Home

Service Manual

1. r220V L2 LOAD J6 P6 SEE NOTE GND 1 pay PES cei LI LOAD zi NOTES ls STANDARD OUTPUT IS 220V 2 WIRE WITH NEUTRAL GROUNDED FOR ISOLATED FLOATING NEUTRAL DISCONNECT P6 J6 AND CONNECT CI LEAD FROM CAPACITOR TO J6 NOT TO BE CONFUSED WITH CI TO P3 6 LEAD ALSO ON CAPACITOR 2 LI OR L2 LOAD LEADS CAN NOT BE GROUNDED VRI REGULATOR VOLTAGE TI IGNI COIL IGNITION s2 SWITCH LOW OIL LEVEL RI RESISTOR BATTERY CHARGE K2 SOL REGULATOR LP KI RELAY STARTER G2 MAGNETO IGNITION Gl GENERATOR Fl FUSE E2 FUEL PUMP FUEL SOL LP E SPARK PLUG CI CAPACITOR CRI RECTIFIER BRIDGE CBI CIRCUIT BREAKER AC OUTPUT BTI BATTERY 12V BI MOTOR STARTER AS REMOTE CONTROL STANDARD A2 REMOTE CONTROL DELUXE Al CONTROL ASSY ITEM PART NO suk 2 QTY DESCRIPTION OR MATERIAL 610 0384 FIGURE 12 5 WIRING SCHEMATIC 610 0384 12 6 Redistribution or publication of this document by any means is strictly prohibited A2 AS START START 220V AC Oe a 5 SEE NOTE 1 E 5 ala 3 EDO CES Z Sl L s pesed Pol E L L d P5 1 2 3 4 5 6 NA J5 1 2 3 4 5 6 JI 3 GND Or k a i KI P 2 Saca MOT m B
2. Printed in U S A Begin Spec C Model KV Spec A Models KVC 8 KVD 11 04 981 0518E Redistribution or publication of this document by any means is strictly prohibited 4 WARNING A The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING A Do not use this genset on a boat Such use may violate U S Coast Guard regulations and can result in severe personal injury or death from fire electrocution or carbon monoxide poisoning a 2 f s aasoline warnings Redistribution or publicatiorP Ot ints document by any means is strictly prohibited Table of Contents SECTION PAGE SAFETY PRECAUTIONS cc css rai Eee a Rs a des eee iij 1 INTRODUCTION a sE ORRUERINARERE RE RN R Sous Sane RN K R REN ER 1 1 2 SPECIFICATIONS iik res pardas ese a E ERE 2 1 3 CLEARANCES AND DIMENSIONS x3 2 EP ARR EXP ree 3 1 4 TORQUE SPECIFICATION i aei Een e Edo eR nne RC S idad io 4 1 5 PREPARING FOR SERVICE usina adds 5 1 Troubleshooting oia ee to is 5 1 Special TOOlS cies ke EE Sent OR EE WR HR RETE d ERROR RR EE RACE ERA 5 1 Safety Considerations in cicctassetedtasns pilose ak raa rea aA E RARE 5 2 Removing the Genset n 5 3 Reinstalling the Genset nh 5 8 6 TROUBLESHOOTING x S Zr e LEURS RE eee nc CHER CEPI n 6 1 Troubleshooting Control 00 ree 6 3 Troubleshooting Generator 2 0 0 cece ees 6 15
3. 5 6 Gasoline and LPG liquified pe troleum gas are flammable and explosive can cause severe personal injury or death Do not smoke Keep flames sparks pilot lights arc producing and switching equip ment and all other sources of ignition away from fuel tank and system and areas shar ing ventilation Have an ABC fire extin guisher handy For Gasoline fueled Gensets disconnect the fuel line from the genset and securely plug the end of the fuel line to prevent leakage or an ac cumulation of explosive gasoline vapor LPG is flammable and explo sive and can cause asphyxiation NFPA 58 Section 1 6 requires all persons handling LPG to be trained in proper handling and operating procedures LPG sinks and can accumulate in explo sive concentrations Before disconnecting the LPG fuel line close the fuel shutoff valve s at the LPG container s and move the vehicle outside and away from pits basements and other below grade spaces where LPG could accumulate For LPG fueled Gensets close the fuel shut off valve s at the LPG container s and move the vehicle outside and away from below grade spaces where LPG could accumulate To purge most of the LPG from the fuel line and genset run the genset if it starts until it runs out of fuel LPG container valve closed To purge some of the remaining LPG press the regulator prim er plunger Figure 8 23 on Page 8 19 and Fig ure 8 26 on Page 8 24 while cranking the en
4. Connecting rod and piston N O oO o nm Crankshaft and governor lever shaft LEAK DOWN TEST Perform the leak down test if performance problems or high oil consumption occur and poor compres sion is suspected Follow each of these steps and refer to the test equipment manufacturer s instruc tions 1 Start the engine and allow it to warm up for ten minutes If the engine will not start continue to the next step 2 Disconnect the battery negative cable to prevent accidental starting and remove the spark plug 3 Manually rotate the the engine in the direction of normal operation by turning the fan hub as sembly Stop turning the engine when it reach es top dead center T D C on the compression stroke T D C can be determined by 10 1 A Removing the head cover and observing the valve overlap on the compression stroke B Feeling compression air escaping the spark plug hole C Using a tester with a T D C indicator fea ture Connect the leak down tester to shop air and set calibration see Figure 10 1 Perform the leak down test according to the manufacturer s instructions Secure the fan wheel to prevent the piston from moving during this test Screw air fitting into spark plug hole Attach plug fitting to tester The tester needle indicates the percentage of cylinder leakdown The following describes the general condition of the engine 0 10 Percent leak down Excellent condit
5. Remove the genset as described in Removing the Genset p 5 3 1 Follow the Generator Disassembly procedure on Page 9 8 through the scroll assembly re moval 2 Inspect and clean the fan hub assembly using a brush or low pressure less than 30 psi com pressed air If the cooling fins are damaged re move the fan hub assembly as described in section 8 and replace the fan 3 Remove the top and bottom air guide housings cowling for access to the engine cooling fins for cleaning 4 Use a brush or low pressure compressed air to remove any dirt or debris that may be lodged on the engine cooling fins Assembly Cooling system assembly is in reverse order of dis assembly Follow the Generator Assembly proce dure on Page 9 10 installing the fan hub assembly if removed for cleaning or replacement On Model KVC gensets make sure all air sealing strips Figure 8 11 and the air seal panel Fig ure 8 9 are in place to prevent recirculation of cool ing air Overheating can result in engine damage To avoid overheating never operate the genset with the access cover or any of the cooling system parts removed 8 7 SEALING STRIPS SEALING STRIPS FIGURE 8 11 AIR SEALING STRIPS MODEL KVC Redistribution or publication of this document by any means is strictly prohibited IGNITION SYSTEM The ignition system consists of the magneto assem bly ignition coil spark plug and ignition wiring If a problem with th
6. START VOLTAGE RELAY K1 REGULATOR VR1 CAPACITOR C1 CIRCUIT BREAKER CB1 CONTROL ASSEMBLY A1 CONTROL BOX VIEW FROM BOTTOM COVER REMOVED FIGURE 6 2 COMPONENT LOCATIONS MODEL KVC 6 2 Redistribution or publication of this document by any means is strictly prohibited TROUBLESHOOTING CONTROL Figure 6 1 or 6 2 shows the location of the generator Use the following troubleshooting guide to help lo components Refer to the wiring diagram in Section cate problems related to the control 12 Wiring Diagrams for wiring connections Start Cranking Mode Battery positive B is supplied to the control assembly A1 through control fuse F1 Holding the Start Stop switch S1 in the Start position activates control assembly A1 by closing the start signal input circuit While the Start Stop switch is held the control assembly supplies the following outputs e Battery positive B is supplied to the start relay coil K1 This energizes the start relay The start relay con tacts close supplying battery positive B to the starter motor B1 The starter begins to crank the engine to initiate starting STA
7. specified limits but voltage is incorrect electronic voltage regulator is defective Loose brush holder 2 Worn rotor bearing Rotor and stator rubbing together due to a Varnish lumps b Rotor misaligned with crankshaft Generator overloaded due to defective circuit breaker Airflow restricted due to dirt or debris covering vent openings in stator housing Stator windings covered with oil or dirt Defective rotor or stator windings Loose or missing service access cover or improper seal around the endbell assembly Improper installation due to a Insufficient air inlet size b Air inlet location allowing recirculation Refer to governor adjustments Replace electronic voltage regulator Tighten brush holder Replace rotor bearing 9 13 Check for varnish lumps between rotor and stator remove as required Follow specified assembly procedures to correct rotor to crankshaft alignment Replace circuit breaker Do not exceed specified load when operating set Clear away all dirt or debris as required Clean stator windings Test each component for open grounded or shorted windings and replace if defective Check for proper fit of service access cover and check seal around endbell Make sure air inlet is not blocked and that it is properly sized refer to Installation Manual Make sure that air outlet is not blocked and check for recirculation of
