally and audibly for leaks daily at least every eight hours of running time Tailpipe Recommendations Tailpipes are supplied by the RV manufacturer and must meet severa design specifications to ensure safe generator set operation If replacing the tailpipe make certain the replacement part is the same size and configuration as the original part Refer to the following guidelines for selecting and locating the tailpipe Inhalation of exhaust gases can AWARNING result in severe personal injury or death Exhaust gases can enter the coach interior if the tailpipe is damaged missing or improperly installed Follow the recommended exhaust sys
47. 5 PREPARING TO 5 5 1 5 1 Special TOO S i E 5 1 Safety Considerations 5 1 Set Removal 5 2 6 ENGINE PRIMARY SYSTEMS 6 1 Introduction ed odes 6 1 Troubleshooting Engine Primary Systems 6 1 Exhaust System nra e ur rur rote oret 6 4 Cooling System 6 7 Ignition 6 8 Crankcase Ventilation 6 11 Governor qu UA RES 6 11 Fuel System Gasoline 6 12 Fuel System LP 6 20 Electric Starter Spec 6 27 Electric Starter Begin Spec B 6 28 7 CONTROL TEE 7 1 Pes 7 1 Control Description 7 1 BGE Control 7 2
48. 5 solenoid De energizing the K5 relay closes the K5 30 87A con tacts which holds the relay grounded This pre vents the set from restarting if the S1 switch is released from the Stop position Without ignition or fuel the engine stops As the generator output voltage drops the K2 generator relay also de energizes All components return to their de energized position following set shutdown prevents the battery from discharging through the generator windings while the set is stopped 7 10 BGEL CONTROL TROUBLESHOOTING Use the troubleshooting guide to help locate problems related to the BGEL control Figures 7 5 and 7 6 show the location of most of the control components Refer to the wiring diagram in Figure 7 8 for location of all termi nal connections Trouble Engine Does Not Crank The troubleshooting guide is divided into six sec tions After identifying the problem refer to the guide for the possible cause and the recommended correc tive action TROUBLESHOOTING THE BGEL CONTROL Possible Cause If engine cranks at set but not at remote control panel fault is due to a open circuit in remote conirol wiring b remote start switch faulty If engine cranks at remote control panel but not at set fault is due to a open circuit in wiring between S1 switch and PC board b faulty S1 switch Insufficient voltage for cranking due to a battery not charged b termina connections loo
49. AC NORMAL IGN POINTS SWITCH LOW OIL PRESSURE SWITCH START STOP RESISTOR BATTERY CHARGE RELAY USED WITH LPG ONLY 611 1177 FIGURE 8 2 50 HZ RECONNECTABLE 4 WIRE GENERATOR SET WIRING Di GPRAM SCHIMATIC 8 4 Trouble No AC Output Voltage Note This condition may cause the generator set to stop when the Start switch is released AC Output Voltage Too Low Or Too High Noisy Generator TROUBLESHOOTING THE GENERATOR Possible Cause Open circuit breaker Open circuit between brush block an CR4 rectifier Brushes stuck in holder or not making good contact with slip rings Defective CR4 bridge rectifier Open grounded or short circuit in rotor stator or transformer Engine governor incorrectly adjusted Open diode in CR4 bridge rectifier Brushes worn or not making good contact with slip rings If generator frequency is within specified limits but voltage is incorrect transformer is incorrectly connected or defective Open grounded or short circuit in rotor stator or transformer causes low AC output voltage Loose brush holder Worn generator end bearing Rotor and stator rubbing together due to a varnish lumps or b rotor misaligned with crankshaft 8 5 Corrective Action Locate cause of overioad and correct as required Reset breaker Check for continuity and correct if circuit is open Release brushes if jammed in holder Clean sl
50. EL CONTROL Possible Cause Faulty ignition due to worn or fouled spark plugs worn ignition points incorrect ignition timing or faulty plug wires Faulty fuel system due to carburetor mixture screws incorrectly adjusted plugged fuel filter faulty regulator or faulty fuel solenoid Connect a voltmeter between positive terminal on coil and ground Check for battery voltage when 1 is placed in the Start position If voltage is not present fault is due to a open circuit between coil and control or b defective controi PC board 7 12 MOUNTS BEHIND LEFT CYLINDER R6 CHARGE RESISTOR R6 1 R6 2 TO R6 1 AIR CLEANER ADAPTER TROUBLESHOOTING THE BGEL CONTROL Corrective Action Refer to Ignition System section for test and service procedures Refer to Fuel System section for test and service procedures Check for continuity and correct if circuit is open Replace control PC board 1520 Trouble Engine Starts But Stops When Start Switch Is Released Engine Starts And Runs Then Stops Set Restarts Immediately or Set Restarts After Waiting Several Minutes Low Battery TROUBLESHOOTING THE BGEL CONTROL Possible Cause Low oil pressure switch not closing due to low oil level open circuit between switch and control defective low oil pressure switch low oil pressure K5 relay contacts not open ing due to K5 relay
51. HES 1 6620 42 214 mm 1 3750 34 925 mm 71 79 Ibs 9 8 10 9 N 38 42 Ibs 5 3 5 8 N MODELS Valve Face Angle Valve Seat Angle Valve Seat Width Valve Stem Diameter Intake Valve Stem Diameter Exhaust Valve Guide Diameter Valve Stem Clearance Intake Valve Stem Clearance Exhaust Valve Lifter Diameter Valve Lifter Bore Diameter Valve Lifter To Block Clearance Valve Seat Diameter Intake Valve Seat Diameter Exhaust Valve Seat Bore Diameter intake Vaive Seat Bore Diameter Exhaust BGE and BGEL 44 45 0 031 0 047 0 79 1 19 mm 0 3425 0 3430 8 700 8 712 mm 0 3410 0 3415 8 661 8 674 mm 0 344 0 345 8 738 8 788 mm 0 0010 0 0025 0 025 0 064 mm 0 0025 0 0040 0 064 0 102 mm 0 7475 0 7480 18 987 18 999 mm 0 7500 0 7515 19 050 19 088 mm 0 0015 0 0030 0 038 0 076 mm 1 443 1 444 36 652 36 678 mm 1 192 1 193 30 28 30 30 mm 1 4395 1 4405 36 5633 36 5887 mm 1 189 1 190 30 20 30 23 mm 3 3 Redistribution or publication of this document by any means is strictly prohibited Section 4 Torque Specifications MODELS BGE and BGEL 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 16 18 22 24 Connecting Rod 12 14 16 19 Rear Bearing Plate 25 27 34 37 Flywheel Mounting Screw 50 55
52. JUMPER WIRING DIAGRAM AI P3 1 En REMOTE I i 14 R6 AI CRIAI FI BUS BAR T2 A K4 W2 7 z ae g 660506 Wes 1 1 C OND f am 1 CRS El 2 1 163 1 1 1 5 ALKS 5 Bd t P 1 AMG 2 52 KS 87 0_ 1 1 611 1177 IMPORTANT Due to the possibility of ACAUTION unit lead end identification being out of date with the wire diagram schematic of this sup plement do not rely solely on lead markings by trans former when troubleshooting Instead check each lead from point to point to contirm that unitis wired properly 8 4 NOMINAL NOLOADVAC LEADS CR4 AC 5 127 514 5 VAC 2714 R6 RESISTOR BATTERY CHARGE K5 RELAY USED WITH LPG ONLY S3 1GN POINTS S2 SWITCH LOW OIL PRESSURE Si SWITCH START STOP STANDARD REMOTE CONTROL A2 DELUXE REMOTE CONTROL AI CONTROL ASSY b Connect the CR4 AC lead wire to the trans former X2 50 Hz X3 tap and the S1 lead wire to the transformer X5 tap Note This is a prelimi nary connection that may require adjustment to obtain the correct generator output voltage See Transformer Voltage Adjustment in this section c Strip off 1 2 inch of insulation from the ends of tra
53. N CAUSE SEVERE PERSONAL IN JURY OR DEATH Before starting work on the generator set disconnectbatter ies This will prevent accidental arcing Keep your hands away from moving parts Make sure that fasteners on the generator set are secure Tighten supports and clamps keep guards in position over fans drive belts etc Do not wear loose clothing or jewelry while working on gen erator sets Loose clothing and jewelry can become caught in moving parts Jewelry can short out electrical contacts and cause shock or burning e Ifadjustment must be made while the unit is running use ex treme caution around hot manifolds moving parts etc ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Disconnect starting battery before removing protective shields or touching electrical equipment Use rubber insula live mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment Do not wear damp clothing particularly wetshoes or allow skin sur faces to be damp when handling electrical equipment Use extreme caution when working on electrical compo nents High voltages can cause injury or death Follow all state and local electrical codes Have all electrical installations performed by a qualified licensed electrician Tag open switches to avoid accidental closure DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM Hazardous volt ages can
54. Proceed as follows 1 Remove all parts necessary to gain access to valve tappets 2 Remove spark plugs to make turning the engine easier 3 Place a socket wrench on the flywheel capscrew and rotate the crankshaft in a clockwise direction unti 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 the left intake and exhaust valves are closed and there is no pres sure on the valve lifters 4 Clearances are shown in the Specifications section For each vaive ihe gauge should just pass between the valve stem and valve tappet see Figure 9 11 5 Tocorrect the valve clearance turn the adjusting screw as needed to obtain the right clearance The screw is self locking 6 Toadjust valves on the right cylinder turn engine one complete revolution and again line up mark on the flywheel and the TC mark on the gear cover Then follow adjustment procedure given for left cylinder 7 Replace ali parts removed Tighten all screws securely Torque manifold bolts GOVERNOR CUP ROLL PIN ROTATE GOVERNOR CUP SO THAT ROLL PIN FITS INTO THE METAL LINED HOLE OR PLASTIC BUSHING IN THE CUP VT 1026 FIGURE 9 11 VALVE CLEARANCE ADJUSTMENT GEAR COVER Remove the flywheel key and gear cover mounting
55. Remove the crankcase breather hose and air pre heater hose from the air cleaner housing 2 Remove the air cleaner housing center capscrew and lift off the housing and air filter 3 Remove the choke cover retaining nut and lift off the choke cover 4 Disconnect the choke lead wires at the choke terminals 6 12 CRANKCASE BREATHER TUBE CARBURETOR AIR PREHEATER HOSE AIR CLEANER HOUSING AIR FILTER FIGURE 6 12 AIR FILTER ASSEMBLY 5 Remove the three capscrews that secure the air cleaner adapter to the carburetor and lift off the adapter Note that choke linkage must be disen gaged from choke assembly as adapter is removed 6 Remove the two capscrews that secure choke bracket to adapter and lift off choke assembly Assembly Reverse order of disassembly Use a new gasket between adapter and carburetor Carburetor And Intake Manifold Assembly The carburetor and intake manifold assembly con sists of the intake manifold choke pull off assembly air preheaters and carburetor See Figure 6 13 Disassembly Use the following procedures to remove and disassembie the carburetor and intake manifold assembly 6 13 Removethe air filter assembly as described in Air Filter Assembly previously Disconnect the fuel line and governor control link age from the carburetor Removethe intake manifold capscrews and lift off the carburetor air preheater Lift off the carbure tor and intak
56. Repair When the carburetor is completely disassembled clean and repair using the following procedure 1 Soak all metal components not replaced by repair kit in carburetor cleaner Do not soak non metal floats or other non metal parts Follow the cleaner manufacturer s recommendations Most parts cleaning solvents AWARNING are flammable and can result in Emre DAMAGE AND WEAR OCCUR HERE FS 1483 FIGURE 6 16 MIXTURE NEEDLE INSPECTION Installidle mixturescrew assembly Furn inserew until lightly seated and then out the number of turns specified in Table 6 2 UA Forcing the mixture adjustment CAUTION screws tight will damage the needle and seat Turn in only until light ten sion is felt Install needle valve and seat fuel bow gasket and float assembly Make sure all clips and springs are properly placed and the float moves freely without binding See Figure 6 17 severe personal injury if used improperly Follow RS the manufacturers recommendations when Le cleaning parts Clean all carbon from the carburetor espe cially where the throttle and choke plates seat Be careful not to plug the idle or main fuel parts Blow outall passages with compressed air Avoid using wire or other objects for cleaning that might increase the size of critical passages Check the condition of any needie valve not included in repair kit and replace if da
57. Replacement camshaft bearings are precision type and do not require line reaming or line boring after installation Coat the bearing with lubricating oil Position the front bearing so the oil hole in the bear ing is aligned with the oil hole see Figure 9 30 inthe block Position the rear bearing so the elongated slot is aligned with the breaker point plunger hole in the top of the block ALIGN HOLE IN BEARING Tor 1 32 pl TSIDE WITH HOLE IN BEARING BORE ien FIGURE 9 30 CAMSHAFT BEARING Use the combination main and cam bearing driver anda press to install the front and rear cam bearings Push in the bearings to the depth allowed by the flange on the driver Crankshaft Bearings New crankshaft main bearings are precision type which 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 For putting in either the front or rear main bearing always align the oil hole s in the bearing with the oil hole s in the bearing bore The passage must be at least 1 2 open Rear Bearing Use the combination main and cam bearing driver and a press to install the rear main bearing Push the bearing into the bearing plate from the inner side see Figure 9 31 to the depth allowed by the flange on the driver REAR BEARING END PLATE LOCK PIN ALIGN BEARING OIL HOLES WITH OIL HOLES BEARING BORE THRUST
58. Troubie Low Battery Continued Run Lamp Time Meter or Battery Condition Meter Does Not Operate TROUBLESHOOTING THE BGEL CONTROL Possible Cause Disconnect the negative battery cable at the battery and remove control lead P1 6 from the battery positive terminal on the K1 start solenoid Connect a DC ammeter and 5 ampere fuse in series between the P1 6 lead wire and the stud termina on the K1 solenoid With set running the ammeter should read between 0 and 1 ampere If meter shows battery is discharging fault is due to a defective generator charge winding or b CR1 power rectifier open Open circuit between terminal 6 or remote connector plug and terminal 6 on Start Run Stop switch Open circuit between ground terminals on lamp or meters and terminal 1 on remote Start Run Stop switch If battery condition meter works but time meter does not operate time meter is defective If time meter works but battery condition meter does not operate verify that jumper wire is connected between terminals 5 and 6 on remote start stop switch if jumper is in place connect a voltmeter between the positive terminal on battery charge meter and ground Use the following to determine fault a Ifreading equals battery voltage minus 10 voits _ battery meter is defective If reading does not equal battery voltage minus 10 volts zener diode is defective 7 14 Correcti
59. a stiff piece of wire through the small holes in the base of the holder The wire holds the brushes off the slip rings during assembly Install brush block in housing and tighten mounting screws Place the rotor in position for mounting on the end of the crankshaft and install rotor through bolt Tighten through bolt just enough to hold rotor in place Tightening the rotor through ACAUTION bolt to specified torque before the stator assembly is installed can result rotor shaft misalignment Follow recommended install ation procedures to avoid any possibility of shaft misalignment Carefully lower the stator assembly over the rotor and into position for assembly to the engine The rotor end bearing should fit snuggly 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 cap screws that secure the stator housing to the engine to generator adaptor Tighten capscrews to specified torque Note that each locking washer is installed under capscrew head Tighten the rotor through bolt to the specified torque Hold the drip pan in position for mounting to the underside of the set and install the three vibration isolator center screws Tighten the rear generator end center screws to the specified torque Secure ground strap to drip tray usin
60. acket using a 1 4 20 screw and lock washer Tighten strap around muffler using a 1 4 20 screw lock washer and nut Ifreplacing the original tailpipe refer to the Tailpipe Recommendations sections for selecting and locat ing the tailpipe Attach tailpipe to outlet end of muffler and secure using a U bolt type automotive muffler clamp marked 1 3 8 ONLY Support the tailpipe using a shock mounted sup port hanger with 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 Run the generator set for five minutes and check entire exhaust system visually and audibly for leaks or excessive noise Correct as required 10 Clean spark arrester muffier 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 visu ally and audibly for leaks daily at least every eight hours of running time Underfloor Mount Exhaust System Underfloor mount exhaust systems consist of the 6 5 exhaust manifold muffler clamps hanger if required and tailpipe When service is required dis assemble and reassemble as specified in the follow ing steps UU Disassembly Proceed as indicated 1 Loosenthe muffler clamp atthe muffler inlet see Figure 6 2 and remove the muffler support bracket screws 2
61. ad in front of the engine to cushion and protect the scroll Attach a hoist or other suitable lifting device to the lifting plate Lift the set as shown in Figure 8 6 until it is completely vertical and resting on the scroll Remove lifting plate when complete 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 away from the drip pan 13 14 15 16 17 LIFTING PLATE CAPSCREW G 1176 FIGURE 8 6 GENERATOR SET LIFT Remove the four capscrews lock washers and nuts that secure the stator housing to the engine to generator adapter Install a puller on the end of the stator housing as shown in Figure 8 7 Use two 5 16 18 x 1 cap screws to secure the puller to the housing Tighten puller center screw against rotor through bolt until housing lifts free of rotor and end bearing Remove puller when complete Carefully lift the stator assembly straight up until it clears the rotor Careless handling of the stator A CAUTION can damage the insulation on the stator windings Do not brush the stator windings against the rotor as it is lifled clear Place a 3 8 inch allen wrench in the head of the rotor through boit Use a rubber mallet and sharply strikethe allen wrench sothe through bolt is driven in a counterclockwise viewed from generator end direction Several sha