8. Opening 78 58 70 before top dead center Valve Opening Closing 118 98 110 after bottom dead center Closing Timing when cool Exhaust Opening 118 98 110 after bottom dead center Closing 78 58 70 before top dead center Valve Spring Reference Value 1 299 1 319 33 0 33 5 Free Height Allowable Limit 1 287 32 7 Load and Height Reference Value 12 94 1b 0 8858 in 5 87 kgf 22 5 m Allowable Limit 11 64 Ib 0 8858 in 5 28 kgf 22 5 m Allowable Squareness Limit 0 0591 1 5 Valve Seat Valve Seat Angle Intake Exhaust Reference Valve 0 0394 0 0512 Valve Seat Width Allowable Limit 0 0591 3 1 Redistribution or publication of this document by any means is strictly prohibited INCHES MILLIMETERS Valve Lifter Outer Diameter Reference Value Clearance Between Valve Lifter and Guide Camshaft Standard Journal Diameter Clearance Between Camshaft Journal Bearing Flywheel Side Allowable Limit Intake Reference Value Exhaust Cam Height Allowable Limit Exhaust Allowable Side Clearance Limit Bending Limit Timing Gear Backlash Cylinder Reference Value Inner Diameter Allowable Limit Minimum Clearance Between Cylinder and Piston Piston Outer Diameter Skirt Diameter Piston Ring Gap Reference Value Allowable Limit Clearance Between Ring and Ring Groove Reference Limit Allowable Limit 0 0014 0 0030 0 035 0 075 0 5892 0 5899 14 966 14 984 0 0006 0 0020 0 016 0 052
9. 282 El PI I e ac b HW H e EA Ce EE e Eo amp AA TN 63H Hip GE m S 2 T a E 5 START SOL OUTPUT 5 PI 3 o E IGN ENABLE OUTPUT 7 pesto El a L S E a d Q BATTERY GND INPUT S a A PI 7 Y Y z EI ee E TI IGN gt CI VRI ELSE BI PS x2 o 94 67 dio B2 ree xi z4 2 bs be oF 3 06 99 012 T2 Q2 TI ei e gt 1 CBI Li LOAD 220V L2 GND 12 4 Redistribution or publication of this document by any means is strictly prohibited START START G2 DS y 2 m z DN 220V AC i 5 a ie th i 2 i 3 6 DHHG 3 D 835 OOO o Q E E X fd TI IGN a pol L L L 3 P3 10 P3 9 P5 1213 1516 NY J5 112 4 5 6 PANY SE JI 3 GND E e ko 4s CRI AC 2 QS KI pu CBI LINE OA OT BTI tL v y l N GND 4 Bl Fl m P3 12 a E2 P3 11 N JI Z4 CB I LOAD Z4 GND GI T2 a _ 9 q 2 TE L2 gt al 3 6 I us ERI JI 7 GND I Ha Z4 E me Pig NP GND pa Ja RI KI 1 2 VRI IREGULATOR VOLTAGE oF TI IGN COIL IGNITION EL s2 S2 SWITCH LOW OIL LEVEL E RI RESISTOR BATTERY CHARGE JI 4 as K2 SOL REGULATOR LP KI RELAY STARTER CBI G2 MAGNETO IGNITION LA Sen GI GENERATOR ul LINE FI FUSE E2 FUEL PUMP FUEL SOL LP El SPARK PLUG P G2 2 T e CI CAPACITOR T El CRI RECTIFIER BRIDGE 62 1 li c CBI CIRCUIT BREAKER AC OUTPUT L ES BTI BATTE
10. 5 Install float bowl and main mixture screw as sembly Turn screw in until lightly seated and then turn out the number of turns specified in Table 8 2 Forcing the mixture adjustment screws tight will damage the needle and seat Turn in only until light tension can be felt When carburetor is installed on genset make final adjustments to mixture screws as de scribed in Carburetor Mixture Screw Adjust ments Page 8 16 Choke Assembly The genset has an automatic choke assembly that consists of a bimetal choke coil coil housing mounted on the exhaust tube and choke linkage The choke linkage connects to the choke shaft lever on the carburetor When the engine is cold the choke coil position causes the linkage to hold the choke nearly closed When the engine starts hot air from the exhaust manifold enters the coil housing The choke coil ex pands pulling the linkage to partially open the choke As the engine warms up the coil continues to expand and gradually opens the choke and holds it open while the engine is operating This action varies the fuel air mixture as the engine warms up to provide smooth engine operation If the engine starts but runs rough and exhausts black smoke after a minute or two of operation the choke setting is too rich If the engine starts but sput ters or stops before it warms up the choke setting is too lean The choke housing becomes very hot during operation and can cause severe bur
11. 61 01 5 Z1 CRI AC I Bic arre Ja LT EC el zi VRI imm a a P3 7 J2 3 S MEE Y S Gr i eae OF Hie Su R ue P5 6 E L i E care AN os pole o o ol H END tos 6 9 12 o o o o S ET Emu 15 SN R os yo GND ci Vs P E qp or cis PS a degere Ga E HET El GI Q2 PI JI RES FIGURE 12 2 WIRING DIAGRAM 610 0382 12 3 Redistribution or publication of this document by any means is strictly prohibited VRI REGULATOR VOLTAGE TI IN COIL IGNITION S2 SWITCH LOW OIL LEVEL R RESISTOR BATTERY CHARGE K2 SOL REGULATOR LP K RELAY STARTER G2 AGNETO IGNITION G GENERATOR F FUSE E2 FUEL PUMP FUEL SOL LP E SPARK PLUG CI CAPACITOR CRI RECTIFIER BRIDGE CBI CIRCUIT BREAKER AC OUTPUT BTI BATTERY 12V B OTOR STARTER AS REMOTE CONTROL STANDARD A2 REMOTE CONTROL DELUXE A CONTROL ASSY ITEM DESCRIPTION FIGURE 12 3 WIRING SCHEMATIC 610 0383 ll Ht Ri BTI gt A2 A3 Ey x f A CRI START KI BI FOR DO ap z LU 5 ooob SF E hs gt 2 pues PL AXA A KU TT Al n og BATTERY INPUT OA 3 PI 4 aaa 3 s2 Ez GE Z FUEL PUMP OUTPUT
12. BATTERY 12V MOTOR STARTER REMOTE CONTROL STANDARD REMOTE CONTROL DELUXE CONTROL ASSY FIGURE 12 13 WIRING SCHEMATIC 610 0396 50 HZ KVC 12 14 Redistribution or publication of this document by any means is strictly prohibited AZ A3 START START G2 Ot N T z 1 Ka 7 2 600660 JO OOG T1 IGN P3 10 P3 9 P5 BIC Der v JS BIC rE bp AVP J 3 100V AC 324 A S la o R 8 G1 S J2 2 K Q2 au Pe r ii AN fo 1 TA T2 BT1 2 cm B1 E CB1 LINE L E2 GND Wa P3 12 CB1 LOAD past K4 3 7 GND GND PA S2 zi p A i 2F1 ka T1 Ji 4 G2 2 5 ee 4 e CB1 3 B m G1 T1 1 L LINE p3 2 J2 12 P4 a 3 4 1 1 2 E379 61 01 41 1 3 S Gt F S G2 1 VR1 a K S2 C1 Z1 o o o J2 4 o o o I A1 P3 8 ren P2 J4 G1 B2 J3 E TH G1 81 mies JE SI A 21 G1 F E T x 32 Es Emm G1 02 S s Z2 z2 s 5 5 N E2 a i S Z3 10 os 61 80 23 apt s h 20 07 Lo 10 ad z3 z2 z io sa Pa sess A A
13. E E A R E2 i l H Z3 APIS in 1o os L oA oH 20 07 270 80D _ _ 73 22 S so o 7 l PSC io fioi Pa sof PB A A he z J1 rt P1 KTS M1 FIGURE 12 12 WIRING DIAGRAM 610 0395 60 HZ KVC 12 13 Redistribution or publication of this document by any means is strictly prohibited BT1 A2 A3 fac i AAT CUNT START K1 B1 m M1 a 1 2 0606 LA a Vw RAN s e i Z KY oz Ob o5 BATTERY 95 2 2 INPUT Pie 252 8 S2 K Z oO P FUEL PUMA E N E 2 OUTPUT e il B 62 5 START sol E OUTPUT P1 3 8 e a IGN ENABLE OUTPUT P2 4 xi gt gt gt 5 gt BATTERY Zo z do GND INPUT P1 7 5 8 E o KI amp a E1 e e 3t 3 E WALK em 12 T1 3 F C1 VR1 B AV FE R2 B1 P3 as is 07 d o2 s vs o 72 03 06 09 T1 N CB1 L1 LOAD 100V 2 NEUT GND B1 A3 A2 A1 REGU TRAN COIL LATOR VOLTAGE SFORMER STEPUP GNITION SWITCH LOW OIL LEVEL RESISTOR ASSY FIXED METER TIME TOTALIZING SOL REGULATOR LP RELAY STARTER MAGNET O IGNITION GENERATOR FUSE FUEL PUMP FUEL SOL LP SPARK PLUG CAPACITOR CIRCUIT BREAKER AC OUTPUT
14. El SPARK PLUG C1 CAPACITOR CB1 CIRCUIT BREAK BT1 BATTERY 12V B1 MOTOR STARTER A3 REMOTE CONTROL STANDARD AZ REMOTE CONTROL DELUXE A1 CONTROL ASSY FIGURE 12 11 WIRING SCHEMATIC 610 0395 60 HZ KVC 12 12 Redistribution or publication of this document by any means is strictly prohibited gt N o lt gt M START START G2 fe Y G n 06060 0 O0 L T1 IGN P3 10 P3 9 P5 A Ic p E F v Y A BICJD E F SMA ES J5 Fe F 34123 J2 1 81 o E la x E i 2 G1 6 jZ Ja T J2 2 B2 Q2 a le 9 a io K1 OT E i SS for gt n 12 BT1 B1 A F4 CB1 LINE E GND 7 PE P3 12 CB1 LOAD a Ka nc GND GND m S2 z1 1 E 2 1 K1 1 T1 Jt 4 NER S G2 2 e Ex E1 l CB1 DLA Gen f L1 LINE 65 2 P3 6 oo 61 01 G1 F G2 1 TEX VR1 E z J2 3 C1 Z 1 os 67 be o o o o J2 4 CB1 LINE a a csse yy o7 93 9 S i GND P3 8 3 96 o ov o o o o A1 TE i P2 J2 G1 B2 ct P3 J3 BE G1 B1 Ch gt gt G1 F ATP2 J w 6 z1 La m P3 7 1 G1 02 o 4 a 5 Z2 Z2
15. F1 L e 2 fem i A1 i 1 z o o5 E Pra Rel g 3 S2 5 3 0 3 Pr FUEL pure OUTPUT st 9 gt gt G S 5 5 9 1 7 BATTERY GND INPUT 89 zo to E1 ee E T1 IGN SE veri REGULATOR VOLTAGE C1 Teg COIL IGNITION S2 SWITCH LOW OIL LEVEL zi B VR1 2 E 2 SOL REGULATOR LP i RELAY STARTER P3 G2 MAGNETO IGNITION lod C4 GENERATOR r4 FUSE a l l i gt FUEL PUMP FUEL SOL LP l T 9 wa E4 SPARK PLUG C1 CAPACITOR CB4 CIRCUIT BREAKER AC OUTPUT 871 BATTERY 72V B MOTOR STARTER A3 REMOTE CONTROL STANDARD pu A2 REMOTE CONTROL DELUXE CB1 L1 LOAD NM A1 CONTROL ASSY L2 NEUT ITEM DESCRIPTION OR MATERIAL GND 4 FIGURE 12 7 WIRING SCHEMATIC 610 0388 60 HZ BEGIN SPEC F 12 8 Redistribution or publication of this document by any means is strictly prohibited P5 A s c pIE F J5 L 4 BSIc pIEIF 313 120V AC e NE KA z uo Y 628 KZ E SA d Su K1 ix 1 len OT he aL 1 EN BT1 B4 B F1 E2 J1 1 CB1 LOAD G1 T2 L2 K1 CR1 11 7 GND SIS P3 3 GND F1 2 1 K1 1 ye CB1 BIH L LINE 2377 P3 6 G2 1
16. Use the highest ohm meter scale if not using a megger Touch one test prod to the generator housing or stack if removed Touch the other test prod see Figure 9 6 to the ter minals specified in Table 9 2 A resistance of less than 1 megohm indicates a grounded winding Re place a grounded stator with a new stator Tests for Open Windings To test for open wind ings set the ohmmeter for the highest resistance scale and then connect the test prods see Figure 9 6 to the terminals specified in Table 9 3 The ohmmeter should indicate continuity between ter minals A high resistance reading indicates an open winding If an open circuit is measured replace the stator Tests for Shorted Windings To test for shorted windings use a digital type ohmmeter that reads to within 0 01 ohms Connect the test prods to the ter minals specified in Table 9 3 A reading of less than the value shown in Table 9 3 at 77 F 25 C indi cates a shorted winding If stator tests indicate a shorted winding replace the stator If stator tests good check jumper leads X1 X2 X8 X4 and X5 X6 for continuity and for good elec trical connection with the stator terminals Also check remaining stator wire connections for conti nuity and good electrical contact with stator 9 7 TABLE 9 2 STATOR GROUND TESTS OHMMETER TEST LEAD LOCATION READING T1 to Ground T2 to Ground B1 to Ground Infinity Infinity Infinity Infinity Infinity Infin
17. gine for 10 seconds Disconnect the fuel line from the genset and plug the end of the hose to prevent fuel from escaping if someone inadver tently opens the shutoff valve s at the LPG container s Redistribution or publication of this document by any means is strictly prohibited The genset is heavy and can result n severe personal injury if dropped during re moval Use the recommended removal tech niques and keep hands and feet clear while re moving mounting bolts Removing Model KVC from RV Remove the air seal panel Figure 5 3 and make sure to support the genset while removing the four mounting bolts Then lower the genset until it clears the skirt of the vehicle It may be necessary to tip the genset and pull it forward slightly to free the back edge from resting on top of the vehicle frame Removing Compartment Mounted Set from RV When the genset has been disconnected from the electrical exhaust and fuel systems examine the genset mounting and support system Locate all mounting bolts and support members for the gen set In most installations the genset housing will be bolted to the coach framework Depending on the installation the genset may be removable from the side back or bottom Verify that the genset is adequately supported be fore loosening any of the mounting bolts or support members The most satisfactory way to lift or move the genset is to use a forklift truck 5 7 Removing Under floo
18. 12 1 WIRING SCHEMATIC 610 0382 12 2 Redistribution or publication of this document by any means is strictly prohibited TI IGN pa f Eel E d L L La P3 10 P3 9 P5 Ile NA deBlsTe KA Ka ges J5 Ex Ji 3 120V AC E CRI AC I B al 5 2 GI o e l6 2 12 3 rit AM E ST o CRI AC 2 B2 02 E KI i P TR O 4 y y TI T2 BTI NE BI i FI CBI LINE P4 n E2 GND d Sid P3 12 P3 11 CB I LOAD GI T2 x 9 a 8 KI I o S 3 e JI 7 E NL GND T pa Ja RI VRI REGULATOR VOLTAGE Ki 2 TI IN COIL IGNITION FI S2 SWITCH LOW OIL LEVEL y o kii so RI RESISTOR BATTERY CHARGE 2 SOL REGULATOR LP JI 4 m Yer RELAY STARTER 7 G2 MAGNETO IGNITION CBI G GENERATOR SP BE FI FUSE LINE px E2 FUEL PUMP FUEL SOL LP EI SPARK PLUG CI CAPACITOR P3 6 ES S N e CRI RECTIFIER BRIDGE EI CBI CIRCUIT BREAKER AC OUTPUT ES BTI BATTERY 12V a B MOTOR STARTER CI ZI A3 REMOTE CONTROL STANDARD i J2 4 A2 REMOTE CONTROL DELUXE be Ein l Al CONTROL ASSY Al E TI IGN ITEM DESCRIPTION P2 J2 ERISACES
19. 30 inches WC Set the adjusting screw locknut and test lock off pressure again Repeat the procedure if necessary If the lock off pressure is less than 0 10 inches WC loosen the lock nut on the lock off adjusting screw and turn in the screw clockwise until the lock off pressure falls 8 23 between 0 10 and 0 30 inches WC Set the adjusting screw locknut and test lock off pressure again Repeat the procedure if necessary Replace the demand regulator if it contin ues to leak after lock off pressure adjust ments have been attempted Priming Solenoid Prior to Spec L on Model KV or Spec B on Model KVD Priming Solenoid Test Upon completing the lock off pressure test energize the priming solenoid by connecting battery positive to the orange lead and battery negative to the green lead Replace the regulator assembly if the priming solenoid does not cause the regulator to open Priming Solenoid Adjustment See Figure 8 25 If the genset does not start when it is hot rotate the dial 1 4 turn counterclockwise the fuel mixture could be too rich If the genset does not start when it is at ambient temperature rotate the dial 1 4 turn clockwise the fuel mixture could be too lean RED PLASTIC DIAL Adjust the primer solenoid by holding on to the metal disk and rotating the red dial For recommended setting turn the dial all the way in cw and then out ccw 1 1 2 turns DO NOT CONTINUE TO ROTATE DIAL ONCE
20. 5 Hz 52 0 5 on 50 Hz units 8 25 Adjust governor speed adjustment nut if neces sary to obtain required frequency Turn the idle adjustment screw inward until volt age and frequency drops and engine begins to run rough or starts hunting Back out idle ad justment screw until engine runs smoothly with out hunting If a CO meter is available follow the manufacturer s instructions for use and ad just the idle mixture screw to obtain 4 to 6 per cent CO Turn the governor speed adjustment screw counterclockwise until the speed is lt 50 Hz so that the throttle lever on the carburetor is rest ing against the throttle stop screw Adjust the stop screw to obtain a setting of 55 1 Hz 45 1 Hz on 50 Hz units Readjust the governor speed screw so that the frequency is within 62 5 0 5 hertz 52 0 0 5 hz on 50 hertz units Adjust the sensitivity of the governor as specified in Governor on Page 8 11 Add and remove a half load several times to make certain the genset does not bog down or hunt THROTTLE STOP SCREW MAIN ADJUSTMENT SCREW IDLE ADJUSTMENT SCREW M 1878 FIGURE 8 28 LPG CARBURETOR ADJUSTMENTS PRIOR TO SPEC E MODEL KV Redistribution or publication of this document by any means is strictly prohibited Carburetor problems not corrected by mixture ad justments may be caused by dirt in fuel passages or worn internal parts Under normal conditions the carburetor should seldom
21. 61 01 R LI SE 74 G1 F J2 4 2 3 VRI A1 Fag o 94 67 de o o o o Re P29 61 82 a NM NES i v G1 B1 BNO ies MARS o o o o S EN ct P3 J3 d m P3 7 5 Cts g y IZ E G1 F Por 61 02 uM N E E2 m E E lt i TEES d aol P5 A o API o h 20 07 2 x GD ES 30 o6 so PS B o os qa so PSB P1 J1 El KI S FIGURE 12 10 WIRING DIAGRAM 610 0389 50 HZ BEGIN SPEC F 12 11 Redistribution or publication of this document by any means is strictly prohibited Ile BT1 5d B1 M1 0006 NY AN WE T HE SA 95 of o5 5 Pts BATTERY INPUT T E 32 R S i El P1 1 FUEL PUMP OUTPUT T a KA E l E 2 P13 BTART SOL OUTPUT 5 AI 3 P2 4 GN ENABLE OUTPUT OD 50 A A i P1 7 BATTERY GND INPUT i E E ep l Ll el ET ee Bl T1 VR1 fs AWE P3 07 A ve og L1 LOAD 120V L2 NEUT GND L PUMP FUEL SOL LP ER AC OUTPUT M1 METER TIME TOTALIZING VR1 REGULATOR VOLTAGE T1 COIL IGNITION S2 SWITCH LOW OIL LEVEL K2 SOL REGULATOR LP K1 RELAY STARTER G2 MAGNETO IGNITION G1 GENERATOR F1 FUSE E2 FUE
22. 8 9 or 8 10 Cooling air can contain poisonous exhaust gases that can result in severe personal injury or death Never use discharged cooling air to heat the vehicle interior The generator housing air inlet is sized to allow the required flow rate of cooling air The air inlet opening must be kept free of any obstructions to avoid re stricting airflow Dirt dust or other debris that may clog the air duct openings should be removed dur ing periodic maintenance Dirt might also become lodged between the cooling fins on the engine block and cylinder head If this happens heat transfer is greatly reduced and overheating can occur if the fins are not cleaned The cooling system consists of the genset housing and base assembly enclosure insulation duct scroll assembly fan hub assembly air duct and air guide The following section covers service proce dures for the cooling system Inspection Remove the spark plug boot and inspect the engine cooling fins by viewing the area around the spark plug If the engine is clean in this area and the air in let area is clean disassembly for cleaning the en gine will not be necessary If debris is visible in the area of the spark plug or at the air inlet area pro ceed to the Disassembly section following 8 6 AIR SEAL PANEL FIGURE 8 10 MODEL KVD COOLING AIRFLOW Redistribution or publication of this document by any means is strictly prohibited Disassembly
23. B2 windings and cause the Running Time meter to operate when the genset is off Resistor R1 Spec C E Model KV The battery charge resistor can be checked with an ohmmeter Disconnect the leads from the resistor and measure the resistance between terminals on one end to the resistor and the terminals on the oth er end Figure 7 1 The resistor should measure between 4 and 6 ohms If an abnormal reading is measured replace the resistor 7 7 BRIDGE RECTIFIER CR1 AC BRIDGE RECTIFIER SCHEMATIC ES2015s FIGURE 7 5 DIODE BRIDGE CR1 CHECK Redistribution or publication of this document by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited 8 Engine Primary Systems The engine primary systems include the following e Exhaust System Cooling System gnition System e Crankcase Ventilation Governor Gasoline Fuel System or e LPG Fuel System Electric Starter The engine primary systems can often be serviced without removing the genset from the recreational vehicle and without major genset disassembly Use Section 6 Troubleshooting to help locate problems related to the engine primary systems EXHAUST SYSTEM The exhaust system consists of the muffler and muf fler support brackets tail pipe clamps and hangers needed for installation of the tail pipe Figures 8 1 8 2 and 8 3 show typical exhaust systems E
24. M E m j P1 J1 K1 S M1 FIGURE 12 14 WIRING DIAGRAM 610 0396 50 HZ KVC 12 15 Redistribution or publication of this document by any means is strictly prohibited SbEb S39 JILVWAHIS ne UND T noz AN 1 D GVO 1I 182 SP l l NE m ao oro I Ed I LA i Me 13 Hc l 9 NOI L 1 I l IE e e 13 d 1ndino STBVN3 NO v Zd 2 I an E I En I LL i J i E 2 31 Q zb wo d I ES l dl e Ld NOQG i 17 i i 3 RG 69 1 Lg Tavis l a ab e soe ee I EV ZW L19 AV3DVIO DNISIM S A m LE ld me jroo 5 S t 90 oe y ze mam tt A we so os a gt z019 23 S G Sd E 35 FER odd a 5 E er 35 35 te uas o o o 1 EE ES a ONS wots ERT ed gt MS C e Ed S x Ezr van 59 13 IVIN3LVA YO NOLLAINOS30 Wall UU m Dl 10419 ASSY OMINO2 Lv a LO 3Xn 13d