62. age is present fault is due to a K1 relay not grounded b defective K1 relay or C defective starter If voltage is not present as described in step 5 test fault is due to open circuit between K1 relay and control PC board or b defective control PC board 7 4 Corrective Aclion Check for continuity and and correct if circuit is open Replace remote start control switch Check for continuity and correct if circuit is open Replace 1 switch Check condition of battery and recharge or replace Clean and tighten all connections at battery K1 start solenoid and starter motor Short circuiting AWARNING the battery cables can result in severe per sonal injury Disconnect the nega tive battery cable at the battery terminal before servicing Replace fuse 5 ampere Tighten solenoid bracket mounting screw Replace K1 start solenoid Refer to Electric Starter section for test and service procedures Check for continuity and correct if circuit is open Replace control PC board R6 CHARGE RESISTOR MOUNTS BEHIND LEFT CYLINDER 8 TO TERMINAL FIGURE 7 2 BGE CONTROL TROUBLESHOOTING THE BGE CONTROL Trouble Possible Cause Corrective Action Engine Faulty ignition due to worn Refer to Ignition System Cranks But or fouled spark plugs worn section for test and Does Not Start ignition points incorrect service procedures ignition timing or faulty plug
63. aining commutator bars A high resistance reading indicates an open circuit between the commutator bars and armature wind ings Replace an open armature with new part Brush Inspection Measure brushes see Figure 6 36 and replace if worn to less than 1 4 inch 6 4 mm Check to see that brushes move smoothly in the brush holders Replace brushes that are burned Housing Inspection inspect the inside of the starter housing Magnets are glued to the housing and must be secure and free of cracks 0 25 IN 6 35 mm WEAR LIMIT G 1173 FIGURE 6 36 BRUSH INSPECTION Assembly 1 Wipe off all dirt and oil from starter components using a clean cloth or blow off dirt with filtered low pressure compressed air Do not immerse bearings in ACAUTION cleaning fluid Use a brush dipped in clean engine oil for dirt removal 2 Assemble brushes in brush holder so the cham fered edge is away from the brush springs Make certain brush wires do not rub against commuta tor or end cap gt 3 Tighten brush screws to to 3 1 2 ft lbs 4 to 5 Nem torque 4 Tighten lug terminal nut to 4 to 5 ft lbs 5 to 7 Nem torque 5 Apply a thin film of silicone base grease GE Ver silube 322 L or equivalent to the portions of the armature shaft that contact the bearings Apply a heavy coat of silicone base grease to the starter drive section of the shaft 6 Install the pinion gear stop nut and tighten to 20 to 25 ft Ibs 27 t
64. also damage the non running engine COOLING SYSTEM Aconstant airflow is critical for engine and generator cooling to prevent excessive heat build up All Eme rald series generator sets use a Vacu Flo cooling system to provide the required airflow With Vacu Flo cooling a flywheel fan draws cool air in from the generator end of the compartment see Figure 6 3 The cool air passes over the cooling fins on the engine and absorbs the heat The heated air is then discharged through the opening in the bottom of the Vacu flo scroll Carbon monoxide can result in AWARNING severe personal injury or death Never use discharged cooling air for heating the coach interior since discharged cooling air can contain poi sonous exhaust gases The generator compartment air inlet is sized see SPECIFICATIONS to allow the required flow rate of air The air inlet opening and the air discharge open ing must be kept free of any obstructions to avoid AIR OUT FIGURE 6 3 COOLING AIRFLOW restricting airflow Dirt dust or other debris that may clog the air duct openings should be removed during periodic maintenance Dirt might also become lodged between the cooling fins on the engine block and cylinder heads If this happens heat transfer is greatly reduced and overheating can occur if the fins are not cleaned The cooling system consists of the noise shield cylinder air housings scroll flywheel and scroll backplate When service i
65. am in Figure 8 2 for the location of all terminal connections The troubleshooting guide is divided into four sections After identifying the problem refer to the guide for the possible cause and the recommended corrective action 8 2 REMOTE PANELS DELUXE ADD JUMPER WIRING DIAGRAM T2 x H2 BUS BAR 8 811 1174 Ret FIGURE 8 1 60 HZ GENERATOR SET WIRING DIAGRAM SCHEMATIC STANDARD SCHEMATIC Bri R6 AI CRIAI FI KI 7 l AIK4 W2 2 2 gt gt Bass __ AG E Ar pi di 1 I POTA I o 1 1 1 l 1 1 NOMINAL NO LOAD VAC LEADS 51 CR4 AC 1272534 5VAC JUMPER WIRE TRANSFORMER IGN IGN POINTS SWITCH LOW OIL PRESSURE SWITCH START STOP RESISTOR BATTERY CHARGE RELAY USED WITH LPG ONLY START SOLENOID CHOKE GENERATOR FUSE FUEL PUMP OR FUEL SOLENOID T2 TI 5 2 Si RS K5 DELUXE REMOTE CONTROL CONTROL ASSY 8 3 REMOTE PANELS DELUXE STANDARD MeL hE xe ADD JUMPER WIRING DIAGRAM SCHEMATIC a eae eae igo nuo a BUS BAR u d ne amp 1 4 2 Ar Pr 2 NI 7 1 EM NS 1 3 E2 NS UE NOMINALNO LOAD V
66. and Camshaft 9 7 Lubrication System n 9 7 Piston 9 8 eee hes dor vta wies wana errr A qe Em 9 12 Cylinder Ren 9 13 Inga Re EE 9 16 Seals au ad rne MEO 9 16 SERVICE CHECKLIST TM 10 1 Mounting 10 1 Lubrication 10 1 6 mm 10 1 Initial Start Adjustments d 10 1 Output Check ate aaah wha unte Caer Jes pl ere 10 1 Exhaust System 10 1 Fuef System 10 2 CONDON 10 2 Mechanical 5 o lee haer Ve TES 10 2 Section 1 Introduction ABOUT THIS MANUAL This manual provides service information for Onan BGE BGEL series recreational vehicle generator sets This is a complete service manual for the expe rienced serviceperson covering troubleshooting dis assembly repair reass
67. and death from hazards of fuels and rotat ing paris Be sure to review the important safety precau lions contained in the Service Manual before undertaking any of the procedures listed in this Supplement Redistribution or publication of this document by any means is strictly prohibited Nikki Carburetor Throttle Stop Fuel Mixture Adjustment and Float Setting Throttle Stop Idle Adjust Connect frequency meter to generator set Start the generator set and operate at no load Turn in the throttle stop screw idle adjust to contact the throttle lever tab While adjusting screw pull the governor linkage toward the engine and monitor the frequency meter Adjust the screw to obtain the follow ing setting 60 Hz Model 55 1 hertz 1650 30 r min 50 Hz Model 45 1 hertz 1350 30 r min Release governor linkage and check unit frequency and voltage Refer to Governor Adjustments in section 6 of service manual Perform necessary adjustments to achieve proper setting Mixture Screw Adjustments generator set voltage and frequency r min cannot be satisfactory adjusted and the generator set operation is erratic stop the generator set and review the following idle and main fuel mixture screw adjustments mixture screw adjustment Carefully remove screw adjustment limiter cap Using a screwdriver carefully turn the idle mix ture screw inward until lightly seated and then back out exact
68. and wear Replace bearing inserts that are scored have the overlay wiped out show fatigue failure or are badly scratched bearings appear to be serviceable check them for proper clearance Piston Clearance Proper piston tolerances must be maintained for satis factory operation Use a micrometer to measure the piston diameter atthe point shown in Figure 9 22 When the cylinder bore is measured see Cylinder Block sec tion subtractthe piston diameter from the cylinder bore diameter to obtain the piston to cylinder wall clearance Refer to the Dimensions and Clearances section for the recommended piston clearance 4 MEASURE X DIAMETER HERE gt CT 1063 FIGURE 9 22 PISTON CLEARANCE MEASUREMENT Fitting Piston Rings Before installing new rings on the piston check the ring gap by placing each ring squarely in its cylinder ata position corresponding to the bottom of its travel Figure 9 23 The gap between the ends ofthe ring is given in Dimensions and Clearances section The practice of filing ririg ends to increase the end gap is not recommended If the ring end gap does not meet specifications check for the correctness of ring and bore sizes A cylinder bore that is 0 001 inch 0 03 mm undersize will reduce the end gap 0 003 0 08 m Standard size rings may be used on 0 005 inch 0 13 mm oversize pistons Rings that are 0 010 0 020 0 030 and 0 040 inch 0 25 0 51 0 76 and 1 02 mm oversize are to be
69. apscrews that secure the adapter to the engine block and remove the adapter and gasket Assembly is the reverse of disassembly Use a new adapter gasket and install so the two small oil holes are aligned with the oil holes in the block Gasket should be installed dry Coat the threads of each capscrew with non hardening sealer and tighten to recommended torque LOW OIL PRESSURE SWITCH ADAPTER OIL FILTER DRIP SHIELD UA FIGURE 9 1 OIL FILTER amp ADAPTER 9 1 f CYLINDER HEADS Remove the cylinder heads for cleaning when poor engine performance is noticed Use the following procedures to service 1 Use a 1 2 inch socket wrench to remove the cylinder head capscrews and lift off the head Warpage can occur if the ACAUTION heads are removed while hot Wait until engine has cooled before removing heads After removing heads clean out all carbon depos its Be careful not to damage the outer sealing edges where gaskets fit The heads are made of aluminum and can be damaged by careless handling Use new head gaskets and clean both the heads and the cylinder block thoroughly where the head gaskets rest Place heads in position and follow head torque tightening sequence shown in Figure 9 2a Start out tightening all bolts to 5 ft Ibs 7 Nem then 10 ft Ibs 14 Nem etc until all bolts or stud nuts are tightened to the specified torque see TORQUE SPECIFICATION section Retorque before engin
70. at reads to within 0 01 ohms Disconnect the transformer stator leads as specified in the Ground Test section Connect the test prods see Figure 8 15 to the leads as specified in Table 8 4 A reading less than the value shown in Table 8 4 indi cates shorted windings If the low reading is between T1 T3 and one of the transformer primary lead wires H1 or the source of the short could be either the stator windings or the transformer windings To isolate disconnect the trans former primary leads from the stator T2 from H2 and T4 from H4 Test each winding separately as specified in Table 8 4 to locate the short Replace the stator or transformer if test indicates a shorted winding G 1172 1 FIGURE 8 15 TESTING STATOR AND TRANSFORMER FO OPENS OR SHORTS 8 16 CR4 Bridge Rectifier Test The CR4 bridge rectifier can be tested using an ohmmeter Remove the two AC leads and the positive and negative leads from the rectifier terminals Connect one of the test prods to one of the terminals and the other test prod to the positive terminal Observe the reading on the ohmmeter and then reverse the test prod connections Observe the second reading and compare with the first reading A good rectifier will have a higher reading in one direction If both readings are the same the rectifier is defective and must be replaced Repeat test procedure with test prod connected to other AC terminal and with te
71. ce or it will be damaged The camshaft center pin cannot be pulled outward or removed without damage If the center pin extends too far the cup will not hold the flyballs properly 9 7 gear The camshaft and gear are removed as an assembly Before removing the camshaft and gear assembly remove the cylinder head and valve assemblies Then remove the operating plunger for the breaker points and tappets Each timing gear is stamped with O near the 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 CRANKSHAFT 1029 FIGURE 9 14 TIMING GEAR REMOVAL AND INSTALLATION LUBRICATION SYSTEM All generator set engines use an oil pump to providea constant flow of oil to the engine parts The oil supply collects in the base where it is picked up by the oil pump pick up cup A bypass valve is used to controt 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 15 is mounted on the front of the crankcase behind the gear cover and is driven by the crankshaft gear The inlet pipe and screen assembly is attached directly to the pump body A discharge passage in the cover of the pump reg
72. ch connect B to the ignition coil and the fuel solenoid Opening the K4 9 15 contacts disconnects B from the K1 start solenoid De energizing the K1 start solenoid disconnects B from the starter motor which stops cranking When the S1 switch is placed in the RUN position the engine continues to run Relays K2 generator relay run relay and K5 stop relay are energized while relays K1 start solenoid and K4 start relay are de energized Generator voltage is rectified to DC by the CR1 power rectifier and supplied to the battery through the charge resistor R6 This charges the battery at a constant rate 1 ampere maximum dur ing set operation 2 2 REMOTE SWITCH 1 Start Run Stop switch S2 Low oil pressure cut out switch S3 Breaker points CR1 Power rectifier CR4 Field rectifier F1 Fuse Bi Starter motor G1 Generator START SOLENOID STARTER MOTOR REMOTE SWITCH BATTERY CONDITION METER RUN LIGHT ES T547 1 E1 Spark plug E2 Spark plug E3 Fuel solenoid R6 Battery charge resistor K1 Start solenoid K2 Generator relay AC K3 Run relay K4 Start relay K5 Stop relay FIGURE 7 4 TYPICAL CONTROL SCHEMATIC Stopping Placing the Start Stop Run switch S1 in the Stop position grounds the run relay This de energizes the relay which opens the K3 2 8 and K3 9 15 relay contacts to disconnect from the ignition coil fuel solenoid run light meters and K
73. collapse This causes transient cur rents that can damage the control if not blocked The 5 diode is spliced into the control wiring harness between the circuit board assembly and Start Run Stop switch 7 8 BGEL CONTROL OPERATION This operation description applies to BGEL series generator sets The schematic diagram shown in Fig ure 7 4 is intended as an example to help follow the circuit description Always refer to the specific wiring diagram that corresponds to the model and spec number of the generator set when troubleshooting problems Starting Placing the Start Run Stop switch in the Start posi tion connects battery ground B to the start relay This energizes the K4 relay which closes two sets of contacts K4 2 8 and K4 9 15 that connect battery positive B to the generator field windings CR4 T1 ignition coil fuel solenoid valve K5 stop relay and K1 start solenoid Connecting as described produces the following control responses e Flashes the field to ensure that there is adequate residual magnetism to induce voltage build up Energizes the ignition coil T1 so it can begin pro ducing an ignition spark when the breaker points open and close Energizes the fuel solenoid valve which opens to allow fuel to flow to the carburetor Energizes the K5 stop relay to open the K5 contacts Energizes the K1 start solenoid to close the K1 contacts Opening the K5 sto
74. d and block has been tho roughly cleaned and dried 1 Makea 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 preseni the white coating will become discolored at the defective area Always replace a cracked cylinder block 2 Inspect all machined surfaces and threaded holes Carefully remove any nicks or burrs from machined surfaces Clean out tapped holes and clean up any damaged threads 3 Check top of block for flatness with a straight edge and a feeler gauge Cylinder Bore Inspection Inspect cylinder bores for scuffing scratches wear and scoring If cylinder bores are scuffed scratched scored or worn they must be rebored and honed for the next oversize piston When the appearance of cylinder bores is good and there are no scuff marks check cylinder bore for wear or out of roundess as follows 1 Check cylinder bore for taper out of round and wear with a cylinder bore gauge telescope gauge or inside micrometer These measure ments shouid be taken at four places top and bottom of piston ring travel and parallel and per pendicular to axis of crankshaft 2 Record measurements taken at top and bottom of piston travel as follows see Figure 9 28 9 13 Measure and record as A
75. diameter so the original pistons with new rings may still be used The reason for deglazing a cylinder is to provide cavities to hold oil during piston ring break in 1 2 Wipe cylinder bores with a clean cloth which has been dipped in clean light engine oil Use a brush type deglazing tool with coated bris tle tips to produce a crosshatch pattern in the cylinder bore The deglazing tool should be driven by a slow speed drill Move deglazing tool up and down in cylinder 10 to 12 complete strokes rapidly enough to obtain a crosshatch pattern as shown in Figure 9 29 9 15 PRODUCE GROSS HATCH SCRATCHES FOR FAST RING SEATING AVOID THIS FINISH C 1091 FIGURE 9 29 CROSSHATCHING Never use gasoline or commer ACAUTION cial cleaners to clean cylinder bores after deglazing or honing These solvents will not remove abrasives from the walls Abra sives not removed from engine will rapidly wear rings cylinder walls and bearing surfaces of all lubricated parts Clean cylinder bore thoroughly with soap water and clean rags Continue cleaning until a clean white rag shows no discoloring when wiped through cylinder bore BEARINGS Removal of the camshaft or crankshaft bearings requires complete disassembly of the engine Use a combination main and cam bearing removal tool and a press to drive out the bearings Support the casting to avoid distorting or damaging the bearing bores Camshaft Bearings
76. e connecting rod bolts FIGURE 9 17 REMOVING WEAR RIDGE Lift the rod bearing cap from the rod and push the rod and piston assembly out the top of the cylinder with the handle end of ahammer Be careful not to scratch the crankpin or the cylinder wall when removing these parts Mark each piston and rod assembly so they can be returned to their respective cylinders after overhaul Keep connecting rod bearing caps with thelr respective rods The pistons are fitted with two compression rings and one oi control ring Remove these rings from the piston using a piston ring spreader as shown Fig ure 9 18 FIGURE 9 18 REMOVING PISTON RINGS Mark each piston to make sure the rod will be assembled on the piston from which it was removed Remove the piston pin retainer from each side and push the pin out CT 1059 9 9 Remove dirt and deposits from the piston surfaces with an approved cleaning solvent Clean the piston ring grooves with a groove cleaner or the end of a piston ring filed to a sharp point Figure 9 19 Care must be taken not to remove metal from the groove sides CT 1060 FIGURE 9 19 CLEANING RING GROOVES Using a caustic cleaning solvent or ACAUTION wire brush for cleaning pistons will cause piston damage Use only parts cleaning solvent When cleaning the connecting rods in solvent include the rod bore Blow out all passages with low pressure compressed air Inspection The follow
77. e has run a total of 25 hours FIGURE 9 2a CYLINDER HEAD TIGHTENING SEQUENCE VALVE SYSTEM A properly functioning valve system is essential for good engine performance All generator sets utilize an L head type valve design as shown in Figure 9 2b Access to the valve system can be obtained by remov ing the cylinder heads and the valve covers on top of the engine A valve spring compressor must be used to remove valves see Figure 9 3 from the cylinder block Use the following procedures to inspect and service in the valve system Inspection Valve Face Check the valve face for evidence of burn ing warpage out of round and carbon deposits see Figure 9 4 Burning and pitting are caused by the valve failing to seat tightly This condition is often caused by hard carbon particles on the seat It may also be due to weak valve springs insufficient tappet clearance warpage and misalignment Warpage occurs chiefly in the upper stem due to its exposure to intense heat Out of round wear follows when the seat is pounded by a valve whose head is not in line with the stem and guide If a valve face is burned or warped or the stem worn install a new one Too much clearance in the intake guide admits air and oil into the combustion chamber upsetting carburetion increasing oil consumption and making heavy carbon deposits Carbon prevents heat dissipa tion Clean metal is 4 good heat conductor but carbon insula