25. No load 0 16 gph 0 6 I h 0 16 gph 0 6 I h 0 16 gph 0 6 I h 1 0 Ibs h 0 44 kg h 0 9 Ibs h 0 40 kg h Half load 0 28 gph 1 1 I h 0 23 gph 0 9 I h 0 23 gph 0 9 I h 1 5 Ibs h 0 68 kg h 1 3 Ibs h 0 59 kg h Full load 0 46 gph 1 7 I h 0 32 gph 1 2 I h 0 32 gph 1 2 1 h 2 5 Ibs h 1 1 kg h 2 1 Ibs h 0 92 kg h ENGINE 1 Cylinder 4 Cycle Spark Ignited OHV Air Cooled 2 64 inch 67 mm 2 64 inch 67 mm 2 2 inch 56 mm 2 2 inch 56 mm 12 inch 197 cc 12 inch3 197 cc Compression Oil Capacity 1 quart 0 95 I 1 quart 0 95 I Intake Valve Clearance Cold 0 002 inch 0 05 mm 0 002 inch 0 05 mm Exhaust Valve Clearance Cold 0 002 inch 0 05 mm 0 002 inch 0 05 mm Spark Plug Gap 0 025 inch 0 64 mm 0 020 inch 0 51 mm Spark Plug z 1b 17 hm 1 bt 17 hm Ignition Timing magneto type 25 BTDC non adjustable 25 BTDC non adjustable ignition LPG Vapor Sup 9 to 13 inch 229 to 330 mm ply Pressure W C water column DC SYSTEM Nominal Battery Min Battery Cold Cranking Capac 360 amperes 360 amperes ity 60 Hertz models are Listed by CSA and the U S Testing Company See Periodic Maintenance in the Operator s Manual for oil filling instructions 2 1 Redistribution or publication of this document by any means is strictly prohibited GENERATOR 2 Pole Revolving Field Self Excited 1 Phase Electronically Regulated No load 0 16 gph 0 6 l h 0 1
26. Operation in this Control Assembly A1 section and become familiar with the component Optional Remote Start Stop Control A2 A3 locations shown in Figure 7 1 Battery Charge Resistor R1 CONTROL DESCRIPTION e Rectifier Bridge CR1 The control circuitry consists of the following com Wiring Hamess ponents Hour Meter M1 Model KVC BATTERY CHARGE RESISTOR R1 SPEC C E BRIDGE RECTIFIER CR1 SPEC C E g ARP START STOP Miis S1 CONTROL PANEL CONTROL START RELAY K1 ASSEMBLY A1 M1899 4s FIGURE 7 1 CONTROL COMPONENT LOCATIONS MODELS KV AND KVD 7 1 Redistribution or publication of this document by any means is strictly prohibited CONTROL BOX COVER FUEL PUMP E2 FUSE F1 IS BUNDLED IN WIRE HARNESS NOT SHOWN HOUR METER M1 SPARK PLUG IGNITION COIL T1 AN START STOP SWITCH S1 START VOLTAGE RELAY K1 REGULATOR VR1 CAPACITOR C1 CIRCUIT BREAKER CB1 CONTROL ASSEMBLY A1 CONTROL BOX VIEW FROM BOTTOM COVER REMOVED FIGURE 7 2 CONTROL COMPONENT LOCATIONS MODEL KVC 7 2 Redistribution or publication of this document by any
27. RESISTANCE IS FELT OR THE DIAL COULD BE DAMAGED FIGURE 8 25 AUTOMATIC PRIMING SOLENOID Redistribution or publication of this document by any means is strictly prohibited Fuel Shutoff Solenoid Valve Leak Test See Figure 8 26 If there is a smell of gas when the genset is not running or any other reason to suspect that the valve is leaking connect the inlet of the valve to a source of air pressure regulated to not more than 14 inches WC and disconnect the outlet hose Replace the solenoid if it leaks as checked by a soap bubble Operation Test If the genset cranks but does not start first see Section 6 Troubleshooting deter mine whether or not the valve is opening With the source of air still connected energize the valve by connecting battery positive to the top terminal and battery negative to the grounded terminal Replace the solenoid valve if it does not open when it is energized LPG Carburetor Begin Spec E Model KV and Spec A Model KVD See Figure 8 27 An LPG carburetor is not likely to cause problems and should be replaced only after all other causes have been eliminated see Section 6 Troubleshooting It is not necessary to adjust fuel mixture These carburetors are calibrated at the fac tory and the adjustments are sealed A throttle stop screw is provided for adjusting the closed position of the throttle plate to obtain proper governor response when loads are being discon nected
28. SOLENOID Redistribution or publication of this document by any means is strictly prohibited 4 Attach a soap bubble to the end of the LPG sup ply hose which was disconnected from the car buretor While reading the pressure indicated by the manometer and watching the soap bubble blow lightly into the hose being used to pressurize the regulator Regulator lock off pressure is the minimum pressure that will cause air to flow through the regulator as indi cated by the expanding soap bubble At first the soap bubble may expand due to diaphragm movement but will stop expanding if air is not flowing through the regulator If this is a bench test of the regu lator make sure the diaphragm is in a verti cal plane as in the genset otherwise the weight of the diaphragm will cause erro neous readings of lock off pressure Beginning Spec L on Model KY and Spec B on Model KVD Replace the demand regula tor assembly if the lock off pressure does not fall between 0 05 and 0 42 inches WC For Specs E through K on Model KV and Spec A on Model KVD Replace the demand regulator assembly if the lock off pressure does not fall between 0 10 and 0 30 inches WC For Gensets Prior to Spec E Adjust lock off pressure as follows e f the lock off pressure is greater than 0 30 inches WC loosen the lock nut on the lock off adjusting screw and back out the screw counterclockwise until the lock off pres sure falls between 0 10 and 0
29. Troubleshooting Engine Primary Systems 0 00 cece eee eee eee 6 18 Z CONIBOL 20 aana cux pO red RR Ree a Fi nexu E QR me pac e args 7 1 Control Description seri arre PEOR RC RR eie SR Rude R Hamid 7 1 Control Operation uuu sec rex RE dax REOR S MERE d REPRISE eee 7 4 Control Component Tests eene 7 5 8 ENGINE PRIMARY SYSTEMS sino a 8 1 Exhaust System e cocidas toiias ia papal 8 1 Cooling System ces sisi eo e aa 8 6 Ignition SISTE EET 8 8 Crankcase Ventilation cia a RR a a 8 10 E II e 8 11 Gasoline Fuel System casi E NE 8 13 LPG Fuel SVSICN i lt cs RX xis E nO aia A TAR 8 21 Electric SIAM ica as a di 8 26 Redistribution or publication of this document by any means is strictly prohibited SECTION PAGE 9J ENERGIE PER 9 1 Generator Description a e ee Pia Rs 9 1 Generator Operation gessisset aot repe es re eee NET Eaque EE 9 2 Voltage Regulator Tests eese 9 3 Field Voltage Tests 2 or a dne Nas 9 4 Generator Tests cns S ette oed qe qux e Cas RODA dU T RE CAR BUE RO Ente oe 9 4 Generator Sence Letal da P Uu bau tubus teat b ode 9 8 Brushes and Slip BIngsu s ooa teu eg ite teak eee moron urs 9 12 Rotor Bearing Replacement x oy ex EROR x a nas RON E x is x d 9 13 10 ENGINE BLOCK ASSEMBLY Gy p 3x RR ERES EE TAA ERE 10 1 INTOJUCHON rr 10 1 Leak DOWN Tests Loeb sem ku ERR oa 10 1 Oil Pan and Oil Level Switch mien relevo OR e ERU Reate ede tied 10 2 Head Coven acdc cay e rex irera ien
30. charger or other automatic starting device before servicing the genset Do not wear loose clothing or jewelry near mov ing parts such as PTO shafts fans belts and pulleys Keep hands away from moving parts Keep guards in place over fans belts pulleys and other moving parts Redistribution or publication of this document by any means is strictly prohibited 1 Introduction This is the service manual for the KV KVC KVD se ries of generator sets gensets Read and carefully observe all of the instructions and safety precau tions in this manual MODEL KV KVD Improper service or parts replace ment can lead to severe personal injury or death and to damage to equipment and property Ser vice personnel must be qualified to perform electrical and mechanical service Unauthorized modifications or re placement of fuel exhaust air intake or speed control system components that affect engine emissions are prohibited by law in the State of California IMPORTANT ENGINE INFORMATION K lalaa GENERATION ses x r ve AWARNING LPG liquified petroleum gas is o Minneapolis MN 55432 flammable and explosive and can cause as Makes P dion phyxiation NFPA 58 Section 1 6 requires all ie Vda WE i persons handling LPG to be trained in proper H pe Bri handling and operating procedures Fuel Hz Bat Options Wiring Diagram See the Operator s Manual for instructions concern ing operation maintenance and stora
31. flammable liquid fuels and gaseous fuels Class C fires live electrical equipment ref NFPA No 10 Genset installation and operation must comply with all applicable local state and federal codes and regulations GENERATOR VOLTAGE IS DEADLY Disable the automatic genset starting feature of an inverter charger or other automatic starting device before servicing the genset Generator electrical output connections must be made by a trained and experienced electri cian in accordance with applicable codes The genset must not be connected to shore power or to any other source of electrical pow er Back feed to shore power can cause electric shock resulting in severe personal injury or death and damage to equipment An approved switching device must be used to prevent inter connections Use caution when working on live electrical equipment Remove jewelry make sure cloth ing and shoes are dry stand on a dry wooden platform or rubber insulating mat and use tools with insulated handles Redistribution or publication of this document by any means is strictly prohibited ENGINE EXHAUST IS DEADLY s Inspect for exhaust leaks at every startup and after every eight hours of running Learn the symptoms of carbon monoxide poi soning in this manual Never sleep in the vehicle while the genset is running unless the vehicle is equipped with a working carbon monoxide detector Make sure there is ample fresh air when