78. e manifold as an assembly Removethe two intake manifold gaskets and plug the intake ports with a rag to prevent loose parts from accidentally entering ports Remove the two capscrews that secure the car buretor and choke pull off assembly to the intake manifold Disengage the choke pull off linkage from the carburetor and carefully separate the carburetor from the intake manifold AIR PREHEATER INTAKE MANIFOLD CHOKE PULL OFF CARBURETOR FUEL LINE s GOVERNOR CONTROL LINKAGE FS 1607 FIGURE 6 13 CARBURETOR amp INTAKE MANIFOLD ASSEMBLY Assembly Reverse order of disassembly Use new gaskets between intake manifold and engine and between intake manifold and carburetor Do not use any sealer on gaskets Tighten intake manifold cap screws to specified torque Carburetor Mixture Screw Adjustments The most common cause of poor carburetion is unsa tisfactory adjustment of the idle or main mixture adjustment screws Significant variation from the correct settings may result in serious engine trouble An overly rich mixture not only wastes fuel but can increase engine wear by washing the lubricant from the cylinder walls and diluting the crankcase oil An overly lean mixture results in a loss of power flat Forcing the mixture adjustment A CAUTION screws tight will damage the needle and seat Turn only until light tension can be felt Start the engine and allow it to run for about 10 min ute
79. ect both the vehicle negative battery cable and the generator set negative battery cable from their respective battery terminals Close the fuel shutoff valves at the fuel tank for both the generator set fuel supply system and the appliance stove heater etc fuel supply system In addition close the fuel shutoff valves at each appliance LP Gas Propane is extremely flam AWARNING mable and can result in severe per sonal injury or death if accidentally ignited Eliminate all possible sources of ignition such as pilot lights or sparking electrical equipment 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 just enough to allow the LP gas to slowly escape Don t open the fitting too much or a large quantity of gas will be released Disconnect the fuel supply hose from the carburetor and hold it clear of the set Press in and hold the primer button on the regulator to release LP gas from the set fuel system When no more gas can be heard escaping from the open end of the fuel supply hose reconnect the hose to the carburetor and proceed to the appropriate set removal section Disconnecting Set from RV Systems Disconnect the following items from the generator set Refer to Figures 5 1 and 5 2 for component locations in typical generator set installations 1 Disconnect the vehicle negative
80. ed position fol the K3 relay which opens the K3 2 8 and K3 9 15 relay lowing set shut down CR1 prevents the battery from contacts to disconnect B from the ignition coil fuel discharging through the generator windings while pump run light and meters Without ignition or fuel the set is stopped 7 3 CONTROL TROUBLESHOOTING Use the following troubleshooting guide to heip locate problems related to the BGE control Figures 7 2 and 7 3 show the location of most of the control components Refer to the wiring diagram in Figure action 8 2 for location of all terminal connections Trouble Engine Does Not Crank The troubleshooting guide is divided into six sections After identifying the problem refer to the guide for the possible cause and the recommended corrective TROUBLESHOOTING THE BGE CONTROL Possible Cause If engine cranks at set but not at remote control panel fault is due to open circuit in remote control b remote start switch faulty If engine cranks at remote control panel but not at set fault is due to open circuit wiring between 1 switch and PC board or b faulty S1 switch Insufficient voltage for cranking due to a Battery not charged or b Terminal connections loose or dirty Control fuse F1 is open Connect a voltmeter between terminal S on the start solenoid and ground Check for battery voltage when S1 is placed in Start position If volt
81. embly and adjustments for the engine generator and control It is recom mended that the serviceperson be thoroughly famil iar with the principles of gasoline engine operation and have a basic knowledge of electrical fundamen tals Other Onan publications such as Electrical Me chanical Fundamentals 932 0408 Onan Generator Training Manual 932 0404 and BGE BGEL Opera tors Manual 965 0130 and Installation Manual 965 0630 are recommended as additional sources of information Read ail service procedures completely before beginning any repair work and observe all cautions and warnings It is extremely important that the generator set installation maintain compliance with the applicable codes and standards for RV installa tions see Installation Manual The most critical areas of concern include the exhaust system fuel system electrical wiring compartment construction and ventilation system improper servicing can create an unsafe installation that can result in damage to the vehicle and equipment or can cause severe personal injury or death to the user MODEL IDENTIFICATION When contacting an Onan Dealer or Distributor always supply the complete Model Number and Serial Number as shown on the set nameplate This information is necessary to identify your set when ordering replacement parts Always use genuine Onan replacement parts ob tained from an authorized Onan Dealer or Distribu tor Universal replacement type part
82. enser and ignition lead wires screw B Lift cut condenser see Figure 6 6 POINT GAP FIGURE 6 6 BREAKER POINTS 5 Remove the breaker points mounting screws C and lift out the point assembly Replace the condenser and point assembly and instali a in reverse order of removal Use an allen head wrench to adjust set screw D to obtain the gap setting specified in the Specifica tions section Measure the point gap with a flat thickness gauge see Figure 6 6 Make sure feeler gauge is clean and free of any grease oil or dirt The timing is adjusted during initial engine assembly and is fixed by the point gap adjust ment No other adjustment or alignment is necessary 8 Replace the point box cover spark plugs and spark plug leads Connect negative battery cable to negative battery terminal Ignition Coil The ignition coil is a transformer that steps up the battery voltage to about 20 000 volts for spark plug firing The coil is composed of a core a primary winding insulators secondary winding sealing compound bakelight cap and the outside case and necessary terminals Figure 6 7 9 Ignition coils do not normally require any service other than to keep all terminals and connections clean and secure Also check for loose seams dents punctures and other mechanical damage if poor ignition perfor mance is evidentand other ignition components are not at fault the coil can be tested with the
83. erator set load connections Faulty RV wiring Faulty electrical appliance Faulty generator set wiring Rotating Machinery Flywheel fan guard not in place Slippery Surfaces Leaking or spilled Heavy Objects ment mount or below the floor mount In a compart ment mount installation a special compartment see Figure 5 1 is built into the coach to house the gener ator set The compartment is contructed with a vapor tight barrier that seals off the generator set from the coach interior The generator set is usually fastened to the floor of the compartment which must be able to support the weight of the set Access to the compart ment is through a door located in the exterior of the coach Removing generator set from Ry Removing heavy components In below the floor mount installation see Figure 5 2 aspecial housing is used to suspend the genera tor set from the underside of the coach The housing bolts to special support members that are built into the coach framework The housing is mounted near the exterior of the coach and limited access is pro vided through a door located in the exterior of the coach Because of the wide variety of generator set installa tions it is not possible to specify the exact removal procedures for each generator set If after examining the installation a satisfactory method for removing the set cannot be determined contact the RV coach manufacturer
84. flow from the generator set into the utility line This creates a potential for electrocution or property damage Connect only through an approved device and after building main switch is open Consult an electrician in regard to emergency power use GENERAL SAFETY PRECAUTIONS Have afire extinguisher nearby Maintain extinguisher prop erly and become familiar with its use Extinguishers rated ABC by the NFPA are appropr ate for all applications Con sult the local fire department for the correct type of extin guisher for various applications e Hot coolants under pressure can cause severe personal in jury DONOT open aradiator pressure cap while the engine is running Stop the engine and carefully bleed the system pressure Benzene and lead found some gasoline have been iden tified by some state and federal agencies as causing cancer or reproductive toxicity When checking draining or adding gasoline take care not to ingest breathe the fumes or con tact gasoline Used engine 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 not to in gest breathe the fumes or contact used oil Remove all unnecessary grease and oil from the unit Accu mulated grease and oil can cause overheating and engine damage which presents a potential fire hazard DO NOT store anything in the generator compartment such as oil
85. for detailed assembly proce dures Install the noise shield flywheel guard and trans former cover Instali the generator set in the vehicle and securely fasten all mounting screws and hard ware Connect the fuel exhaust and electrical systems in reverse order of disassembly Refer to the Set Removal section Fill crankcase with oil of the recommended classi fication and viscosity BRUSHES AND SLIP RINGS This section covers brush replacement and slip ring service Brush Replacement Remove the brush block cover and inspect the brushes and brush holder for burn marks or other damage If the brushes appearto be in good condition use a piece of wire modified as shown in Figure 8 10 to check for excessive brush wear insert the wire through the hole above each brush Make sure the wire is resting on the brush and not on part of the spring If the painted part of the wire is not visible the brush is excessively worn and must be replaced Always replace the brush springs when installing new brushes to insure that proper tension is maintained Use the following procedure to replace the brushes 1 Disconnect the negative battery cable at the battery terminal 2 Remove the air cleaner cover and air cleaner filter element 3 Disconnect the B outboard and B inboard lead wires from the brush block terminals 4 Remove the brush block mounting screws and lift out the brush block 1in 25 mm G 1174
86. fuel vaporizer and regulator attached to the exhaust manifold Purge the fuel system of LP gas fuel before disconnecting the fuel line at the vaporizer Refer to the Fuel System LP Gas in this section for the recommended purging procedures Assembly Obtain the required replacement parts and then proceed as indicated Exhaust gas can result in severe AWARNING personal injury or death To pre vent exhaust leaks install all gaskets clamps straps and hardware as specified 1 install the exhaust manifold using new gaskets andtighten the four manifold screws to the speci fied torque Install the 5 16 18 screw lock washers and nut that secures the manifold outlet flange to the manifold support bracket and 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 mani fold and exhaust tube and secure flange connec torto manifold using 5 16 18 inch capscrews and lock washers Attach the inlet of the muffler to the exhaust tube using a U bolttype automotive muffler clamp marked 1 2 ONLY Make certain that muffler inlet pipe over laps exhaust tube a minimum of 1 1 2 inches 38 mm Place muffler strap on muffler and position it below cutout in bottom of generator set drip tray Fasten strap to set strap br
87. g a capscrew and two EIT locking washers Note that ground strap is installed between locking washers to ensure a good electrical connection BARREL CONNECTOR Q i WIRE TIE FIGURE 8 9 BRAIDED INSULATION 8 11 10 11 12 13 14 15 16 17 18 Attach the special lifting plate see Figure 8 6 to the end of the stator housing using four 5 16 18 x 1 capscrews Attach a hoist or other suitable lifting device to the lifting plate Carefully tilt the set back until itis resting on the drip tray Remove lifting plate when complete Remove the piece of wire that is holding the brushes off the slip rings Check the brushes to verify that they are centered on the slip rings If brushes are not centered loosen the brush block mounting screws and adjust Retighten mounting screws when complete Connect the B lead wire to the outboard brush terminal and the B lead wire to the inboard brush terminal Install brush block cover and tighten cover mounting screws Connect the appropriate lead wires to the charge resistor low oil pressure cut off switch and igni tion B terminal Place new intake manifold gaskets on the engine block and install the carburetor and intake mani fold assembly Tighten the intake manifold screws to the specified torque Connect the pre heater tube crankcase breather hose fuel lines throttle linkage and choke heater wires Refer to Fuel System Section 6
88. gine to generator adaptor Optional Remote Start Control The remote start contro is an optional accessory that allows the generator set to be started monitored and stopped from a remote location The deluxe control includes a running time meter and battery condition meter Remote control panels are usually mounted on the vehicle dashboard BGE CONTROL OPERATION This operation description applies to BGE series generator sets The schematic diagram shown in Fig ure 7 1 is intended as an example to help follow the circuit description Always refer to the specific wiring diagram that corresponds to the model and spec number of the generator set when troubleshooting problems Starting Placing the Start Run Stop switch in the Start posi tion connects battery ground B to the K4 start relay This energizes the K4 relay which closes two seis of contacts K4 2 8 and K4 9 15 that connect battery positive to the generator field windings through CR4 T1 Ignition coil fuel pump and K1 start solenoid Connecting as described pro duces the following control responses e Flashes the field to ensure there is adequate resid ual magnetism to induce voltage buildup Energizes the ignition coil 1 it can begin pro ducing an ignition spark when the breaker points begin to open and close Energizes the fuel pump E3 which begins pump ing fuel to the carburetor e Energizes the K1 start sole
89. h low pressure 30 psi 207 kPa compressed air Do not use wire or other objects for cleaning that might increase the size of critical passages 4 Check the condition of the mixture screws see Figure 6 27 and replace if worn or damaged 5 Replace all old components seals and gaskets with new parts included in the kit Ee DAMAGE AND WEAR OCCUR HERE FS 1483 FIGURE 6 27 MIXTURE NEEDLE INSPECTION Reassembly and Installation When the carburetor parts are clean and dry reassemble using the follow ing procedure 1 Slide in throttle shaft and install throttle plate using new screws if furnished in repair kit Before tightening the screws the plate must be centered in the throttle bore To do so move the throttle lever to the completely closed position plate by gently tapping on it with a small screwdriver and then tighten the screws Install seai throttle stop lever and collar on the throttle shaft 2 Install the idle and main adjustment screws and turn in until lightly seated For preliminary set tings turn the idle screw out 1 1 4 turn and the main screw out 2 1 2 1 4 turns 1 Forcing the mixture adjustment ACAUTION screws tight will damage the needle and seat Turn in only until light tension is felt 3 Join the upper and lower sections of the carbur etor and instali bowl plug and washer 4 When the carburetor is installed on set make final adjustments to mixture screws as
90. harging battery rags improperly stored Flammable liquids improperly stored Burns Hot exhaust pipes Hot engine and generator surfaces Hot engine oil Electrical short in DC wiring system e Poisonous Gases Carbon monoxide from faulty exhaust LP gas leaking into coach interior Operating generator set where exhaust gases can accumulate Develop Safe Work Habits Unsafe actions are identified as the cause of most accidents involv ing the use of tools and machines Be familiar with the equipment and know how to use it safely Use the correct tool for the job and check its condition before starting Observe the warnings and cautions in this manual and take special pre cautions when working around electrical equip ment Do not work alone if possible and do not take risks Be prepared if an accident does occur Numerous agencies such asthe Red Cross and your local police and fire departments offer basic courses in first aid mouth to mouth resuscitation and fire control Take advantage of these offerings so you are ready to respond when an accident happens Learn to be safety conscious and make sure safe practices a part of your work routine SET REMOVAL Some service procedures will require that the genera tor set be removed from the coach While there are many variations generator set installations are generally classified as either conventional compart e Electrical Shock AC Improper gen
91. impuri ties such as rust or scale from the LP gas before they can clog the regulator or carburetor A magnet within the filter housing traps iron or rust particles while a filter element traps non magnetic particles The fuel filter operates at container pressure and must be carefully assembled to prevent leakage Use the fol lowing procedures to disassemble and clean 1 Remove the four capscrews and lock washers that secure the filter bowl to the filter body 2 Separate filter bow from filter body and discard the O ring seal 3 Remove nut and washer from center stud and pull out the filter element 4 If filter element is clogged wash element in kero sene and blow dry with low pressure 30 psi 207 kPa compressed air Replace filter element if damaged FILTER ELEMENT FIGURE 6 31 FUEL FILTER 5 Wipe the center stud magnet clean of any rust or scale particles that have collected 6 Install clean filter element using new gaskets 2 and securely tighten center stud nut 7 Place a new O ring in the filter bowl sealing groove 8 Align reference mark on filter bowl with reference mark on filter body and install capscrews 4 and lock washers 4 Tighten capscrews to 56 to 74 in Ibs 6 5 to 8 3 Nem torque When fuel system is pressurized check filter for leaks Solenoid Valve The solenoid valve see Figure 6 32 provides a positive fuel shutoff whenever the generator set is stopped The solenoid must be energ