32. follow the trou bleshooting procedures in Section 6 Troubleshoot ing The troubleshooting section has been divided into the following sections e Control Page 6 3 Generator Page 6 15 s Engine Primary Systems Page 6 18 Each troubleshooting section lists typical problems along with possible causes and corrective actions Note that some problems might have several pos sible causes It may be necessary to investigate several possible causes in order to isolate the actual source of the problem SPECIAL TOOLS The following special tools are required to service the genset Some of these tools may be purchased from Onan distributors see Onan Tool Catalog 900 0019 or from other suppliers Engine Tools Torque wrench 0 100 Ft Lbs or 0 130 Nem Feeler gauge 5 1 Leak down tester Pressure gauge Spark plug gap gauge Flywheel puller Gear separator Cylinder ridge reamer Piston ring compressor Piston ring spreader Cylinder hone Valve seat cutter Wire brush Piston groove cleaner Outside micrometer set 0 to 4 in Telescoping gauge set 1 2 in to 6 in Hole gauge 0 300 in to 0 400 in Generator and Control Tools Lead or dead blow hammer Battery hydrometer VOM multi tester Frequency Meter Armature growler Load test panel Jumper wires Fan hub assembly holding tool Redistribution or publication of this document by any means is strictly prohibited SAFETY CONSIDERATIONS Always con
33. gen set compartment and verify that there are no breaks or openings in the vapor proof wall that separates the compartment from the vehicle interior Seal openings as required Make sure that all sound proofing material is in place Redistribution or publication of this document by any means is strictly prohibited 12 Wiring Diagrams DRAWING NO DESCRIPTION PAGE 610 0382 Model KV Wiring Schematic 60 Hertz SPEC C E nrnna 12 2 610 0382 Model KV Wiring Diagram 60 Hertz SPEC CE 12 3 610 0383 Model KV Wiring Schematic 50 Hertz SPEC C E annan 12 4 610 0383 Model KV Wiring Diagram 50 Hertz SPEC CE 12 5 610 0384 Model KV Wiring Schematic 50 Hertz Isolated Ground SPEC C E 12 6 610 0384 Model KV Wiring Diagram 50 Hertz Isolated Ground SPEC C E 12 7 610 0388 Model KV Wiring Schematic 60 Hertz Begin Spec F 12 8 610 0388 Model KV Wiring Diagram 60 Hertz Begin Spec F LLuuuuuue 12 9 610 0389 Model KV Wiring Schematic 50 Hertz Begin Spec F 12 10 610 0389 Model KV Wiring Diagram 50 Hertz Begin Spec F iuuuuuuue 12 11 610 0395 Model KVC Wiring Schematic 60 Hertz 12 12 610 0395 Model KVC Wiring Diagram 60 Hertz 0 0 e eee eee 12 13 610 0396 Model KVC Wiring Schematic 50 Hertz 12 14 610 0396 Model KVC Wir
34. genset and apply a full load Verify that the frequency is within 60 5 1 Hz 50 0 1 Hz on 50 Hz gensets and adjust the governor speed adjustment screw Figure 8 14 if neces sary to obtain required frequency 8 16 3 Turn the main adjustment screw inward until voltage or frequency drop again Locate the point where the voltage and frequency are highest From this setting turn the main adjust ment screw out an additional 1 4 turn 4 Remove the load and verify that frequency is within 62 5 0 5 Hz 52 0 0 5 Hz on 50 Hz gen sets Adjust governor speed adjustment screw if necessary to obtain required frequency 5 Turn the governor speed adjustment screw counterclockwise until the speed is lt 50 Hz so that the throttle lever on the carburetor is rest ing against the throttle stop screw Figure 8 18 Adjust the stop screw to obtain a fre quency of 44 to 46 Hz on 60 Hz gensets 36 to 38 Hz on 50 Hz gensets 6 Turn the idle adjustment screw inward until volt age and frequency drop and engine begins to run rough or starts hunting Back out idle ad justment screw as required for smoothest op eration without hunting Recheck setting in Step 5 7 Readjust the governor speed screw Step 4 and observe the stability of the genset Set the voltage and frequency and adjust the sensitiv ity of the governor as specified in Governor on Page 8 11 Add and remove a full load several times to make certain the gens
35. in the B1 B2 windings for the battery charge circuit e The AC output voltage from the B1 B2 winding is converted to DC voltage when it passes through the full wave rectifier bridge CR1 The voltage is then supplied through battery charge resistor R1 The 12 volt DC output one ampere maximum is used to power the control assembly A1 fuel pump E2 the remote control and to prevent discharge of the genset starting battery during genset operation This output is not sufficient to charge a low or dead battery START STOP SWITCH S1 BATTERY BT1 CONTROL ASSEMBLY A DE BATTERY CHARGE BRIDGE RESISTOR R1 RECTIFIER CR1 AC2 FUEL PUMP E2 FUEL SHUTOFF SOLENOID NM N A STATOR ON LPG MODEL A pa X pee FIGURE 6 7 BATTERY CHARGE MODE SPEC C E 6 11 Redistribution or publication of this document by any means is strictly prohibited Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only trained and experienced personnel with knowledge of fuels electricity and machin ery hazards should perform service procedures Review SAFETY PRECAUTIONS p iii TABLE 6 5 CONTROL TROUBLESHOOTING BATTERY CHARGE MODE Possible Cause Corrective Action Page Low Battery 1 Weak or discharged battery due to Replenish electrolyte and recharge Voltage Low electrolyte level in battery battery Long periods of non use Connect a separate battery charger to Imprope
36. occurs B Also measure and record as B cylinder bore diameter parallel to crankshaft at the bottom of piston travel C Measure and record as C cylinder bore diameter perpendicular to crankshaft near the top of cylinder bore where great est amount of wear occurs D Also measure and record as D cylinder bore diameter perpendicular to crank shaft 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 G If out of round exceeds 0 0039 inch 0 10 mm the cylinder block must be replaced Redistribution or publication of this document by any means is strictly prohibited BOTTOM OF RING TRAVEL C1090s FIGURE 10 27 METHODS OF MEASURING THE DIAMETER OF A CYLINDER BORE Deglazing Cylinder Bores Deglaze the cylinder bores if there are no scuff marks and no wear or out of round beyond specifi cations before installing new rings Deglazing gives a fine finish but does not enlarge cylinder diameter so the original pistons with new rings may still be used The reason for deglazing a cylinder is to provide cavities to hold oil during piston ring break in 1 Wipe cylinder bores with a clean cloth which has been dipped in clean light engine oil 2 Use a brush type deglazing to
37. outlet air Redistribution or publication of this document by any means is strictly prohibited TROUBLESHOOTING ENGINE PRIMARY SYSTEMS the primary systems can be serviced without remov ing the genset from the vehicle Poor engine performance is often caused by a dirty carburetor Make certain that the carburetor is clean before troubleshooting for performance problems Use the following troubleshooting guide to locate problems with the engine primary systems Many of Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only trained and experienced personnel with knowledge of fuels electricity and machin ery hazards should perform service procedures Review SAFETY PRECAUTIONS p iii TABLE 6 9 TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Possible Cause Corrective Action Page Engine Runs 1 Rough 2 Engine Backfires Through Carburetor Dirty air or fuel filter Contaminated fuel Lean fuel mixture due to a Incorrectly adjusted fuel mixture screws b Incorrect float level gasoline sets C Dirt in the carburetor d Vacuum leak e Gasket failure Faulty ignition due to a Worn or fouled spark plug b Poor magneto or coil connections c Faulty ignition components d Faulty plug wire e Incorrect ignition timing Carburetor icing Lean fuel mixture due to a Incorrectly adjusted fuel mixture screws b Dirt in carb
38. sembly A1 to the magneto G2 One wire from the low oil level switch S2 to the control assembly A1 One high tension lead from the ignition coil sec ondary to the spark plug E1 Do not disassemble the genset to check the magne to wiring at this time Thoroughly inspect the ignition wiring for loose con nections and cuts or breaks in the insulation Test suspect leads for continuity with an ohmmeter Use a megger to check for breaks in the spark plug lead Also check control wiring for loose or grounded con nections If any problems are found correct them and repeat the ignition spark check If no problems are found proceed to the Magneto Assembly sec tion following SPARK PLUG BOOT SECONDARY TERMINAL PRIMARY ES 1767 FIGURE 8 13 IGNITION COIL Redistribution or publication of this document by any means is strictly prohibited Magneto Assembly G2 The magneto assembly is a noncontact capacitive discharge breakerless type that is mounted to the generator endbell As the engine cranks two per manent magnets on the fan hub assembly pass very close to the magneto inducing a voltage in two coils in the magneto One coil charges a capacitor that discharges a voltage to the coil when triggered The other coil powers the circuit that triggers the charge circuit The discharge voltage from the magneto approximately 16 to 60 VAC when measured with a digital voltmeter is supplied to the primary of t