92. incorrectly adjusted fuel mixture Screws dirt in carburetor Gasoline sets only 6 2 1a 1b 1 14 Corrective Action Adjust breaker point gap Reset spark plug gap Replace air cleaner Clean fuel filter Test fuel pump and repair or replace if faulty Adjust carburetor main and and idle adjustment screws Adjust carburetor float level Disassemble carburetor and clean all internal passages 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 Clear away any debris that may restrict airflow to set Do not use compartment for storage area Clean away all 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 Oil Pressure TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Possible Cause Sticking or binding governor linkage Incorrect governor adjustment Faulty governor spring Incorrect fuel mixture
93. ing covers inspection procedures for pis tons and connecting rods 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 20 Replace the piston when the side clearance of the top ring reaches 0 008 inch 0 20 mm CT 1061 FIGURE 9 20 CHECKING RING LAND Improper width rings or excessive ring side clearance can result ring breakage New rings in worn ring grooves do not have good cylinder wall contact Figure 9 21 Sv PISTON CYLINDER WALL SS IMPROPER X RING CONTACT r CT 1062 FIGURE 9 21 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 con necting rods with deep nicks signs of fractures scored bores or bores out of round more than 0 002 inch 0 05 mm Use a new piston pin to check connecting rod for wear A push fit clearance is required and varies from engine to engine If a new piston pin falls through a dry rod pin bore as a result of its own weight replace the rod or bushing as required Piston Pin Inspection Replace piston pins that are cracked scored or out of round more than 0 002 inch 0 05 mm Bearing Inspection Inspect bearings for burrs breaks pitting
94. ing from the open end of the fuel supply hose reconnect the hose to the carburetor and proceed to the appropriate component service section Carburetor Air Filter And Intake Manifold Assembly The carburetor air filter and intake manifold assem bly consists of the air cleaner housing air filter air cleaner adapter K5 relay assembly carburetor and intake manifold see Figure 6 24 INTAKE MANIFOLD CARBURETOR BREATHER HOSE Disassembly Use the following procedures to remove and disassemble the carburetor air filter and intake manifold assembly 1 Removethe crankcase breather hose from the air cleaner housing 2 Removethe 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 fuel hose and governor control linkage from the carburetor 7 Removethetwo capscrews that secure the carbur etor to the intake manifold and lift off the carburetor 8 Usethe following procedures if it is necessary to remove the intake manifold a Disconnect the flexible fuel supply line from the fuel vaporizer b Removetheexhaust manifold as described in this section to provide clearance for the lifting off the inta
95. instructions SCROLL FLANGE CONNECTOR 7 4 VJ LOCK E SCREW OX MUFFLER INLET Conventional Compartment Mount Exhaust System Conventional compartment mount exhaust systems consist of the exhaust manifold flange connector muffler muffler strap hanger clamps and tailpipe When service is required disassemble and reassem ble as specified in the following steps Disassembly 1 Loosen the front muffler clamp muffler strap and tailpipe hanger and remove the muffler and tail pipe assembly see Figure 6 1 2 Remove the screws that secure the exhaust tube to the exhaust manifold and remove the exhaust tube and exhaust gasket Completion of the remaining steps requires that the generator set be removed from the vehicle Refer to the PREPARING TO SERVICE section for the set removal procedures 3 Remove the cooling system noise shield and scroll see Cooling in this section to provide access to the exhaust manifold 4 Remove the screw that secures the exhaust mani fold outlet flange to the exhaust manifold support bracket 5 Remove the four exhaust manifold screws and lift off the exhaust manifold and the two manifold gaskets MUFFLER STRAP CUTOUT HANGER BRACKET 3 1 METRE MINIMUM FROM DOWNPIPE OR AT PERIMETER OF VEHICLE FRONT SET VIEW CLAMP MARKED 4 1 2 5 1147 FIGURE 6 1 CONVENTIONAL COMPARTMENT MOUNT EXHAUST SYSTEM 6477 If set is LP gas fueled the
96. iode BOARD CONTROL PANEL START RUN STOP SWITCH ASSEMBLY REMOTE CONNECTOR SOCKET NOTE TAB IS AT BOTTOM OF SOCKET STOP GND STRT COMPONENT SIDE SC 1521 FIGURE 7 3 BGE CONTROL PANEL ASSEMBLY BGEL CONTROL DESCRIPTION The BGEL generator set control consists of the fol lowing components e Printed Circuit Board Assembly e Panel Mounted Start Run Stop Switch S1 e Start Solenoid K1 e Battery Charger Resistor R6 e Optional Remote Start Control e Stop Relay K5 e Blocking Diode CR5 The first five components listed for the BGEL control are either the same or similiar to the components in the BGE control Refer to the BGE Control section for a general description of the printed circuit board assembly panel mounted Start Run Stop switch start solenoid battery charge resistor and remote start control The following sections provide a de scription of the stop relay and blocking diode Stop Relay K5 The K5 stop relay is used to latch off the generator set when the Start Run Stop switch 1 is placed in the Stop position This prevents the set from restarting when the switch is momentarily placed in the Stop position and then released The K5 relay mounts on the air cleaner adapter Blocking Diode CR5 The CR5 blocking diode is used to protectthe control circuitry from reverse flow transient currents When the set is shut down various magnetic fields within the generator
97. ion 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 th top of the piston Unmarked piston rings can be installed either way The oil control ring has an expander Install the expander first and then close until the expander ends butt together Locate the expander gap 180 degrees from the ring gap THIN SIDE OF CAP THIN SIDE WITNESS OF CAP MARKS ROD 2 CT 1065 FIGURE 9 24 ROD CAP ALIGNMENT CT 1066 FIGURE 9 25 INSTALLING PISTON Position the piston and rod assembly in the cylinder block with the connecting rod oil hole toward the camshaft Tap piston down into bore with handle end of hammer until connecting rod is seated on journal Check bearing clearance before proceeding to 5 step see Rod Bearing Clearance section Lubricate the rod bearing journal and install the connecting rod cap Tighten connecting rod bolts to specified torque The bearing cap must be tapped several times to properly align it with the connecting rod Clear ance varies on the journal if this is not done Install the remaining pistons and rods inthe same manner Crank the engine by hand to see that all bearings are free Rod Bearing Clearance 1 Mark ali parts so they can be installed in their original positions and wipe all parts clean of any oil or grease 2 piece of the correct size Plasti gage across the ful
98. ip rings if dirty Test rectifier and replace if defective Test each component for open grounded or shorted windings and replace if defective Refer to Governor section Test CR4 rectifier and replace if defective Check length of brushes and replace if worn excessively Clean or replace slip rings Adjust tap connections on transformer secondary windings to obtain correct voltage Replace transformer if voltage cannot be corrected with adjustments Test each component for open grounded or shorted windings and replace if defective Tighten brush holder Replace end bearing Check for varnish lumps between rotor and stator and remove as required Follow specified assembly procedures to correct rotor to crankshaft alignment CIRCUIT BREAKER lt CR4 CASU 60 HZ TO 5 MODEL Gq lt lt CIRCUIT BREAKER CB1 LOAD BLACK TO BRUSH SLOCK f AC 4 Q Ps si TO BRUSH BLOCK STATOR HOUSING 51 TO TRANSFORMER X6 12 TRANSFORMER H2 74 TO STATOR CLAMPS 9 25 5 S 2 fps M NS 2 A VIN T p x 62 TO TERMINAL TAB 2 10 CR4 ACI STATOR RG 1 ROTOR THROUGH BOLT CHOKE 1 FIGURE 8 3 GENERATOR G 1171 1 8 6 Trouble Generator Overheats STATOR HOUSING TROUBLESHOOTING THE GENERATOR Possible Cause Generator overloaded d
99. isters with a drilled passage in the crankcase Parallel pas sages distribute oil to the front main bearing rear main bearing and pressure control bypass valve OIL PUMP ASSEMBLY CRANKCASETURNED 14 ON LEFT SIDE 15 1109 FIGURE 9 15 OIL PUMP ASSEMBLY Circumferential grooves in the main bearings supply oil to the connecting rod bearings through drilled pas sages from each main journal A drilled passage con nects the front main bearing oil supply to the front camshaft bearing The oil overflow from the bypass valve furnishes lubrication to the camshaft drive gears Normal oil pressure should be 13 5 psi 93 07 kPa or higher when the engine is at normal operating temper ature If pressure drops below this value at governed speed inspect the oil system for faulty components Check the oil pump thoroughly for worn parts Cil the pump to prime it before reinstalling Except for gaskets and pick up cup the component parts of the pump are not available individually Install anew pump assembly if any parts are worn Oil Bypass Valve The bypass valve located to the right and behind gear cover Figure 9 16 controls oil pressure by allowing excess oil to flow directly back to the crankcase Normally the valve begins to open about 13 5 psi 93 07 kPa The valve is non adjustable and normally needs no maintenance To determine if abnormal high or low oil pressure is caused by improper valve operation inspect as
100. it snuggly into the bear ing 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 cap screws that secure the stator housing to the engine to generator adapter Tighten capscrews to speci fied torque Note that each locking washer is installed under capscrew head Tighten the rotor through bolt to the specified torque Hold the drip pan in position for mounting to the underside of the set and install the three vibration isolator center screws Tighten the rear generator end center screws to the specified torque Secure ground strap to drip tray using a capscrew and two EIT locking washers Note that ground strap is installed between locking washers to ensure a good electrical connection BARREL CONNECTOR INSULATION 5 1552 FIGURE 8 9 BRAIDED INSULATION Redistribution or publication of this document by any means is strictly prohibited TRANSFORMER VOLTAGE ADJUSTMENTS 2 generator output voltage may be adjusted by inging the connections to the transformer secondary taps This is necessary if the set voltage falls outside the recommended voltage range when operating at the specified frequency Use the following procedures to adjust the generator output voltage 1 Adjustthe governor as specified in Section 6 before
101. ith every revolution of the camshaft Point opening is deter mined by the point gap setting The exact timing of the ignition spark is dependent on when the points open It is important that the breaker points have the correct gap for easy starting efficient operation full power and proper cooling A retarded ignition will reduce efficiency while an advanced ignition will cause overheating The condenser extends point life by preventing arc ing across the opening breaker points A defective condenser causes a weak spark and rapid point wear Replace the condenser if defects are suspected A new condenser is supplied with the engine tune up kit Breaker Point Replacement And Adjustment inspect the breaker points at the interval specified in the Operators Manual and replace if pitted or burned Filing of the points is not recommended Use the following procedure to replace and adjust the points The ignition adjustments should be made with the engine in a static condition and cold 1 Disconnect the negative battery cable at the battery 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 Using a hex head socket and socket wrench turn the rotor through bolt in a clockwise direction until the breaker point gap is open the maximum amount 4 Remove the condenser mounting screw A and disconnect the cond
102. ized before fuel will flow to the regulator Service is limited to replacing the complete valve assembly if itdoes not operate properly The valve may be bench tested by connecting battery positive to the top terminal and battery negative B to the grounded terminal The plunger assembly should with draw and open the valve when the solenoid is ener gized Replace the solenoid valve if it does not operate properly 5 1553 FIGURE 6 32 SOLENOID VALVE 6 26 ELECTRIC STARTER SPEC ONLY A 12 volt electric starter with negative ground is used for cranking the generator set When the starter 15 energized an inertial engagement system causes the starter pinion gear to engage the fan and ring gear assembly As the starter spins the starter pinion gear drives the ring gear causing the generator set to crank Because the starter is an integral part of the set con trol system check the complete control before servic ing the starter Use the following procedures to dis assemble inspect and assemble the starter It may be necessary to remove the generator set from the vehicle before the starter can be serviced Refer to the PREPARING TO SERVICE section for the set removal procedures Disassembly Use the following procedures to remove and disas semble the starter 1 Disconnect the generator set negative battery cable from the set starting battery 2 Disconnect the generator set positive battery
103. justments to the trans former 2 With the unit operating at no load adjust the speed adjustment nut to achieve the following frequency and voltage 60 Hz 120 Volts 62 Hz 127 5 4 5 Volts 50 Hz 110 220 Volts 52 Hz 233 9 Volts 50 Hz 120 240 Volts 52 Hz 255 9 Volts 3 Stop the set and adjust the transformer tap connec Aions as shown in TABLE 8 1 to increase or decrease the voltage as required 4 Repeat the voltage check and continue to make adjustments until voltage is within range specified 5 Check the no load and full load voltage and quency as specified in Section 6 for the Governor Voltage frequency should stay within the limits shown i in Table 6 1 TABLE 8 1 TRANSFORMER TAP CONNECTIONS VOLTAGE ADJUSTMENT To Decrease Voltage GENERATOR TESTING This section covers the test procedures for the stator rotor transformer and CR4 bridge rectifier 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 generator set and allow itto stabilize Meas ure the field voltage with no load applied and then with full load applied Both readings should fall within a range of 18 to 60 volts DC Remove test leads and replace brush block cover when test is complete Rotor Test The rotor
104. ke manifold CRANKCASE AIR CLEANER HOUSING AIR FILTER XFS 1612 AIR CLEANER ADAPTER FIGURE 6 24 CARBURETOR AIR FILTER AND INTAKE MANIFOLD ASSEMBLY 6 21 CAL Bending ihe fuel vaporizer A CAUTION tubing will weaken the metal which cause cracks to form Do not bend the vaporizer 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 rags to prevent loose parts from accidentally enter ing the ports Assembly Reverse order of disassembly Use new gaskets between the exhaust manifold and engine the intake manifold and engine and carburetor and intake manifold Tighten exhaust and intake manifold capscrews to specified torque Tighten fuel vaporizer fittings and check for leaks Carburetor Mixture Screw Adjustments LP gas carburetors have three adjustment screws that must be properly set for satisfactory operation The throttle stop screw controls how much the throt tle plate remains open when the throttle is pulled back to the closed position The idle adjustment screw controls the fuel mixture when the set is operat ing at no load The main adjustment screw controls the fuel mixture when the set is operating at full load No other adjustments are required with an LP gas carburetor since there are no float or choke adjustments Mixture screws should not be adjusted until
105. l exhaust and fuel systems examine the set mounting and support system Locate all mount ing bolts and support members for the set In most installations the generator set drip tray will be bolted to the coach framework Depending on the installa tion theset may be removable from the side back or bottom Verify that the generator set is adequately supported before loosening any of the mounting bolts or sup port members The most satisfactory way to lift or move the generator set is to use a forklift truck The generator set is heavy and can AWARNING result in severe personal injury if dropped during removal Use the recommended removal techniques and keep hands and feet clear while removing mounting bolts Removing Underfloor Mounted Set From RV When the generator set has been disconnected from the electrical exhaust and fuel systems the set may be partially removed for limited service or completely removed from the RV for major service The genera tor set is mounted on a support tray which serves as the bottom of the underfloor housing Theinner edge of the support tray is hinged to the rear panel assem bly The outer edge of the support tray is bolted to a support bracket A front and rear panel assembly serve as sides to complete the housing 5 4 The generator set is completely suspended under neath the RV coach by the housing assembly To avoid dropping the set during removal follow the recommended set removal pr
106. l vaives can be reconditioned badly warped valve must be replaced because the excessive grind ing required to make it seat correctly removes the margin To make a valve gas tight every trace of pitting must be removed from the valve face and seat Deeply pitted or cut valves must be replaced because the grinding removes the margin Valve seats should be ground with a 45 degree stone and the width of the seat band should be 1 32 inch to 3 64 inch 0 79 to 1 2 mm wide Grind only enough to ensure proper seating Place each valve in its proper location Check each valve for a tight seat Make several marks at regular intervals across the valve face using machinists bluing Observe if the marks rub off uniformly when the valve is rotated part of a turn against the seat The valve seat should contact the valve face evenly at all points The line of contact should be at the center of the valve face Valve Guide Replacement Worn valve stem guides can be replaced from inside the valve chamber a seal is provided behind the intake valve guides only The smaller diameter of the tapered valve guides mustface toward the valve head Tappets are also replaceable from the valve chamber after first removing the valve assemblies Removal Before removing valve guides use an electric drill with a wire brush to remove carbon and other foreign material from top surface of guides Failureto perform this operation may result in damage to the guide
107. l width of the bearing cap about 1 4 inch 6 mm off center 3 Install the bearing cap and tighten to the speci fied torque Do not rotate the crankshaft after the cap is in place 4 Remove the bearing cap and leave the flattened Plasti gage on the part to which it adheres Com pare the widest point of the flattened Plasti gage with the graduations on the envelope see Figure 9 26 to determine the bearing clearance FIGURE 9 26 MEASURING BEARING CLEARANCE CRANKSHAFT To remove the crankshaft loosen the rear bearing plate screws and remove the bearing plate gasket thrust washer and shims Turn the crankshaft so the crankthrow is aligned with the notch in the rear open ing of the crankcase Carefully slide the crankshaft out of the crankcase Inspection Inspect the rod and main bearing journals If they are worn or scored and cannot be smoothed out by pol ishing either the journals should be reground to use one of the standard undersize bearings or the crank shaft should be replaced Remove only as much metal as is required to restore the journal surface while maintaining the recommended bearing clearance Whenever making major repairs on the engine always inspect the drilled passages of the crankshaft Clean them to remove any foreign material and to ensure proper lubrication of the connecting rods Installation Lubricate the front and rear main bearings with engine oil Use oil or gea
108. la tion to confirm that the genesator set will operate properly and will pull full rated load Check each of the following areas before putting the set into service MOUNTING Examine ail mounting bolts and supporting members to verify that the generator set is properly mounted All fasteners should be tightened securely to prevent them from working loose when subjected to vib ration LUBRICATION If the 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 hooked up properly Check each of the following e Load Wires e Control Wires e Ground Strap Battery Cables INITIAL START ADJUSTMENTS Adjust the carburetor idle and adjustment screw and main adjustment screw as specified in the Fuel Sys tem section to allow starting Start the set and immediately adjust the governor speed adjustment to obtain a safe no load operat ing speed With no load applied listen for any un usual sounds or vibrations When the choke is com pletely open adjust the carburetor and governor as specified in the Fuel System section OUTPUT CHECK Apply a full load to make sure the set will produce its full rated output Use a load test panel to apply a progressively greater load until full load is reached EXHAUST SYSTEM With the generato
109. lows with the slide hammer tighten the hex nut 9 4 USE NEW VALVE SEAT TO ADJUST PULLER DEPTH FIGURE 9 9 VALVE SEAT REMOVAL Replacement After the old seat has been removed clean out any carbon or metal burrs from the seat insert recess Use a valve seat insert driver and a hammer to install the insert insert the pilot of the tool into the valve guide hole in the cylinder block Quickly drive the valve seat insert in so that the insert goes evenly to the bottom of the recess in the cylinder block Make certain that the valve seat insert rests solidly on the bottom of the recess all the way around its circumference Figure 9 10 The valve seat must be staked to ensure a tight fit and eliminate the danger of its loosening in the bore Insert valve seat staker in the cylinder block valve guide hole Rotate the staking tool until it drops to the original stake marks Rotate staking tool another 60 degrees 1 6 turn Using a lead hammer strike the staking tool a sharp blow to wedge the new valve seat securely in place Before installing valves it will be necessary to refinish valve seat inserts VALVE SEAT INSERT DRIVER USE PROPER TOOL CHECK THIS SURFACE FOR BURRS BEFORE VALVE SEAT INSERTING SEAT VT 1025 FIGURE 9 10 INSERTING NEW VALVE SEAT Tappet Adjustment The engine is equipped with adjustable valve tappets Adjust the valve clearance only when engine is at ambient temperature
110. ly one 1 full turn Carefully replace screw adjustment limiter cap over screw head with limiter lever located atthe LOW altitude position Take care not to change setting and confirm that limiter cap is fully seated over screw head B Main mixture screw adjustment Carefully remove screw adjustment limiter cap e Turn the main mixture screw inward until lightly seated and then back out exactly one and one quarter 1 1 4 full turns out Carefully replace screw adjustment limiter cap over screw head with limiter lever located atthe LOW altitude position Take not to change setting and confirm that oe is fully seated over screw head Review Governor Adjustments in section 6 Add and remove a full load several times to make certain the generator set does not bog down or hunt Stop genera tor set remove meter s and tools and close up genera tor set compartment FS 1691 FIGURE 1 THROTTLE STOP AND FUEL MIXTURE ADJUSTMENT SCREWS Float Setting To adjust the float the carburetor must be removed from the generator set Refer to Carburetor Overhaul Removal Cleaning and Reassembly instruc tions in section 6 of the service manual Perform similar procedures to adjust the float by bend ing the tab and checking proper float position The Nikki carburetor float position is measured from the carbure tor housing to the far side bottom side of the float Proper float adjustment should reflecta mea
111. m includes all functions that relate to starting monitoring for fault conditions instrumen tation battery charging and stopping This section covers how the control operates where the compon ents are located and basic troubleshooting proced Separate control systems are used for the and BGEL series generator sets Each system is covered separately in this section BGE CONTROL DESCRIPTION The generator set control consists of the following components Printed Circuit Board Assembly e Panel Mounted Start Run Stop Switch S1 e Start Solenoid K1 Battery Charge Resistor R6 Optional Remote Start Control The following sections provide a general description of each component and how it functions Printed Circuit Board Assembly The printed circuit board assembly is the center of the generator set control system The PC board cir cuitry controls the start starter disconnect run stop and battery charging functions The primary compo nents of the PC board include three relays one power rectifier two diodes one capacitor five resistors and 5 fuse The only serviceable component is the fuse which is removable from the front of the control panel connections to the PC board are made through an eight pin connector P1 mounted on the board and through the six lead wiring harness The PC board assembly mounts on the back of the control panel 7 1 The PC board assembly is desig
112. maged Figure 6 16 Replace float if loaded with fuel or damaged Check the choke and throttle shafts for excessive play in their bore and replace if necessary Replace oid components with new parts included in repair kit SPRING POSITION HOOK UNDER TANG ON FLOAT POSITION OF SPRING AFTER INSTALLATION FS 1610 FIGURE 6 17 FLOAT INSTALLATION 4 nvert the float and needle valve assembly and check float level by measuring between the float and gasket at the point shown in Figure 6 18 The Reassembly and Installation When the carburetor parts are clean and dry reassemble using the follow ing procedure 1 Slide in throttle shaft and install throttle plate using new screws if furnished in repair kit Before tightening the screws the plate must be centered in the bore To do so back off the throttle stop screw as necessary and completely close the throttle lever Seat the plate by gently tapping with a small screwdriver then tighten screws Install the choke shaft and plate in the same manner 6 16 full weight of the float should be resting on the needle valve and spring The correct distance is specified in Table 6 2 If the setting is incorrect remove float and bend tab to adjust Bend the float only at the point indicated Attempting adjustments with ACAUTION the float assembly installed can damage the inlet needle and seat Remove float assembly making adjustments BEND
113. moving to ensure correct placement when reassembling See Figure 6 26 for component designations Removal and Disassembly Remove the carburetor from the intake manifold as specified in the Carbur etor Air Filter And Intake Manifold Assembly section Use the following procedure to disassemble the carburetor AWARNING Most parts cleaning solvents are flammable and can result in severe personal injury if used improperly Follow the manu facturers recommendations when cleaning parts 1 Remove the throttle stop collar and throttle stop lever from the end of the throttle shaft 2 Remove the throttle plate retaining screws and throttle plate Remove dust seals from throttle shaft and carefully pull out throttle shaft 3 Remove main and idle mixture screw assembly 4 Separate lower section bowl of carburetor from the upper section bowl cover 6 23 THROTTLE STOP SCREW IDLE ADJUSTMENT SCREW FIGURE 6 26 CARBURETOR OVERHAUL Clean and Repair When the carburetor is completely disassembled clean and repair using the following procedures 1 Soakall metal components not replaced by repair kit in carburetor cleaner Do not soak any non metal parts or they may be damaged by the clean ing solution Follow the cleaner manufacturer s recommendations 2 Clean all carbon from throttle bore especially where the throttle plate seats Be careful not to plug the idle or main fuel ports 3 Blow out all passages wit
114. nd only side electrode when setting gap Splash Fouled Check for accumulated com bustion chamber deposits See Cylinder Head section e LightTan or Grey Deposits Normal plug color ES 1374 FIGURE 6 9 CHECKING PLUG GAP Wiring Ignition system wiring includes 1 One positive wire which carries the low voltage current from the battery to the primary winding of the coil 2 One negative wire which carries low voltage to the points and condenser 3 Two high tension wires that carry the high voltage current from the secon dary winding of the coil to the spark plugs The spark plugs and coil secondary are all grounded to the engine making a complete circuit forthe voltage back to the battery The ignition coil primary low voltage side is grounded when the breaker points close Check all low voltage wiring for loose connections and cuts or breaks in the insulation Clean ail termi nals and connections and test for continuity with an ohmmeter Use a megger to check for breaks in the spark plug wire insulation 6 10 CRANKCASE VENTILATION SYSTEM The crankcase breather prevents pressure from building up in the crankcase It also prevents oil con tamination by removing moisture or gasoline vapors and other harmful blow by materials from the crank case These vapors are routed to the carburetor where they are mixed with incoming air and burned in the combustion chamber A sticky breather valve can cause oil
115. ndings with a new rotor 5 1559 FIGURE 8 13 TESTING ROTOR FOR OPENS OR SHORTS TABLE 8 2 RESISTANCE VALUES FOR ROTORS OHMS OF STACK LENGTH RESISTANCE 10 3 5 8 90 50 Hz Stator Transformer Test The stator and transformer can be tested for grounded or open windings using an ohmmeter Testing for shorted windings requires a digital type ohmmeter than can read to within 0 01 ohms Figures 8 14 and 8 15 show the stator and trans former removed from the generator for testing How ever it is possible to test both components without removing them from the generator Remove the con trol panel and transformer cover to obtain access to the specified lead wires during testing Ground Test To test for grounds disconnect the following transformer and stator leads e Stator lead T1 T3 from CB1 e Stator lead S1 from tap X2 50 Hz Stator lead S2 from CR4 AC1 Stator lead 1 from R6 1 H1 1 lead wire Stator lead B2 from ground tab e Transformer lead H1 from ground e Transformer lead from ground CR4 AC2 lead wire from tap X5 Insulate or position the lead wire ends so they are not touching the generator set housing Set the ohmmeter forthe highest resistance scale and then connectone test prod to the generator housing Touch the other test prod see Figure 8 14 to the leads specified in Table 8 3 A reading less than one megohm indicates a ground 8 15 G 1172 1
116. necting Rod Bearing Clearance Section 3 Dimensions and Clearances BGE and BGEL Dimensions not in parentheses are INCHES 3 2490 3 2500 82 525 82 550 mm 0 005 0 127 mm 0 002 0 051 mm 0 0044 0 0066 0 112 0 168 mm 0 0100 0 0200 0 254 0 508 mm 0 080 0 081 2 03 2 06 mm 0 080 0 081 2 03 2 06 mm 0 188 0 189 4 78 4 80 mm 0 002 0 008 0 051 0 203 mm 0 6875 0 6877 17 46 17 47 mm 0 0002 0 0007 0 005 0 018 mm 0 0020 0 0160 0 051 0 406 mm 0 0020 0 0033 0 051 0 084 mm 3 1 MODELS CRANKSHAFT AND CAMSHAFT Crankshaft Main Bearing Journal Diameter Crankshaft Rod Journal Beating 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 Spring Tension Open Valve Spring Tension Closed BGE and BGEL Dimensions not in parentheses are in INCHES 1 9992 2 0000 50 861 50 886 1 6252 1 6260 41 280 41 300 mm 2 0024 2 0034 50 860 50 886 mm 0 0025 0 0038 0 064 0 097 mm 0 006 0 012 0 15 0 30 1 3740 1 3745 34 900 34 912 1 376 1 377 34 950 34 976 mm 0 0015 0 0030 0 038 0 076 mm 0 003 0 08 mm Dimensions not in parentheses are in INC
117. ned so it will not be damaged by reversed battery polarity or by a short in the lead wires from the board or remote start control The relays are sealed and filled with dry nitrogen for maximum contact life Start Run Stop Switch The Start Run Stop switch 51 is a single pole dou ble throw SPDT rockertype switch used for starting or stopping the generator set Placing the switch in either the Start or Stop position will initiate the appropriate control function The switch will auto matically return to the center Run position when released The switch is mounted on the control panel and is removable for service replacement Start Solenoid The K1 start solenoid is used for opening or closing the circuit between the starter motor and the battery Because of the high current loads imposed during starting the start solenoid is designed with heavy duty contacts rated to withstand 300 amperes A sin gle small terminal provides a connection point forthe 12voltDC solenoid coil The solenoid is mounted inside the control The large stud that protrudes through the control housing is for battery connection while B cable connects to ground position on tray Battery Charge Resistor The battery charge resistor is a fixed value 2 5 ohm 50 watts resistorthat limits the battery charge rate to no more than 1 ampere The charge rate may not be altered The resistor mounts between the left cylinder as viewed from flywheel end and the en
118. ng a carburetor are given as follows Carefully note the position while removing all parts to ensure correct placement when reassembling Read through all the instructions before beginning for a better understanding of the procedures involved Carburetor components are shown in Figure 6 15 Removal and Disassembly Remove the carburetor and intake manifold assembly as specified in the Carburetor and Intake Manifold Assembly in this sec tion Remove the carburetor from the intake manifold and disassemble using the following procedure 6 15 IDLE CHOKE SHAFT ADJUSTMENT THROTTLE STOP SCREW THROTTLE PLATE THROTTLE SHAFT NS FUEL INLET VALVE BUOYANCY SPRING FLOAT FLOAT BOWL MAIN ADJUSTMENT SCREW ASSEMBLY XFS 1604 FIGURE 6 15 CARBURETOR CVERHAUL 6 Remove theair cleaner adapter and the automatic choke assembly Remove throttle and choke plate retaining screws then plates Pull out throttle and choke shafts being careful not to damage the teflon coating applied to some throttle shafts Remove main andidie mixturescrew assemblies Separate the lower section of the carburetor fuel bowl from the upper section fuel bowl cover of the carburetor Carefully note position of float assembly parts then slide out retaining and remove the float assembly any springs or clips and the needle valve Unscrew and remove needle valve seat Clean and
119. ng the AC output voltage is required The voltage regulating transformer allows the generator to provide a stable AC output voltage under varying load conditions Each transformer primary winding H1 H2 and H3 H4 is connected in series with one of the stator AC output windings The full AC output current pro duced by the generator flows through these two primary windings Increasing or decreasing the cur rent output from the transformer winding produces a corresponding increase or decrease in the current produced in the secondary winding The secondary winding is connected in series with the circuit that supplies AC current for rectification to DC field current During operation adding load increases the current flow through thetransformer primary windings which causes corresponding increase in the current out put from the transformer secondary winding This boosts the DC field current to a higher level to offset the voltage drop that would normally occur when a load is applied the same manner decreasing the load reducesthe DC field currentto offset the voltage rise that would normally occur when a load is removed Continuously adjusting the field current as the load changes is how voltage regulation is achieved GENERATOR TROUBLESHOOTING Use the following troubleshooting guide to help locate problems related to the generator Figures 8 3 and 8 4 show the location of most of the generator components Refer to the wiring diagr
120. ng the element cover make sure the slotted tang on the cover engages the bi metal strip OUTER TAB FS 1606 FIGURE 6 20 BI METAL SPIRAL STRIP Choke Pulloff Diaphragm Adjustments The choke pulloff diaphragm partially opens thechoke plate fol lowing engine startup This helps prevent flooding and provides for smoother engine operation as the set is warming up Use the following procedure to adjust 1 Remove the complete air filter assembly as speci fied in Air Filter Assembly in this section to provide access to the choke plate 2 Disconnect diaphragm hose from intake mani fold and apply 4 to 18 inches 102 to 457 mm Hg vacuum to the diapnragm 6 18 CHOKE LEVER CHOKE PLATE CLOSED PULL OFF LINKAGE PULL OFF DIAPHRAGM DIAPHRAGM MTG BRKT BEND HERE FS 1603 FIGURE 6 21 CHOKE PULLOFF DIAPHRAGM 3 Apply light finger pressure against the choke lever to take up all freeplay in the pulloff linkage see Figure 6 21 4 Check alignment as viewed from the top of diaph ragm stem pulioff linkage and slot in choke lever Correct alignment as required 5 Measure distance between choke plate and bottom of carburetor atthe pointindicated in Figure 6 21 If necessary bend diaphragm mounting bracket to obtain 0 39 to 0 43 inches 9 9 to 10 9 mm clear ance 6 Movechokelever back and forth to check for free movement Verify that choke does not bind or stick 7 Remove vacuum supply from diaphragm and ins
121. noid to close the K1 contacts Closing the K1 start solenoid contacts connects B to the starter motor This energizes the starter motor which begins to crank the engine to initiate starting Starter Lockout Run When the engine starts the low oil pressure switch S2 closes to connect battery ground B to the K3 runrelay As the engine comes up to speed AC output voltage from the generator is supplied to the choke heater element H1 and to the K2 generator relay This activates the heating element which opens the choke and also energizes the K2 relay Energizing the K2 relay closes one set of contacts K2 2 5 that connect B to the K2 run relay This energizes the relay which opens two sets of contacts to produce the fol lowing contro responses 7 2 Closing the K3 9 15 contacts which parallel the 4 2 8 contacts provides an alternate pathway for supplying to the T1 ignition coil and fuel pump Opening the K3 1 8 contacts disconnects B CR4 positive terminal from the generator field windings Closing the K3 2 8 contacts connects B to the run light time meter and battery condition meter Opening the K3 9 16 contacts disconnects B from the K4 start relay causing it to de energize De energizing the K4 relay opens the K4 2 8 and K4 9 15 relay contacts Opening the K4 2 8 contacts has no effect since they are in parallel with the closed K3 9 15 contacts which connect B to the igni