39. strictly prohibited Valve seats should be ground with a 45 degree stone to the specified width Grind only enough to provide proper seating See Figure 10 10 Always wear safety glasses with side shields when grinding to prevent severe eye damage 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 dropped against the seat The valve seat should contact the valve face evenly at all points The line of contact should be at the center of the valve face 45 A VT1041s FIGURE 10 10 VALVE SEAT Intake Valve Seal Replacement A worn or cracked valve seal can cause high oil con sumption and spark plug fouling Replace a defec tive intake valve seal as follows 1 Pull the old valve seal out carefully to avoid damaging the valve guide Coat the intake valve stem with engine oil and insert it into the valve guide Press valve seal into valve guide by hand 10 6 4 After insertion use a special tool made for installing the seal Figure 10 11 to press the seal into the valve guide until the shoulder of the seal rests against the cylinder head VALVE SEAL INSTALLATION TOOL INTAKE VALVE VALVE SEAL VALVE GUIDE FIGURE 10 11 VALVE SEAL INSTALLATION Valve Seat and Valve Guide Replacement Worn valve stem guides or valve seats that a
40. surface finishing If the slip rings are in bad condition and there is no power build up refinish using a fine sandpaper Use the following procedure to service 1 Follow Generator Disassembly this section to remove generator endbell and rotor 2 Place rotor in machine lathe and center Turn rotor and use fine sandpaper against rotating slip rings to clean and true slip rings Turn rotor until all grooves or roughness are smoothed out Contact with rotating machin ery can result in severe personal injury Keep hands hair clothing jewelry and fin gers clear while servicing slip rings Careless handling of rotor can damage the insulation on the windings 3 Clean rotor and prepare for reinstallation Fol low the Generator Assembly procedure on Page 9 10 to reinstall rotor and remaining gen erator components ROTOR BEARING REPLACEMENT The rotor bearing is pressed onto the rotor shaft This bearing must be replaced very carefully to avoid damaging the collector ring assembly and the rotor shaft Use the following procedure to replace the rotor bearing 1 Measure and record the distance between the bearing and the collector ring assembly refer enced later for reassembling See Fig ure 9 11 9 13 MEASURE SPACE BETWEEN BEARING AND COLLECTOR RING ASSEMBLY ROTOR COLLECTOR RING ASSEMBLY BEARING FIGURE 9 11 ROTOR BEARING SPACING Redistribution or publication of this document by any means is strictl
41. the ap propriate test or adjustment procedure The section and page number in the right column lists the loca tion of the test or adjustment procedure in this manual Conditional schematics are used to highlight the cir STARTER MOTOR B1 BRIDGE RECTIFIER CR1 SPEC C E BRUSH BLOCK MAGNETO IGNITION G2 PUMP E2 RELAY K1 CAPACITOR C1 MODEL KVD VOLTAGE REGULATOR VR1 cuitry that is energized during the sequence of events These conditional schematics are for a typi cal gasoline fueled genset Always refer to the wir ing schematic and diagram in Section 12 Wiring Diagrams that corresponds to the model and spec number of the genset when troubleshooting Make a thorough inspection of the genset wiring to make sure that good wire harness and ground con nections are made Correct wiring problems before performing tests or replacing any components BATTERY CHARGE RESISTOR R1 MODEL KV VOLTAGE REGULATOR VR1 IGNITION COIL T1 CONTROL ASSEMBLY A1 START STOP SWITCH 1 CIRCUIT BREAKER CB1 FIGURE 6 1 COMPONENT LOCATIONS MODELS KV AND KVD Redistribution or publication of this document by any means is strictly prohibited CONTROL BOX COVER FUEL PUMP E2 FUSE F1 IS BUNDLED IN WIRE HARNESS NOT SHOWN HOUR METER M1 ENGINE GENERATOR STARTER MAGNETO BRUSH BLOCK SPARK PLUG ASSEMBLY SAME AS MODEL KV FIGURE 6 1 IGNITION COIL T1 AN START STOP SWITCH S1
42. the genset Verify that the weight of the genset is supported by the forks before proceeding Remove the bolts that secure the genset to the side mounting brackets and rear mounting braces Slowly lower the genset until it clears all ob structions and can be safely moved out from under the vehicle When reinstalling the genset be sure that all bolts brackets and electrical exhaust and dh ES ip FORKLIFT Ny el y Es aa e fuel system components are connected exactly as they were before removal REINSTALLING THE GENSET Generally reinstallation is the reverse of removal Contact the RV coach manufacturer to obtain their recommendations if installation is not obvious See Section 11 Service Checklist Make sure the vapor and fire shields between the genset and interior of the vehicle are secure Reseal any holes through the barriers where wiring or fuel lines were pulled through or bolts loosened EXHAUST GAS IS DEADLY Seal all openings into the vehicle interior to keep out ex haust gas FIGURE 5 4 COMPLETE SET REMOVAL MODEL KV 5 8 Redistribution or publication of this document by any means is strictly prohibited B Troubleshooting This troubleshooting guide is divided into three sec tions Control Page 6 3 Generator Page 6 15 and Engine Primary Systems Page 6 18 Com mon problems are listed with their possible causes Refer to the Corrective Action column for
43. the voltage regu lator during starting refer to Control section 7 for control assembly test procedure 9 4 GENERATOR TESTS The quickest way to check out most generator prob lems and to determine whether the fault is in the generator or in the voltage regulator is to discon nect harness connector P3 from the voltage regula tor and to use the connector as a test point in the fol lowing procedure See Figure 9 3 1 Disconnect all loads by turning off line circuit breaker CB1 Disconnect harness connector P3 from the voltage regulator Conduct the Rotor Tests Page 9 6 using pins P3 9 F and P3 10 F as the test points Service as necessary if the circuit is open or has a resistance of less than 16 ohms or is grounded Check for open stator windings across pins P3 2 and P3 3 line and pins P3 11 and P3 12 quadrature using the lowest scale on an ohmmeter Service as necessary if either cir cuit has a resistance greater than 1 ohm Sta tor Tests Page 9 7 Assemble a fused 24 VDC power supply as shown Figure 9 3 The fuse must be in the positive side of the circuit and be rated not more than 3 amps Connect pin P3 9 to the positive side of the 24 VDC power supply and pin P3 10 to the negative side Ground the negative side of the 24 VDC power source to the engine block If the fuse blows either the rotor has a ground short through the bearings or a loose field lead is g
44. to switch is burned out If remote switch functions properly for starting and stopping genset but meters and run lamp do not operate and step 1 checks OK control assy A1 defective Too much DC load over 2 amps connected to the remote output Check fuel and oil level and refill if low Refer to choke section for adjustments Remove any objects or debris that may restrict airflow Make sure fuel system is installed correctly Refill tank with fresh fuel Check continuity between remote control and control assembly A1 Replace time meter Connect a voltmeter between the positive terminal on battery charge meter and ground Use the following to determine fault If reading equals battery voltage minus 10 volts battery condition meter is defective If reading does not equal battery voltage minus 10 volts zener diode is defective Replace remote Start Stop switch S2 Check remote running output voltage approximately 12 VDC during run condition from control assembly J1 2 to ground and from P5 6 to ground If voltage is not present replace control assembly A1 If voltage is present check continuity of remote control wiring Turn off the genset disconnect the remote control and check for shorts or too many remote accessories Redistribution or publication of this document by any means is strictly prohibited Battery Charge Mode Spec C E With the genset running AC voltage is produced
45. 0 l0J1NO2D 310NW3H ZV O QHVONVIS IOMINOO SLOWSY EV 9 Ed Y431YV1S 3010W Lg 1 7 ACL AY3I11W9 L1a 2 E I P LAdLNO IV 334V348 LINDYID 19 e i3 2 NT Lo dis BOlDvav2 15 um o vt 9nd YV dS 13 TS pura 91 10S 1302 dWNd TANS 24 N gt 3snd 4 e HOLVHS3N39 19 oO A UT NOLLINDI O L3ND YA Z5 E LA L e I Ld ddlHVlS AV I3H LA d Y OLVINDAY 10S ZA NOLLINDI 1102 NO L UU ADV LIOA YOLV INDAY LYA o QNO o E Ed a a GND za zi ii lt ZO S E GERE lt Zi Ed Ya z GND Za TM a EST o la la E E Sus z ZL LL gt Od Y 7 T r N tc be 7 cope Ly 7 T 2i z zr LOS S zo za zi ZA eso 5 M 5 E 1 GND A JV AOZL SU T S 3prpappew Sf u A 5 2412101271919 eed E e LL OL Ed NOEL N A v E 3 Y DIO z Li v ut WP er l hg gt ee DA ZO Tavis Davis EV ZY Redistribution or publication of this document 12 16 by any means is strictly prohibited Onon Cummins Power Generation 1400 73rd Avenue N E Minneapolis MN 55432 763 574 5000 Fax 763 528 7229 Cummins and Onan are registered trademarks of Cummins Inc Redistribution or publication of this document by any means is strictly prohibited
46. 0 9705 24 65 0 9705 24 65 0 9665 24 55 0 1 0 9665 24 55 0 0079 0 20 0 0020 0 05 Reference Value 0 0036 0 0056 0 092 0 141 Allowable Limit 0 0079 0 20 0 0039 0 10 0 0016 0 04 2 6354 2 6362 66 94 66 96 0 0354 0 90 2 6378 2 6386 67 00 67 02 0 0079 0 0157 0 20 0 40 0 0008 0 0024 0 02 0 06 0 0039 3 2 0 10 Redistribution or publication of this document by any means is strictly prohibited ITEM INCHES MILLIMETERS E Piston Pin Outer Diameter 0 5906 0 5907 15 000 15 005 Connecting Rod Small End Inner Diameter Reference Value 0 5911 0 5915 15 015 15 025 Clearance Between Reference Value 0 004 0 0010 0 010 0 025 Small end amp Piston Pin Allowable Limit 0 0039 0 10 Connecting Rod Bending Limit 0 0016 0 04 Torsion Limit 0 0016 0 04 Bolt Tightening Torque 10 1 14 5 ftelb 10 1 14 5 ftelb 13 7 19 6 Nem Crankshaft Pin Diameter Reference Value 1 1798 1 1804 29 967 29 982 Wear Limit 1 1780 29 92 Reference Value 0 0007 0 0021 0 018 0 054 Crank Pin Oil Clearance owane Umi Reference Value Journal Dia Wear Limit Side Clearance ATTowable Limit Bending Limit Ignition Plug Standard Gap 0 0236 0 0276 0 6 0 7 3 3 Redistribution or publication of this document by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited 4 Torque Specifications Mounting screws and nuts must be tightened to the specified torque setting
47. 2 Z4 2 bs ve oy i 03 96 n or E CB1 L1 LOAD 220V L2 GND VR1 THI S2 REGULATOR VOLTAGE COIL IGNITION SWITCH LOW OIL LEVEL K2 K1 G2 G1 F1 SOL REGULATOR LP RELAY STARTER MAGNET O IGNITION GENERATOR FUSE EZ El C1 CB1 FUEL PUMP FUEL SOL SPARK PLUG CAPACITOR EEJ CIRCUIT BREAKER AC OUTPUT 811 81 A3 A2 Al BATTERY 12V MOTOR STARTER REMOTE CONTROL STANDARD REMOTE CONTROL DELUXE CONTROL ASSY ITEM Redistribution or publication of this document by any means is strictly prohibited DESCRIPTION OR MATERIAL FIGURE 12 9 WIRING SCHEMATIC 610 0389 50 HZ BEGIN SPEC F G2 06 d Er E 220V AC i i i 7 a 5 2 F E gt gt T4 IGN 5 P3 10 P3 9 P5 A B c B E F 5 A B C D E F J5 EN F 143 GND 24 O o S K1 CB1 LINE 1 I Or NEM Y GND BTT B1 F1 P3 12 E P31 1 1 zs CB1 LOAD Z4 GND xi K1 m 41 7 Z4 P3 2 GND 2F14 K1 1 S2 z EE J1 4 G2 2 CB1 Ma 61 11 T E1 L1 LINE i j l l P3 6 G2 1 AS IG
48. 6 gph 0 6 l h Half load 0 28 gph 1 1 1 h 0 28 gph 1 1 1 h Full load 0 46 gph 1 7 1 h 0 46 gph 1 7 I h ENGINE 1 Cylinder 4 Stroke Cycle Spark Ignited OHV Air Cooled Mechanically Governed DC SYSTEM Nominal Battery Voltage 12 volts 12 volts Min Battery Rating Cold Cranking Amps CCA 360 450 360 450 Q 0 F 18 C above below 32 F 0 C above below 32 F 0 C INSTALLATION Weight of Genset with engine oil 100 Ibs 45 kg Minimum Compartment Size 15 5 inch x 17 5 inch x 20 2 inch H x D x W 394 mm x 445 mm x 512 mm Minimum Free Air Inlet Area 40 inch 258 cm Muffler Outlet Collar O D 1 13 inch Fuel Connection 1 4 inch barb fitting for gasoline hose Listed by CSA and the U S Testing Company Seethe Installation Manual for additional considerations when sizing the genset compartment 2 2 Redistribution or publication of this document by any means is strictly prohibited H H IS GENERATOR 2 Pole Revolving Field Self Excited 1 Phase Electronically Regulated No load 0 20 gph 0 76 I h 0 85 Ibs h 0 39 kg h Half load 0 30 gph 1 14 I h 1 45 Ibs h 0 66 kg h Full load 0 43 gph 1 63 I h 2 35 Ibs h 1 07 kg h ENGINE 1 Cylinder 4 Stroke Cycle Spark Ignited OHV Air Cooled Mechanically Governed Spark Plug Gap 0 025 in 0 64 mm 0 020 inch 0 51 mm Spark Plug Tightening Torque 13 Ibs ft 17 N m 13 Ibs ft 17 N m Ignition Timing magneto type ignition 25 BTDC non adjusta
49. 6s FIGURE 7 3 CONTROL ASSEMBLY A1 START STOP SWITCH TEST Redistribution or publication of this document by any means is strictly prohibited Control Assembly A1 Output Checks Figure 7 3 shows the control assembly A1 and the harness connector connectors J1 and J2 Voltages can be checked using a voltmeter with long test prods Table 7 1 lists the control outputs at the J1 and J2 connector plugs for each control mode Electrical shock can cause severe personal injury or death Do not touch the volt meter or any wiring when the genset is operat ing Attach and remove meter leads only when the genset is stopped Measure the control output voltages between the connector pins shown in Table 7 1 and ground Bat tery B voltage must be present at the J1 4 P1 4 connection at all times If battery voltage is present at the J1 4 P1 4 connection and the control outputs are not present check continuity between the J1 P1 and J2 P2 connections If the connections and Start Stop switch 81 check good replace the con trol assembly with a new control assembly and re check genset operation TABLE 7 1 CONTROL OUTPUTS CONTROL MODE CRANK RUN STOP 29 VDC 0 VDC 0 VDC OVD 9 VD OVD CONTROL OUTPUT CONNECTOR PIN STARTER SOLENOID J1 3 P1 3 PLIMP Ale io masa 2ovoe owo ove AVR FIELD FLASH 29 VDC 0 VDC 0 VDC J2 3 P2 3 REMOTE RUN 0 VDC 29 VDC 0 VDC 7 6 Start Relay K1 Replace the start re
50. 7 Reinstall the head cover and torque head cover bolts to specified torque VT1057s FIGURE 10 12 VALVE LASH ADJUSTMENT CRANKCASE COVER Remove the crankcase cover mounting bolts and lightly tap cover with plastic faced hammer to loos en See Figure 10 13 Be careful not to lose crank shaft and camshaft shims When installing the cover make sure the governor shaft is properly positioned Use a new gasket and clean the crankcase cover and the engine block where the gasket rests Place crankcase cover in position and torque until all bolts are tightened to the specified torque see Section 4 Torque Specifications CRANKCASE COVER GASKET FIGURE 10 13 CRANKCASE COVER CAMSHAFT AND TAPPET REMOVAL The camshaft gear is pressed onto the camshaft and should be removed from the engine as a set Check for matching mark with crankshaft before re moving camshaft The tappets can be removed af ter camshaft removal See Figure 10 14 CAMSHAFT C1 114s FIGURE 10 14 CAMSHAFT AND TAPPETS Redistribution or publication of this document by any means is strictly prohibited GOVERNOR With the crankcase cover removed the governor can be inspected or disassembled for service The governor assembly must spin freely on the center pin without excessive looseness or wobble Sleeve tip wear is the most common cause of governor fail ure If governor sleeve gear or flyweights are worn or otherwise damaged replace t
51. Loosen the clamp securing the tail pipe to the muffler and pull the tail pipe away Figure 8 3 3 While supporting the muffler loosen the muffler clamp and remove the mounting bracket screw and then pull the muffler down and away Model KVD Assembly 1 If the genset has been removed first install the genset in the vehicle 2 If the flanged exhaust tailpiece has been re moved secure it to the genset exhaust outlet flange with a new gasket Torque the two 2 flange nuts to 7 Ib ft 10 N m Put the U bolt muffler clamp on over the muffler inlet collar and snug the nuts Push the muffler inlet collar on over the tailpiece Holding the muffler level secure the muffler mounting bracket to the engine with the screw and washer Torque the screw to 13 lb ft 18 N m See that the muffler is level and tighten the muf fler clamp nuts Secure the tail pipe to the muffler outlet collar with a suitable muffler clamp See Tail Pipe if re placing the tail pipe Run the genset for five minutes and look and listen for exhaust system leaks and excessive noise Shut down the genset immediately and correct any problems EXHAUST OUTLET FLANGE STUDS FLANGED EXHAUST TAILPIECE SECURE MUFFLER MOUNTING BRACKET TO ENGINE SCREW TO HOLD SPARK SCREEN MUFFLER U BOLT SECURE TAIL PIPE TO MUFFLER OUTLET FIGURE 8 3 MODEL KVD MUFFLER Redistribution or publication of thi
52. OD GROUND ON ENGINE 12 VOLT GENSET LEADS TEST LEADS 12 VOLT FIGURE 9 3 GENERATOR TEST SETUP AT HARNESS CONNECTOR P3 9 5 Redistribution or publication of this document by any means is strictly prohibited Rotor Tests Use an ohmmeter for rotor winding tests A megger or insulation resistance meter is preferable for grounded winding tests Begin by disconnecting the voltage regulator and checking resistance between pins 9 and 10 of the harness plug Less than 16 ohms indicates a shorted winding High resist ance indicates poor brush slip ring contact or an open winding Then check resistance between ei ther pin and a good ground on the engine or genera tor use the highest ohmmeter scale if not using a megger A resistance of less than 1 megohm indi cates a grounded winding If any of the preliminary tests indicate a rotor prob lem remove the fan see Generator Disassembly p 9 8 to gain access to the slip rings and continue by conducting the following tests Test for Grounded Windings Use the highest ohmmeter scale if not using a megger Touch one test prod to the rotor shaft and hold it there Touch the other test prod to one of the slip rings as shown in Figure 9 4 A resistance of less than 1 megohm indicates a grounded winding Replace a grounded rotor with a new rotor Test for Open Windings To test for open windings set the ohmmeter on the highest resistance scale Place test prods on the slip rings
53. 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 8 32 and replace if worn less than 0 425 11 mm 8 27 FIGURE 8 30 TESTING ARMATURE FOR GROUNDS HACK SAW NEW 0 472 INCH 12 mm 0 315 INCH 8 mm WEAR LIMIT FIGURE 8 32 BRUSH INSPECTION Redistribution or publication of this document by any means is strictly prohibited 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 Oil on armature will damage starter Do not immerse bearings in clean ing fluid Use a brush dipped in clean en gine oil for removing dirt from bearings Avoid getting oil on brushes or commuta tor 2 Push negative brush terminals over through bolt holes on brush endcap See Figure 8 33 3 Insert positive brush stud into hole and torque to 25 30 in Ib 2 8 3 4 Nem 4 Place brush springs into brush holders Insert brush tabs into spring ends and slide brushes TORQUE TO 5 10 IN LBS 57 1 13 Nem TORQUE TO 25 30 IN LBS 2 8 3 4 Nem into brush holders in endcap Be sure all brush wires are facing up Place washer on commutator end of shaft and put arm