122. not list every malfunction and the cause In some situa tions the serviceperson will have to rely on expe rience and a knowledge of the product to locate the problem and service as required SPECIAL TOOLS The following special tools may be required to ser vice the generator set Some of these tools may be purchased from Onan while others may be pur chased from outside suppliers A complete listing of thetools available from Onan is contained in the Catalog 900 0019 which is available from Onan Dealers or Distributors Engine Tools Torque wrench 0 175 Ft Lbs or 0 240 Nem Feeler gauge Pressure gauge Spark plug gap gauge Carburetor adjustment wrench Points adjustment tool Flywheel puller Snap ring pliers Gear puller with puller ring Cylinder ridge reamer Combination main and cam bearing remover Combination main and cam bearing driver Cil seal loader and driver Piston ring compressor Piston ring spreader Cylinder hone Valve seat cutter Valve spring compressor Valve lock replacer Valve seat driver Valve guide driver Slide hammer Piston groove cleaner Outside micrometer set 0 to 4 in Telescoping gauge set 1 2 in to 6 in Hole gauge 0 300 in to 0 400 in Plasti Gage bearing clearance guide Generator and Control Lead or dead blow hammer Battery hydrometer VOM multi tester Frequency meter Armature growler Load test panel Jumper wires SAFETY CONSIDERATIONS Always conside
123. nsformer primary leads H2 and H4 and from stator leads T2 and T4 M d Twist each stator lead around the end of the corresponding transformer primary lead T2 to H2 and T4 to H4 Place a 6 uninsulated barrel connector over the lead ends and crimp tightly using a 6 staking tool Wire nuts or other non crimp ACAUTION type connectors can loosen during set operation Use only the specified connector and crimping tool when connecting stator leads to transformer primary leads e Slidea2 1 2inch 64 mm long piece of braided insulation over each connection as shown in Figure 8 9 Use a wire tie to hold insulation securely in place Pull each brush outward from the brush holder and at the same time insert a stiff piece of wire through the small holes in the base of the holder The wire holds the brushes slip rings during assembly Install brush block in housing and tighten mounting screws Place the rotor in position for mounting on the end of the crankshaft and install rotor through bolt Tighten through bolt just enough to hold rotor in place Tightening the rotor through ACAUTION boit to specified torque before the stator assembly is installed can result in rotor shaft misalignment Follow recommended instal lation procedures to avoid any possibilily of shaft misalignment Carefully lower the stator assembly over the rotor and into position for assembly to the engine The rotor end bearing should f
124. o 34 Nem torque 7 Place the armature end cap in position on the starter housing and then carefully insert the armature into the housing Install starter through bolts and tighten securely 8 Mount starter on generator stator housing and secure using hex head capscrews lockwashers and nuts Tighten mounting screws to 30 to 33 ft lbs 41 to 45 Nem torque 9 Connect generator set positive battery cable to starter lug terminal 10 Connect generator set negative battery cable to generator set starting battery ELECTRIC STARTER Begin Spec B The following procedures cover the disassembly and testing of electric starter Disassembly Use the following procedure to remove and disassem ble the starter 1 Disconnect the generator set negative battery cable from the set starting battery 2 Disconnect the generator set positive battery cable from the starter lug terminal 3 Removethe starter mounting screws and then care fully disengage the starter from the stator housing 4 Remove starter through bolts and carefully separ ate the brush end cap housing and armature assembly 5 Use a 1 8 to 5 32 inch set to remove roll pin Remove return spring gear and clutch assembly as required When reassembling always use a new roll pin See Figure 6 38 6 28 ROLL PIN STARTER THROUGH BOLTS 25 1008 FIGURE 6 37 191 1667 STARTER SUPPORT PLASTIC RETAINER WITH 5 32 to 1 8 NAIL SET
125. ocedures AWARNING The generator set is heavy and can result in severe personal injury if dropped during removal Use the recommended removal techniques and keep hands and feet clear while removing mounting bolts generator set will be left in the down tilted position for more than 30 minutes first drain the oil Oil in the engine cylinders can ACAUTION cause engine damage during start ing attempts Oil can enter the engine cylinders when the generator set is in the lowered tilted position Do not leave the generator set in this position for more than 30 minutes if the oil has not been drained MMMM Partial Set Removal Park the recreational vehicle on as level a surface as possible surface must support floor jack wheels Then follow these instructions very carefully Itis assumed that disconnecting the fuel exhaust etc has already been performed as described previously 1 Put the vehicle in its park position lock the brakes and remove the ignition key Make sure no one moves the vehicle while performing this procedure Dropping the generator set can AWARNING result in severe personal injury or death Make sure no one moves the vehicle during this procedure and that the procedure is performed very carefully and only as instructed 2 Usea floor jack similar to the one shown Figure 5 3 and position the floor jack under the rein forcement ribs of the drip tray as shown 3 Raise the floor
126. orn or otherwise damaged remove the spacer by splitting with a chisel Use a press to install a new spacer on the camshaft gear 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 The governor cup and flyballs are easily installed when the camshaft assembly is removed from the engine If necessary the engine may be tilted up to install the cup and flyballs Put the flyballs between the spacer arms and install the cup on the center pin Lock the cup in place with the snap ring The camshaft center pin extends out 3 4 inch 19 TIMING GEARS AND CAMSHAFT If replacement of either the crankshaft gear or the camshaft gear becomes necessary it is recommended that both gears be replaced To remove the crankshaft gear first remove the snap ring and retainer washer then attach the gear pulling ring using two No 10 32 screws Figure 9 14 Tighten the screws alternately until both are tight Attach a gear puller to the puller ring and remove the mm from the end of the camshaft This distance provides an in and out travel distance of 7 32 inch 5 6 mm forthe governor cup as illustrated Hold the cup against the flyballs when measuring If the dis tance is less the engine may race especially at no load Remove the center pin and press in a new pin the specified amount Do not hammer the new pin into pla
127. ots gently clean the surface with crocus cloth Most paris cleaning solvents A WARNING are flammable and can result in severe personal injury if used improperly Follow the manufacturers recommendations when cleaning parts Insert plunger in tube buffer spring end first Check fit by slowly sliding the plunger back and forth in the tube It should move fully without any tendency to stick If a click cannot be heard as the plunger is slid from one end to the other the internal pump assembly is not functioning prop erly and the pump should be replaced install plunger spring cup valve O ring seal and washer Compress the spring and install the retainer with ends in the side holes of the tube Check cover gasket and replace if deteriorated Place cover gasket and magnet in the bottom cover and install filter and cover assembly on pump Twist cover on by hand and tighten secure ly with a 5 8 inch wrench Pump Test for units built June 1986 and after Testthe fuel pump by checking the pump outlet pressure Use the following procedure 1 Removethefuelline from the pump outlet and install a pressure gauge 2 Press the START switch and hold it for several seconds until pressure reading is constant 3 The pressure reading for a good pump should fall within 3 1 2to 5 psi 17 240 34 4 kPa The pressure should stay constant or drop off very slowly If pressure reading is below 3 1 2 psi 17 2 kPa replace fuel pump
128. p relay contacts opens the circuit that holds the run relay grounded This allows the relay to energize when connected to Closing the K1 start solenoid contacts connects B to the starter motor This energizes the starter motor which begins to crank the engine to initiate starting Starter Lock out Run When the engine starts the low oil pressure switch S2 closes to connect battery ground B to the K3 run relay As the engine comes up to speed AC output voltage from the generator is supplied to the K2 gener ator reiay This energizes the K2 relay which closes one set of contacts K2 2 5 that connect B to the K3 run relay This energizes the K3 relay which opens two sets of contacts and closes two sets of contacts to produce the following control responses 7 9 e Closing the K3 9 15 contacts which parallel the K4 2 8 contacts provides an alternate pathway for supplying to the T1 ignition coil and fuel solenoid valve Opening the K3 1 8 contacts disconnects CR4 positive terminal from the generator field windings Closing the K3 2 8 contacts connects to the run light time meter and battery condition meter Opening the K3 9 16 contacts disconnects from the K4 start relay causing it to de energize De energizing the K4 relay opens the K4 2 8 and K4 9 15 relay contacts Opening the K4 2 8 contacts has no effect since they are in parallel with the closed K3 9 15 contacts whi
129. r lubricant to hold the front thrust washer in place against the engine block The flat side of the thrust washer goes against the block Position the crankshaft so the crank throw is aligned with the notch at the rear of the crankcase and install the crankshaft Make sure the front thrust washer did not slip out of place during installation Place the oil seal loader on the oil seal guide and driver and insert into the rear bearing plate Remove the seal guide and driver leaving the loader in the bearing plate The loader prevents the seal from being cut on the crankshaft keyway during installa tion of the rear bearing plate Use oil or gear lubricant to hold the shim s and rear thrust washer in position on the rear bearing plate see Figure 9 31 The shim goes against the bearing plate and the flat surface of the thrust washer goes against the shim Place the bearing plate gasket in position on the block making sure the hole on the back of the block is exposed Install the rear bearing plate and fasten with two nuts or capscrews tightened to the specified torque Make sure the rear thrust washer and shim s did not slip out of place during installa tion The crankshaft should turn freely by hand Checking Endplay After tightening two rear bearing plate nuts or cap screws to the specified torque check the crankshaft endplay at the point shown in Figure 9 27 using a feeler gauge Lightly tap the front of the crankshaf
130. r must be rotated clockwise from reference position Marks on choke housing are spaced at 5 intervals 5 Rotate element cover as specified and then tighten cover mounting screws 6 Move choke lever back and forth to check for smooth operation Lever should return automati cally to the free position when released from the open position without sticking or binding 7 install plastic choke cover and tighten center mounting nut Choke Replacement If the choke fails to open remove the protective plastic cover and check to see if the heating element is working The heating element cover shouid become hot after a few minutes of operation If the element cover does not get hot start the set and then use AC voltmeter to check for voltage approx imately 20 VAC at the element cover terminals If voltage is not present check for opens or shorts in the control wiring If the voltage is present at the heating element cover terminals stop the set and remove the heating element cover Inspect the heating element and replace if burned out or broken Also inspect the bi metal spiral strip and replace if damaged deteriorated or dragging in the housing Wheninstalling a new bi metal strip maintain the orig inal direction of spiral see Figure 6 20 The outer tab must point in a clockwise direction Make sure the coil sets squarely in the housing and the inner end of the Coil engages the slot in the choke shaft When instal li
131. r set operating inspect the entire exhaust system including the exhaust manifold muffler and exhaust pipe Visually and audibly check forleaksatall connections welds gaskets and joints and also make sure exhaust pipes are not heating surrounding areas excessively If leaks are detected correct immediately Inhalation of exhaust gases can AWARNING result in severe personal injury or death Inspect exhaust system audibly and visually for leaks daily Repair leaks immediately EXHAUST GAS IS DEADLY Exhaust gases contain carbon monoxide an odorless and colorless gas formed during the combustion of hydrocarbon fuels Carbon monoxide is poisonous and can cause unconsciousness and death Symptoms of carbon monoxide poisoning are the following e inability to Think Coherently Vomiting e Muscular Twitching e Throbbing in Temples Dizziness Headache Weakness and Sleepiness if you or anyone else experience any of these symptoms shut down the unit and get out into the fresh air immediately If symptoms persist seek medical attention DO NOT OPERATE THE UNIT UNTIL IT HAS BEEN INSPECTED AND REPAIRED The best protection against carbon monoxide inhalation is proper installation and regular frequent visual and audible inspections of the complete exhaust system 10 1 FUEL SYSTEM With the generator set operating inspect the fuel supply lines return lines filters and fittings for leaks Check any flexible
132. r the safety aspects of any service procedure Generator sets present several hazards that the serviceperson must be aware of if the job is to be completed safely Read through the safety precautions listed on the inside cover and familiarize yourself with the various hazards shown in Table 5 1 Once the hazards are known approach the job with a safety con scious attitude Being safety conscious is the most effec tive way to avoid injury to yourself or others Reduce the chance that an accident will occur by adopting the following safeguards Safeguards to Avoid Hazards Use Personal Protection When the situation calls for it protect your body by wearing the appropriate safety equipment Protective clothing includes such items as safety shoes gloves safety glasses and hard hats Leave rings and jewelry off and do not wear loose clothing that might get caught on equipment Work to Reduce the Hazard The workshop area and all pieces of equipment used can contribute to reducing the hazard potential Keep guards and shields in place on machinery and maintain equipment in good working condition Store flammable liquids in approved containers away from open flame Keep the workshop clean and well lighted and provide adequate ventilation Keep fire extinguishers and safety equipment nearby and be prepared to respond to an emergency TABLE 5 1 HAZARDS AND THEIR SOURCE Fire and explosions Leaking fuel Hydrogen gas from c
133. rating If the engine starts but runs roughly and blows out black smoke after a minute or two of operation the choke is set too rich If the engine starts but sputters or stops before it warms up the choke is set too lean Choke Adjustment Table 6 3 lists the choke settings for various ambient temperatures Stop the set and allow it to cool down before making adjustments Use the following procedures to adjust 1 Remove the protective plastic choke cover see Figure 6 19 and loosen the heating element cover screws 2 Rotate heating element until choke plate is about halfway open 3 Slowly rotate cover counterclockwise CCW while tapping the carburetor choke lever and making the choke lever bounce Continue rotation until tapping the choke lever no longer makes it bounce This is the fully closed position and becomes the refer ence position TABLE 6 3 CHOKE ADJUSTMENTS Ambient Air Temperature 40 F 4 C 45 F 7 C 50 F 10 C 55 F 13 C 60 F 16 C 65 F 18 C 70 F 21 C 75 F 24 C 80 F 27 C 85 F 29 C 90 F 32 C 95 F 35 C 100 F 38 C Rotation From Reference Mark 8 CW 12 CW 16 CW Each mark on choke housing equals 5 angular rotation 6 17 HOUSING ELEMENT COVER BI METAL SPIRAL STRIP PLASTIC COVER XFS 1605 FIGURE 6 19 CHOKE ASSEMBLY 4 Refer to Table 6 3 to determine the number of degrees element cove
134. rmer helps to provide stable generator output voltage under varying load conditions Voltage transformers are constructed with two primary windings and a single secondary winding Each primary winding H1 H2 and H3 H4 is connected series with one of the generator AC output windings The transformer secondary winding is connected in series with the field current circuit Taps on the secondary allow for field current adjustments The voltage regulating transformer mounts on the out side of the generator housing and is enclosed with a special cover The cover must be in place during oper ation for transformer cooling Field Current Rectifier CR4 The CR4 rectifier is a full wave bridge rectifier used to rectify a portion of the generator AC output voltage to DC for field excitation The positive and negative terminals ofthe rectifier are connected to the genera tor brushes The rectifier mounts inside the generator set control and may be accessed by removing the control panel Brushes The brush block assembly consists of a single brush biock with two brushes The brush block mounts inside the generator housing and can be accessed by removing the small plate at the rear of the housing Wiring Harness separate wiring harness is provided for connecting the generator set to the RV electrical system All lead wires are stranded copper wire to withstand vibra tion The lead wires must be protected with flexible conduit which m
135. rp taps should break loose the through bolt Remove the rotor through bolt and in its place install the tool shown in Figure 8 8 Use a screw driver to turn the rotor tool in a clockwise direction until it bottoms Install a 9 16 12 x 2 capscrew inthe end of the rotor shaft and tighten until rotor breaks loose from crankshaft Remove capscrew from end of rotor when complete 18 Carefully lift the rotor assembly off the end of the engine crankshaft and remove rotor tool 19 Remove the brush biock mounting screws and 8 9 carefully lift out the brush block assembly CAPSCREW FLYWHEEL PULLER G 1177 FIGURE 8 7 STATOR ASSEMBLY REMOVAL CAPSCREW ROTOR TOOL 10 IN 254 mm G 1175 FIGURE 8 8 ROTOR TOOL 20 Use following procedure to remove trans former from housing a Remove the braided insulating material from the transformer primary lead wire T2 H2 and T4 H4 connections b Cut off the crimped barrel connectors and separate the transformer primary leads from the stator leads c Disconnect the lead wires from the transformer secondary taps d Remove the four screws that secure the trans former to the stator housing and lift off the transformer assembly The transformer air gap ACAUTION might be altered if the mount ing bracket is removed from the transformer Do not loosen or remove any screws that pass through the transformer laminations 21 Use the following
136. s The location of the adjustment screws is shown in Figure 6 14 Use the following procedure to adjust IDLE ADJUSTMENT SCR THROTTLE STOP SCREW spots in acceleration and a greater tendency to burn valves and spark plugs CARBURETOR FUEL MIXTURE ADJUSTMENTS Mixture screw adjustment should be checked with every engine tune up and whenever a carburetion prob lem is suspected Before adjusting be sure the ignition system is working properly and the governor is correctly set If the carburetor is totally out of adjustment use the mixture settings given in Table 6 2 as preliminary adjustments Turn the mixture screws in until lightly seated then turn out the specified number of turns MAN ADJUSTMENT SCREW FS 1608 FIGURE 6 14 MIXTURE SCREW ADJUSTMENT 6 14 TABLE 6 2 CARBURETOR ADJUSTMENT SPECIFICATIONS MIXTURE SETTINGS FLOAT 1 16 1 32 in ee Measure between bowl gasket end of float 1 Stop the set and connect a voltmeter frequency meter and load bank to the generator output leads 2 Start the generator set and apply a full load Verify that the frequency is within 59 49 2 hertz and adjust the governor speed adjustment nut if neces sary to obtain required frequency 3 Turnthe main adjustment screw inward until volt age or frequency drop and then outward until voltage or frequency drop again Locate the point where the voltage and freq
137. s usually in tended for automotive use often look similar but might not perform to Onan specifications Only genuine Onan replacement parts are designed and tested for the application to ensure reliable service and dependable operation Time Rating Insul NEMA Class Amb 40 C For Recreational Vehicle Use Only Pour Usage Dans Les Vehicules Recreatlfs Type Fuel Gasoline Made in USA 99 1360 1572 ONAN NAMEPLATE INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN SEVERE PERSONAL INJURY AND OR EQUIPMENT DAMAGE SERVICE PERSONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND OR MECHANICAL SERVICE Redistribution publication of this document by any means is strictly prohibited Section 2 Specifications GENERAL Engine Design Four Cycle Air Cooled Two Oylinder Generator Design Revolving Field Four Pole Q tp t Ratings es Unity Power Factor Starting System Automotive Type Starter 12 Volts Engine 50 Hz 1500 r min 60 Hz 1800 r min Weight 228 165 104 kg 60 2 218 Ibs 99 ENGINE DETAILS Displacement RPM I 47 7 in 781 8 Compression vada qu 6 91 BOVE e Ee aA 3
138. s necessary disassemble and assemble the cooling system as specified in the following sections Disassembly Remove the muffler and tailpipe assembly see Exhaust System section to provide access to the cooling system and then proceed as indicated 1 Remove the capscrews that secure the noise shield see Figure 6 4 to the engine and lift off the noise shield 2 Remove the three nuts located along the lower edge of the scroll that fasten the fan guard to the scroll 3 Remove the capscrews that fasten the scroll to the backplate and lift away from scroll 4 Remove the screws that fasten the cylinder air housings to the backplate and cylinder heads and lift off the air housings 5 Loosen the flywheel capscrew and back it out several turns 6 Attach puller tool to the flywheel as shown in Figure 6 5 The too has two jack screws that fit into the tapped holes in the flywheel 7 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 8 Removethe lead from the low oil pressure cut off switch 6 7 NOISE SHIELD CYLINDER HOUSINGS SCROLL BACKPLATE FLYWHEEL FAN GUARD FIGURE 6 4 COOLING SYSTEM 9 Remove the exhaust manifold as described in Exhaust System in this section 10 Remove the capscrews that secure the backplate to the engine and lift off the backplate
139. sas sembly follow steps 2c through 2e to connect stator output leads to transformer 2 the transformer was removed from the stator housing during disassembly use the following procedures to install the transformer on the stator housing Hold transformer position for mounting on the stator housing Install the two mounting screws and tighten securely 8 10 b Connect the CR4 AC lead wire to the trans former X5 tap and the S1 lead wire to the trans former X2 50 Hz X3 tap Note This isa prelimi nary connection that may require adjustment to obtain the correct generator output voltage See Transformer Voltage Adjustment in this section Strip off 1 2 inch of insulation from the ends of transformer primary leads H2 and H4 and from stator leads T2 and T4 d Twist each stator lead around the end of the corresponding transformer primary lead T2 to H2 and T4 to H4 Place a 6 uninsulated barrel connector over the lead ends and crimp tightly using a 6 staking tool Wire nuts or other non crimp ACAUTION type connectors can loosen during set operation Use only the specified con nector and crimping tool when connecting stator leads to transformer primary leads e Slide a 2 1 2 64 long piece of braided insulation over each connection as shown in Figure 8 9 Use a wire tie to hold insulation securely in place Pull each brush outward from the brush holder and at the same time insert
140. screws Gently tap the gear cover with a plastic faced hammer to loosen it see Figure 9 12 When installing the gear cover make sure that the pin in the gear cover engages the nylon lined smooth hole in the governor cup Turn the governor cup so the nylon lined hole is at the three o clock position Use a small amount of grease to assist in holding governor cup in position The rounded side of the governor yoke must ride against the governor cup Turn the governor arm and shaft clockwise as far as possible and hold in this position until the gear cover is installed flush against the crankcase Be careful not to damage the gear cover oil seal Refer to Oil Seals section if replacing the gear cover oil seal GOVERNOR GOVERNOR ARM GOVERNOR SHAFT GOVERNOR SHAFT YOKE SMOOTH SIDE TOWARD IF FEELER WILL ENTER HOLE 1 2 IN 13 mm BALL HAS FALLEN OUT OIL SEAL VT 1027 FIGURE 9 12 GEAR COVER ASSEMBLY 9 6 WHEN GOVERNOR 1 PROPERLY ASSEMBLED THE DIMENSION SHOWN pcd ON DRAWING WILL BE AS INDICATED CENTER PIN SNAP RING GOVERNOR CUP GOVERNOR FLYBALL VT 1028 FIGURE 9 13 GOVERNOR CUP GOVERNOR CUP With the gear cover removed the governor cup can be taken off after removing the snap ring from the camshaft center pin see Figure 9 13 Catch the fly balls while sliding the cup off Replace any that is grooved or has a flat spot If the arms of the ball spacer are w
141. se or dirty Control fuse F1 is open Connect a voltmeter between terminal S on the start Sole noid and ground Check for battery voltage when 1 is placed in Start position If voltage is present fault is due to K1 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 control PC board 7 11 1a 1b 2a 2b 3a 3b 5a 5b 5 Corrective Action Check for continuity and and correct if circuit is open Replace remote start control switch Check for continuity and correct if circuit is open Replace S1 switch Check condition of battery and recharge or replace Clean and tighten connections at battery K1 start solenoid and starter motor AWARNING Short circuiting AWARNING the battery cables can result in severe per sonal injury Disconnect the nega tive battery cable at the battery terminal before servicing Replace fuse 5 ampere Tighten solenoid bracket mounting screws Replace K1 start solenoid Refer to Electric Starter section for test and service procedures Check for continuity and correct if circuit is open 6b Replace control PC board TO IGNITION Engine Cranks But Does Not Start mw ES FROM 5 85 B2 TO TERMINAL TAB gt TO 5 85 FIGURE 7 5 BG
142. seat may cause inconsis tent starting or idling These granules are seldom the result of insufficient filtration The foreign matter is dissolved in the liquid propane and forms into granules as the fuel is vaporized Remove regulator front cover and diaphragm assembly see Figure 6 29 to check for dirt or oil deposits If granules are imbeded in the Vitton rubber of the secondary valve wash the valve and seat clean 6 24 3 the primary seal is sound the gauge should read approximately 1 1 2 psi 10 3 kPa and the pressure 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 con stant If the pressure reading drops the sec ondary seat is leaking If the regulator does not pass either test it must be rebuilt or replaced SECONDARY DIAPHRAGM WK a 572 VALVE PRIMARY e PU DIAPHRAGM 791539 FIGURE 6 30 REGULATOR TEST XFS 1600 FIGURE 6 29 REGULATOR DISASSEMBLY Regulator Test The regulator may be bench tested using compressed air and simple automobile fuel pressure gauge Use the following procedure to test 1 Attach the pressure gauge to the test port on the back of the regulator as shown in Figure 6 30 2 Attach a pressure hose to the inlet opening and open the air pressure valve 6 25 Fuel Filter The fuel filter see Figure 6 31 removes solid
143. specified proce dures When replacing the coil observe proper polarity The negative terminal connects to the breaker points and the positive terminal connects to a battery posi tive B source within the control HIGH TENSION TERMINALS SECONDARY WINDING 6 9 LOW TENSION LOW TENSION TERMINAL TERMINAL PRIMARY WINDING CORE FIGURE 6 7 IGNITION COIL Ignition Coil Testing A quick test of coil output can be made by checking the ignition spark Remove one of the spark plugs Reconnect the spark plug wire to the spark plug Ground the spark plug to bare engine metal and crank the engine A good spark should be observed between the plug center electrode and side elec trode If the spark is weak the coil points and con denser or wiring is probably defective Direct Testing With Ohmmeter To test a coil directly remove all the attached wires For easier access to the terminals the coil may be removed from the engine Use the following procedure to test 1 Inspect terminals for corrosion looseness cracks dents or other damage Look for evidence of electrical leakage around high tension termi nals indicated by carbon runners Damaged or leaking coils should be replaced Clean the outside of the coil with a cloth damp ened in parts cleaning solvent 3 To measure resistance in the primary circuit connect one ohmmeter lead to the positive terminal and the other to the negative
144. st prod connected to negative terminal Replace lead wires when test is complete TABLE 8 4 RESISTANCE VALUES FOR STATORS AND TRANSFORMERS TEST WINDING 10 STATOR TRAN EM 110 220V 120 240V T1 T3 to H1 T1 to H1 T1 T3 to T3 to H3 B1 to B2 X1 to X6 OHMS OF RESISTANCE STATOR ONLY T1 T3 to T2 T1 to T2 T1 T3to 4 T3to T4 TRANS ONLY H4 to H3 H2 to H1 50 Hz Only 8 17 Redistribution or publication of this document by any means is strictly prohibited Section 9 Engine Block Assembly GENERAL The engine block assembly includes the pistons and connecting rods crankshaft camshaft valves and lifters cylinder heads lubrication system timing gears governor mechanism bearings and cylinder block Performing any major service on the block assembly will require that the generator set be removed from the coach see Set Removal section In addition to gain complete access to the block assembly the control generator and all primary engine systems must also be removed Refer to the previous sections for the disassembly and removal procedures OIL FILTER AND ADAPTER Open the oil drain valve and drain the crankcase oil Remove the filter see Figure 9 1 by turning counter clockwise with a filter wrench The low oil pressure cut off switch is installed in a threaded hole in the filter adapter and may be removed if required Loosen the two c
145. st system is extremely critical on RV generator sets because of the possibil ity of exhaust gases entering the coach The exhaust system must be serviced immediately if inspection reveals leaking joints or connections loose fasteners or broken or damaged components Always replace worn components with new original equipment replacement parts Do not attemptto repair a broken exhaust pipe or manifold by welding and do not replace worn out components with parts that do not meetfactory specifications Contact an Onan distributor for proper 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 shortening the downpipe might allow poisonous exhaust gases to enter the coach Use only original equipment replacement parts when servicing the exhaust system Unauthorized modifications will also void the warranty and cancel the UL Listing CSA Certification Liability for injury or damages due to unauthorized modifications becomes the responsi bility of the person making the change Two basic exhaust systems used with Emerald ser ies generator sets Figure 6 1 shows a typical exhaust system for a compartment mount generator set Figure 6 2 shows a typical exhaust system for an underfloor mount generator set Separate sections cover the ser vice procedures for each exhaust system Also refer to specific kit installation
146. stem Governor The engine primary systems can often be serviced without removing the generator set from the recrea tional vehicle and without major disassembly of the set Use the following troubleshooting guide to help locate problems related to the engine primary sys tems Refer to Troubleshooting Generator Set Con e Fuel System LP Gas Liquid Withdrawal TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Trouble Engine Misfires Engine Backfires Possible Cause Faulty ignition due to worn or fouled spark plugs worn ignition points incorrect ignition timing faulty ignition coil or faulty plug wires Lean fuel mixture due to a incorrectly adjusted fuel mixture screws b incorrect float level C dirtin carburetor d vacuum leak Contaminated fuel Carburetor icing Gasoline sets only Faulty ignition due to a incorrect ignition timing b incorrect spark plug gap Lean fuel mixture due to a incorrectly adjusted fuel mixture screws b incorrect float level c dirt carburetor Mechanical damage to engine Gasoline sets only trol for problems related to starting the generator set Corrective Action Replace spark plugs Replace breaker points Set breaker point gap Test coil and replace if necessary Test spark plug wires and replace if faulty Adjust carburetor main and idle adjustment screws Adjust carburetor float level Disassemble carburetor and clean
147. sure distortion Check spring ten sion at the installed height for both the valve open and closed position using an accurate 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 B and series generator set engines With this method different seat and face angles are used and line contact between the valve face and seat occurs The valve 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 vaive and the top of the valve seat see Figure 9 6 VT 1021 FIGURE 9 6 VALVE INTERFERENCE ANGLE The valves should not be hand lapped because the sharp contact will be destroyed This is especially important where chrome cobalt faced valves and seats are used Valve faces must be finished in a machine to 44 degrees ACAUTION 1 16 INCH 1 6 mm MINIMUM REFER TO SPECIFICATIONS FOR CORRECT DIAMETER uL CHECK FOR BENT STEM Ve 1022 FIGURE 9 7 VALVE MARGIN Every valve must have a minimum of 1 16 inch 1 6 mm margin Figure 9 7 If the valve has less margin than this it will heat up excessively It will retain that heat during the compression stroke and pre ignite the mixture causing loss of power and economy This valve is also susceptible to warping and breakage Not al
148. surement of 59 to 63 inch 15 to 16 mm ADJUST 8 um BOWL FLANGE 0 59 0 63 IN 15 16 GASKET TAB CONTACTING HEAD PIN WITH FULL WEIGHT OF FLOAT COMPRESSING INLET VALVE SPRING FS 1611 FIGURE 2 FLOAT LEVEL Redistribution or publication of this document by any means is strictly prohibited ADD JUMPER WIRING DIAGRAM ae 5 Pa SCHEMATIC 2 E REMOTE P R6 A Pi AI CRI AI FI Kl 4 W2 2 2 85 Al K4 dis Al Pi 3 n 163 J CONNECTOR INSULATED WI 2 JUMPER WIRE T2 TRANSFORMER T S3 IGN POINTS S2 SWITCH LOW OIL PRESSURE SWITCH START STOP RESISTOR BATTERY CHARGE RELAY USED WITH LPG ONLY FUEL PUMP OR FUEL SOLENOID IMPORTANT Due to the possibility of ACAUTION unit lead end identification being out CIRCUIT BREAKER AC OUTPUT of date with the wire diagram schematic of this sup piscis IEO ANC plement do not rely solely on lead markings by trans CAPACITOR former when troubleshooting Instead check each lead none from point to point to confirm that unitis wired properly STANDARD REMOTE CONTROL DELUXE REMOTE CONTROL CONTROL ASSY 8 3 ADD
149. t with a plastic faced hammer to take up the freeplay Refer to the Dimensions and Clearances section for the recommended crankshaft endplay If necessary remove the rear bearing end plate and add or remove shims as required Install the end plate and tighten all nuts or capscrews to the specified torque Make sure the shim and thrust washer are in place and recheck crankshaft endplay Verify that the crank shaft turns freely without binding MEASURE ENDPLAY HERE REFER TO DIMENSIONS AND CLEARANCES CT 1068 FIGURE 2 27 CHECKING ENDPLAY 9 12 CYLINDER BLOCK The cylinder block is the main support for all other basic engine parts Crankshaft and camshaft are supported by the block assuring alignment of the crankshaft and cylinder bores Cleaning After removing pistons crankshaft cylinder heads etc inspect block for cracks and extreme wear If block is still serviceable prepare it for cleaning as follows 1 Scrape all old gasket material from block Remove oil bypass to allow cleaning solution to contact inside of oil passages 2 Remove grease and scale from cylinder block by agitating in a bath of commercial cleaning solu tion or hot soapy washing solution 3 Rinse block in clean hot water to remove cleaning solution Inspection When rebuilding the engine thoroughly inspect block for any condition that would make it unfit for further use This inspection must be made after all parts have been remove
150. t section When adjusted cor rectly the hone should not shake or chatter in cylinder bore but will drag freely up and down when hone is not running Connect drill to hone and start drill Feel out bore for high spots which cause an increased drag on stones Move hone up and down in bore with short overlapping strokes about 40 times per minute Usually bottom of cylinder must be worked out first because it is smaller As cylinder takes a uniform diameter move hone up and down all the way through cylinder bore Check diameter of the cylinder regularly during honing A dial bore gauge is the easiest method but a telescoping gauge can be used Check size at six places in bore measure twice at top mid dle and bottom at 90 degree angles Crosshatch formed by the stones should form an included angle of 23 degrees This can be achieved by moving the rotating hone 250 to 450 rpm up and down in cylinder bore about 40 times per minute Cleancylinder bores thoroughly with soap water and clean rags A clean white rag should not become soiled on wall after cleaning is complete Do not use a solvent or gasoline since they wash oil from the walls but leave metal particles Dry crankcase and coat it with oil Deglazing Cylinder Bores Deglaze the cylinder bores if there are no scuff marks and no wear or out of round beyond specifications before installing new rings Deglazing gives a fine tinish but does not enlarge cylinder
151. tall filter assembly on 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 following procedureto test and repair replacethe pump A WARNING Do not substitute automotive type electric fuel pumps for standard Onan supplied electric pumps The output pressure is much higher and can cause carburetor flooding or fuel leakage creating a fire hazard Pump Test for units built June 1986 and before Test the fuel pump by checking the pump outlet pressure Use the following procedure 1 Remove the fuel line from the pump outletand install a pressure gauge 2 Press the START switch and hold it for several seconds until pressure reading is constant 3 The pressure reading for a good pump should fall within 4 to 5 psi 27 5 to 34 4 kPa The pressure should stay constant or drop off very slowly A low pressure reading with little orno pressure drop indicates a weak or broken diaphragm or diaphragm spring worn linkage or leaky check valves If pressure is above maximum the pump diaphragm is too tight or the diaphragm or plunger return spring is too strong Any of the above conditions are cause for repair or replacement of the pump Fuel Pump Repair for units built
152. tart the generator set Allow the generator set to operate until it runs out of fuel Crank the set a few times after it stops to make sure the fuel system is completely purged of all LP gas fuel 6 20 If the generator set cannot be operated move the RV coach to an outdoor location that is well ventilated and is away from fire or flame Disconnect both the vehicle negative battery cable and the generator set negative battery cable from their respective battery terminals Close the fuel shutoff valves at the fuel tank for both the generator set fuel supply system and the appliance stove heater etc fuel supply system In addition close the fuel shutoff valves at each appliance WARNING LP Gas Propane is extremely flam AWARNING mable and can result in pet per sonal injury or death if accidentally ignited Eliminate all possible sources of ignition such as pilot lights or sparking electrical equipment 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 just enough to allow the LP gas to slowly escape Do not open the fitting too much or a large quantity of gas will be released Disconnect the fuel supply hose from the carburetor and hold it clear of the set Press in and hold the primer button on the regulator to release LP gas from the set fuel system When no more gas can be heard escap
153. tem replacement procedures to ensure safe operation e Use 1 3 8 inch I D 18 gauge rigid steel tubing for tailpipe Do not use flexible exhaust tailpipe since it might break due to road shock and vibration Install exhaust tailpipe at least 3 inches 76 mm away from the fuel tank and any combustible mate rial 1f 3 inches clearance cannot be maintained install suitable heat shielding between tailpipe and combustible material or fuel tank to prevent exces sive heating Do not terminate the exhaust tailpipe A Under a window door or any opening that might allow exhaust gases to enter the coach interior B Ahead of or under the generator compart ment air intake to prevent recirculation of exhaust gases Terminate tailpipe to the rear of the compartment air intake if possible C Under the fuel tank fill spout to prevent spilled fuel from being ignited by a hot tailpipe d Under the vehicle to prevent exhaust gases from entering the coach interior through small openings in the underside of the vehicle Extend the tailpipe at least one inch 25 mm beyond the perimeter of the vehicle Direct exhaust gases down and away from the vehicle and away from windows doors or compartment openings Do not connect the generator set exhaust tail pipe to the 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
154. tes and retains heat This increases combustion chamber temperatures which causes warping and burning 2 Unburned carbon residue gums valve stems and causes them to stick in the guide Deposits of hard carbon with sharp points projecting become white hot and cause pre ignition and pinging Valve Stem Seal valve stem seal is used on the intake valve guides This seal must be replaced each time the valve is removed sis VT 1018 FIGURE 9 3 VALVE SPRING COMPRESSOR Stems and Guides Always check valve stems and guides for wear as shown in Figure 9 5 Use a hole gauge to measure the valve guide When clearance with stem exceeds original clearance by 0 002 inch 0 05 mm replace either valve or guide or both as may be necessary Always regrind seat to make con centric with the newly installed guide VT 1017 FIGURE 9 4 VALVE FACE NOTE SEE VALVE TAPPET gt CLEARANCES VALVE ADJUSTING 2 VALVE RETAINER VALVE SEAT _ VALVE SPRING INSERT VALVE GUIDE VALVE SPRING WASHER LOCK VT 1019 FIGURE 9 2b VALVE SYSTEM 9 2 VT 1020 FIGURE 9 5 VALVE STEM amp VALVE GUIDE INSPECTION Springs Check valve springs for cracks worn ends distortion and tension If spring ends are worn check valve spring retainer for wear Check for spring dis tortion by placing spring on a flat surface next to a square Measure height of spring and rotate it against square edge to mea
155. the cylinder bore diameter parallel to crankshaft near the top of cylinder bore where greatest amount of wear occurs B Also measure and record as B cylinder bore diameter parailel to crankshaft at the bot tom of piston travel C Measure and record as C cylinder bore diameter perpendicular to crankshaft near the top of cylinder bore where greatest amount of wear occurs D Also measure and record as D cylinder bore diameter perpendicular to crankshaft at the bottom of piston travel E Reading A subtracted from reading B and _ reading C subtracted from reading D indicates cylinder taper F Reading A compared to reading C and reading B compared to reading D indi cates whether or not cylinder is out of round If out of round exceeds 0 003 inch 0 08 mm the cytinders must be rebored and honed to the nextoversize A reboring machine is used when going to oversize pistons The following repair data covers honing to oversize by use of a hone Reboring the Cylinder Rebore and hone engine whenever cylinder bore is worn damaged out of round or if cylinder taper exceeds specifications A worn cylinder bore should beresized to the smallest standard oversize diameter at which it will clean up The final finish and bore diameters should then be obtained by honing BOTTOM OF RING TRAVEL C 1090 FIGURE 9 28 METHODS OF MEASURING THE DIAMETER OF A CYLINDER
156. the igni tion system governor and other fuel system compo nents have been checked for correct operation If the carburetor is totally out of adjustment turn the mix ture screws in until lightly seated For a preliminary adjustment turn the main adjustment screw out 2 1 2 1 4 turns and the idie adjustment screw out 1 1 4 turn 3 Forcing the mixture adjustment ACAUTION screws tight will damage the needle and seat Turn in only until light tension can be felt IDLE ADJUSTMENT SCREW THROTTLE STOP SCREW MAIN ADJUSTMENT SCREW FS 1601 FIGURE 6 25 MIXTURE SCREW ADJUSTMENTS Start the engine and allow it to run for about 10 min utes at light load Figure 6 25 shows the location of the adjustment screws Use the following procedure to adjust 1 Stop the set and connect a voltmeter frequency meter and load bank to the generator output leads 2 Start the generator set and apply full load Verify that the frequency is within 59 2 hertz and adjust the governor speed adjustment nut if necessary to obtain required frequency 3 Turn the main adjustment screw inward until vol tage or frequency drops and then outward until voltage or frequency drops again Set the main adjustment screw at the point where the voltage and frequency are highest 4 Remove the load and verify that frequency is within 62 1 hertz Adjust governor speed adjustment nut if necessary to obtain required frequency 6 22 5 Turn the
157. 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 Remove K1 S lead wire from the S terminal on the K1 start solenoid Connect a pushbutton type Switch normally open in series between the K1 S lead wire and the S terminal on the K1 start solenoid Place a jumper wire between remote connector plug terminals 1 and 3 Press the pushbutton switch to crank the engine and then release switch as soon as the engine starts Hold commutator stone Onan too 4420 0259 against rotating slip rings until carbon is removed and all grooves or roughness is smoothed out Contact with rotating machinery AWARNING can result in severe personal injury Keep hands and fingers clear while ser vicing slip rings Remove jumper wire from remote connector plug Remove insulating material from ends of brush lead wires and then install brush block Follow steps 5 through 10 in the Brush Replacement section TRANSFORMER VOLTAGE ADJUSTMENTS The generator output voltage may be adjusted by changing the connections to the transformer secon dary taps This is necessary if the set voltage falls outside the recommended voltage range when oper ating at the specified frequency Use the following procedures to adjust the generator output voltage 1 Adjust the governor as specified in Section 6 for the Governor before making ad
158. tion coil and the fuel pump Opening the K4 9 15 contacts disconnects B from the K1 start solenoid De energizing the K1 start solenoid disconnects B from the starter motor which stops cranking When the 1 switch is placed in the RUN position the engine continues to run Relays K2 generator relay and run relay are energized while relays K1 start solenoid and K4 start relay are de energized Generator voltage is rectified to DC by the CR1 power rectifiers and supplied to the battery through the charge resistor R6 This charges the battery at a constant rate 1 ampere maximum during set operation R6 START SOLENOID MOTOR STARTER REMOTE SWITCH BATTERY CONDITION METER RUN LIGHT TO REMOTE SWITCH 5 1554 1 Start Run Stop switch E1 Spark plug S2 Low oil pressure cut out switch E2 Spark plug S3 Breaker points ES Fuel pump CR1 Power rectifier R6 Battery charge resistor CR4 Field rectifier H1 Choke heater element F1 Fuse K1 Start Solenoid B1 Starter K2 Generator relay AC G1 Generator K3 Run relay T1 Ignition coil K4 Start relay FIGURE 7 1 TYPICAL CONTROL SCHEMATIC Stopping Placing the Start Stop Run switch S1 in the Stop the engine stops As the generator output voltage position grounds the output of resistors R1 and R2to drops the K2 generator relay also de energizes All remove B from the K3 run relay This de energizes components return to their de energiz
159. ts shown in Table 6 1 5 Adjust the governor sensitivity to give the closest regulation least speed and voltage difference between no load and full load without causing hunting condition To increase sensitivity closer regulation turn the sensitivity adjustment screw counterclockwise To decrease sensitivity turn the sensitivity adjustment screw clockwise 6 Recheck the speed setting made in step 3 and readjust if necessary 7 Setthe carburetor throttle stop screw as in Fuel System of this section TABLE 6 1 CHECKING VOLTAGE AND SPEED FREQUENCY 50 Hz ae 19 4 Wire 110 220 120 240 121 242 99 198 Voltage Maximum No Load Minimum Full Load Speed Frequency Maximum No Load Speed r min Frequency Hz Minimum Full Load Speed r min Frequency Hz 132 264 108 216 FUEL SYSTEM GASOLINE The fuel system must be in good condition and prop erly adjusted for efficient generator set operation The main components of the fuel system are the air cleaner assembly carburetor choke intake mani fold fuel filter fuel pump and air preheater When servicing disassemble assemble and adjust as spec ified in the following sections Air Filter Assembly The air filter assembly consists of the air cleaner housing air filter air cleaner adapter and choke assembly see Figure 6 12 Disassembly Use the following procedures to remove and disassemble the air filter assembly 1
160. ue 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 stator o transformer Incorrect transformer connection CONDUIT ELBOW Corrective Action Remove part of load and replace circuit breaker Clear away all dirt or debris as required Clean stator windings Test each component for open grounded or shorted windings and replace if defective Refer to Transformer Voltage Adjustments section LZ TO TRANSFORMER GND OuTPur LOAD TO NEUTRALUWHITEY TO TRANSFORMER GRO GREEN TRANSFORMER ES 1557 1 FIGURE 8 4 VOLTAGE REGULATING TRANSFORMER 8 7 GENERATOR SERVICE This section covers generator disassembly and assembly procedures Refer to Figures 8 3 and 8 4 to locate and identify the various generator compo nents described in each sub section Generator Disassembly Use the following procedures to disassemble the generator 1 2 Drain the engine oil while the generator set is still mounted in the vehicie Remove the generator set from the vehicle and place it sturdy work bench Refer to the Set Removal Section 5 for the recommended set removal procedures Remove flywheel guard from scroll opening and the noise shield The carburetor and
161. uency are highest From this setting turn the main adjustment screw out an additional 1 4 turn 4 Remove the load and verify that frequency is within 62 51 5 1 hertz Adjust governor speed adjust ment nut if necessary to obtain required frequency 5 Turn the idle adjustment screw inward until volt ageand frequency drop and engine begins to run rough or starts hunting Back out idle adjustment screw as required for smoothest operation with out hunting 6 Pull the governor linkage toward the front of the set so that the throttle lever on the carburetor is resting against the throttle stop screw Adjust the stop screw to obtain a setting of 55 45 1 hertz 7 Release the governor linkage and observe the stability of the set Set the voltage and frequency and adjust the sensitivity of the governor as speci fied in Governor in this section Add and remove 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 usually a result of gummed up fuel passages or worn internal parts The most effec tive solution is a complete carburetor overhaul In general overhauling a carburetor consists of com plete disassembly a thorough cleaning and re placement of worn parts Carburetor repair kits are available that supply new gaskets and replacements for those parts most subject to wear General instructions for overhauli
162. ush block cover when test is complete Rotor Test The rotor can be tested for grounded open or shorted windings using an ohmmeter Figures 8 12 and 8 13 show the rotor removed from the generator for testing However itis possibleto testthe rotor without removing itfrom the generator To obtain access to the slip rings remove the brush block cover Use a stiff wire to hold the brushes off the slip rings during testing Refer to the Brushes and Slip Rings section for the procedures to use for inserting the wire Ground Test To test for grounds set the ohmmeter for the highest resistance scale Touch one test prod to the rotor shaft and hold it there Touch the other test prod to one of the slip rings A reading less than one megohm indicates the rotor is grounded Replace a grounded rotor with a new rotor 8 14 Redistribution or publication of this document by any means is strictly prohibited Table of Contents SECTION TITLE rs SAFETY PRECAUTIONS inside Front Cover 1 INTRODUCTION 1 1 About This Manual 1 1 Model HE 1 1 2 SPECIFICATIONS 2 1 3 DIMENSIONS AND CLEARANCES 3 1 4 TORQUE SPECIFICATIONS 4 1
163. ust be provided by the RV manufac turer A 3 4 inch conduit elbow is provided to facili tate installation The load wire conductors are black the neutral conductors are white and the ground conductor is green The exit point for the wiring har ness is near the voltage regulating transformer GENERATOR OPERATION Generator operation involves the conirol stator rotor voltage regulating transformer brushes and full wave bridge rectifier The schematic shown in Figure 8 1 is intended as an example to help follow the generator operating description Always refer to the specific schematic that corresponds to the model and spec number of the generator set when trouble shooting problems When the Start Run Stop button is placed in the Start position the rotating field rotor is momentarily connected to battery positive B to ensure ade quate residual magnetism for voltage build up As the engine starts and speed increases the rotating field induces a voltage build up in the stator windings A portion of the AC current generated in the stator windings is rectified to DC by the CR4 bridge recti fier The DC current is supplied to the rotating field windings to create the strong magnetic field required for generating the rated current The AC voltage build up stabilizes at approximately 128 volts when the engine reaches governed speed To prevent an excessive voltage drop when a load is applied to the generator a method for regulati
164. ve Action Refer to Generator section for testing and service procedures Replace contro PC board 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 ASSEMBLY CONTROL PANEL REAR VIEW START RUN STOP SWITCH STOP GND STRT CRS DIODE COMPONENT SIDE FIGURE 7 6 BGEL CONTROL PANEL ASSEMBLY 7 15 SC 1523 Redistribution or publication of this document by any means is strictly prohibited Section 8 Generator INTRODUCTION The BGE and BGEL generator sets have a 4 pole revolving field generator with transformer voltage regulation All AC load connections are made through long generator lead wires that connect directly to a customer supplied junction box A circuit breaker provides overcurrent protection for the generator and also functions as an on off switch in the load circuit GENERATOR DESCRIPTION The generator consists of the following major components e Stator and Housing Rotor Voltage Regulating Transfomer e Field Current Rectifier e Brushes e Wiring Harness Stator and Housing During generator set operation AC current is pro duced in the windings of the stator All stators have two AC output windings T1 T2 and T3 T4 for pow ering the load and a separate winding B1 B2 tor battery charging On 4 0 kilowatt sets
165. wires Faulty fuel system due to Refer to Fuel System sticking choke faulty fuel section for test and pump or carburetor mixture service procedures screws incorrectly adjusted Connect a voltmeter between Checkfor continuity and positive terminal on correct if circuit is coil and ground Check for open battery voltage when 1 is Replace control PC board placed in the Start position If the voltage is not present fault is due to a open circuit between coil and control b defective control PC board 7 5 Trouble Engine Starts But Stops When Start Switch is Released Engine Starts And Runs Then Stops Set Restarts immediately or Set Restarts After Cooling Down Low Battery TROUBLESHOOTING THE BGE CONTROL Possible Cause Low oil pressure switch not closing due to low oil level open circuit between switch and control defective low oil pressure switch low oil pressure Output voltage from generator not being supplied to control due to defective charge resistor open circuit in wiring between generator and control defective bridge rectifier nooutput voltage from generator Defective control PC board Fuel level is below generator set fuel pickup tube or oil level is low Faulty choke operation due to sticking choke linkage incorrect choke adjustment open circuit in wiring between choke heater generator or defective choke heater Vapor lock due to

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