54. RING CONTACT CT 1062s FIGURE 10 20 NEW RING IN WORN RING GROOVE Improper width rings or excessive ring side clear ance can result in ring breakage New rings in worn STE ring grooves do not have good cylinder wall contact FIGURE 10 21 PISTON CLEARANCE Figure 10 20 MEASUREMENT 10 10 Redistribution or publication of this document by any means is strictly prohibited Fitting Piston Rings Before installing new rings on the piston check the ring gap by placing each ring squarely in the cylin der at a position corresponding to the bottom of its travel Figure 10 22 The gap between the ends of the ring is given in Section S Dimensions and Clear ances The practice of filing ring 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 Rings of the tapered type are usually marked TOP on one side or identified in some other manner Install these rings with the identification mark to ward the closed end of the piston CT1125s FIGURE 10 22 CHECKING RING GAP Piston Assembly Installation Lubricate all parts with clean engine oil Position the piston on the connecting rod Install the piston pin 10 11 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 see that they are properly in place before installing th
55. RT STOP SWITCH S1 BATTERY BT1 CONTROL ASSEMBLY A1 START STARTER MOTOR B1 LA INTERNALLY GROUNDED ON KVC FIGURE 6 3 START CRANKING MODE 6 3 Redistribution or publication of this document by any means is strictly prohibited Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only trained and experienced personnel with knowledge of fuels electricity and machin ery hazards should perform service procedures Review SAFETY PRECAUTIONS p iii Not Crank TABLE 6 1 CONTROL TROUBLESHOOTING CRANKING MODE Possible Cause Corrective Action Page Engine Does 1 Open control fuse F1 Insufficient cranking voltage due to Also see Low Bat Voltage pg 6 6 a Battery not charged b Battery connections loose or dirty c Battery cable size too small Start solenoid K1 not energized due to a Open circuit to start solenoid coil b Defective start solenoid coil c Defective Start Stop switch d Defective control assembly A1 Starter B1 not energized due to a Open circuit to starter B1 b Open circuit between battery B and the start solenoid contact BAT c Defective start solenoid K1 d Defective starter B1 If engine cranks from set but not from remote control panel fault is due to a Open circuit between control assy A1 and remote Start Stop switch b Remote Start Stop switch faulty Check fuse I
56. RUSH ENDCAP FIGURE 8 34 STARTER ASSEMBLY Redistribution or publication of this document by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited 9 Generator These gensets use a 2 pole revolving field genera tor design and an electronic voltage regulator All AC load connections are made through generator lead wires that connect directly to a customer sup plied junction box A circuit breaker provides over current protection for the generator and also func tions as an on off switch in the load circuit GENERATOR DESCRIPTION The generator circuit consists of the following major components e Stator s Rotor e Electronic voltage regulator s Brushes Wiring harness Stator The stator consists of a number of steel laminations stacked together with three separate winding groups wound onto it in a toroidal fashion Winding group T1 T2 is the main power winding that pro vides the voltage and current to operate the con nected loads Winding group B1 B2 is for battery charging and internal low voltage loads Winding group Q1 Q2 is an excitation winding that provides power to the voltage regulator Rotor The rotor consists of a stack of laminations wrapped in a field winding a shaft through the laminations molded slip rings on the shaft and a bearing pressed on the shaft The entire assembly is connected di rectly to the tapered engine crankshaft
57. RY 12V CI 52 BI MOTOR STARTER T 2 AS REMOTE CONTROL STANDARD T A2 REMOTE CONTROL DELUXE SS Pac Al CONTROL ASSY Al PEU TI IGN ITEM DESCRIPTION P2 J2 1 0 8 6 K E GI F BUSES Qc FEN 1 x J2 3 VRI ae n P3 7 NEN b Ka oi je 7 bo o o o o L a Z4 XI X2 o2 bs pos MID o o o K ESS GND 2 meet qewerier 18718 go o os i so PS MZ Al PI o MB bae GND cl P3 J3 3o o6 LS go a Ci E 40 05 4 so P9 2 GI F FI GI G2 PI JI EE ir EE FIGURE 12 4 WIRING DIAGRAM 610 0383 1 2 5 Redistribution or publication of this document by any means is strictly prohibited CRI X A e gt a gt 2 gt oF REMOTE START INPUT P1 6 of REMOTE RETURN P1 8 o Fg PE IA PI 4 BATTERY INPUT o gt PI 1 FUEL PUMP OUTPUT PI S START SOL OUTPUT A P2 4 IGN ENABLE OUTPUT P1 7 BATTERY GND INPUT P2 1 BI INPUT P2 2 B2 INPUT P2 3 AVR FIELD FLASH OUTPUT em VRI Sl or 94 67 dio el o2 bs os o
58. S2 PT Z J2 4 AAT P3 8 A1 P2 2 G1 B2 8 5 V y ES A1 P2 J L o0 gt gt ay z1 3 3 u m P3 7 o E 2 n s P5 F EY E2 m te x E PS A lt io 1o 08 1 ee 1 MP1 ok 20 or Nez ro GND so 06 77 ps so Pa eo 40 os 4 56 P5 B J1 F1 P1 KIS FIGURE 12 8 WIRING DIAGRAM 610 0388 60 HZ BEGIN SPEC F 12 9 G2 z if S LA EE 2 T1 IGN P3 10 P3 9 EET J2 1 B1 a l G1 J2 2 82 02 l Ti T2 CB1 LINE GND P3 12 P3 11 S2 z G2 2 oe d E1 G1 01 IG G1 F VR1 J2 3 o o CB1 LINE o o GND 03 o6 99 on o o c1 P3 J33 un G1 F K 61 02 Redistribution or publication of this document by any means is strictly prohibited AZ A3 START TT D S N 12 10 ig A1 E 5 o 5 E P1 4 BATTERY INPUT 26 2 Eu El S2 LR M p w E y E p G2 gt P1 3 START SOL OUTPUT 5 o 2 5 o P2 4 IGN ENABLE OUTPUT E 2 gt gt E 5 5 d p17 BATTERY GND INPUT go Bo too z g m AA M Er eS 0 E1 o e A T1 IGN E C1 VR1 l P3 o 4 d7 de R
59. See Governor on Page 8 11 To adjust the throttle stop screw 1 Connect a frequency meter and start and run the genset until it has warmed up to normal op erating temperature 2 Disconnect all loads Turn the governor speed adjustment screw counterclockwise until the speed is lt 50 Hz so that the throttle lever on the carburetor is resting against the throttle stop screw Figure 8 18 Adjust the stop screw to obtain a setting of 55 1 Hz 45 1 Hz on 50 Hz units 3 Readjust the governor speed screw so that the frequency is within 62 5 0 5 hertz 52 0 0 5 hz on 50 hertz units Adjust governor speed adjustment screw if necessary to obtain re quired frequency FIGURE 8 26 FUEL SHUTOFF SOLENOID VALVE THROTTLE THROTTLE STOP SCREW BALANCE HOSE FITTING GAS HOSE FITTING FIGURE 8 27 LPG CARBURETOR BEGIN SPEC E MODEL KV Redistribution or publication of this document by any means is strictly prohibited LPG Carburetor Prior to Spec E Model KV See Figure 8 28 LPG carburetors prior to Spec E have three adjustment screws that must be properly set for satisfactory operation The throttle stop screw controls how much the throttle plate remains open when the throttle is pulled back to the closed position The idle adjustment screw controls the fuel mixture when the genset is operating at no load The main adjustment screw controls the fuel mixture when the genset is operating at full load No other
60. TI y E l m BI P4 E2 i gil CBI LOAD CBI LOAD 2 J6 KI I enn 2 BRKT GND PAN Bt KI 1 Jl 4 GND J6 P6 x SEE NOTE lt G cl LE Lele I pata 62 1 se Zi J2 4 CBI PLAGNE GI T L1 2 P3 2 m Aue L2 4 GI T2 n Al P2 J2 CRI_AC 2 XI Z CRI AC I A ae E m Al P2 J o o o et 2 2 N Rp L P3 7 1 x e G P5 6 H SE E E2 a E A e d he o vs H AI PI o GND 20 07 2704 G 3o 06 STIE 925 oO 40 o5 4 50 P5 2 FI PI JI KIS FIGURE P3 10 p 3 9 CR CR I AC T AC 2 ES F CBI LINE CBI LINE 2 P3 12 PS 41 Z4 Z4 2 x e s 8 XI o 5 gt o x2 Z4 P3 3 CRI AC 1 AC 2 P6 i pa Ja RI Ki 1 2 s2 o 94 CBI LINE s os Le pos o o o LL ze ee E EI J TI IGN GI QI GI F 7E VRI Z4 XI X2 es 0 YR o o o o EI P3 J3 ES GI F 61 02 12 7 12 6 WIRING DIAGRAM 610 0384 610 0384 Redistribution or publication of this document by any means is strictly prohibited qus BT1 AZ A3 E Wee START K1 B1 W ES Sr w l OOOO
61. XHAUST GAS IS DEADLY Keep exhaust gases from entering the vehicle Do not terminate the exhaust tail pipe underneath the vehicle or closer than 6 inches 153 mm to openings into the vehicle Route the exhaust system such that it is protected from damage Use approved materials only 8 1 The genset exhaust system must be gas tight and prevent entry of exhaust gases into the vehicle A muffler must have a USDA Forest Service spark arrestor and meet RVIA EGS 1 requirements for construction aluminized steel or equivalent and welded or crimped joints A genset without a prop erly installed and maintained spark arresting ex haust system can cause a brush fire or forest fire and is illegal on federal lands Liability for damage injury and warranty expense due to modification of the exhaust system or to use of unapproved parts is the responsibility of the per son performing the modification or installing the un approved parts Unauthorized modifications or re placement of fuel exhaust air intake or speed control system components that affect engine emissions are prohibited by law in the State of California Always replace worn components with new original equipment replacement parts Do not attempt to re pair a broken exhaust pipe or manifold by welding and do not replace worn out components with parts that do not meet factory specifications Contact an Onan distributor for approved replacement exhaust parts Redis
62. actly coincide when the gears are installed in the engine See Figure 10 29 VT1042s FIGURE 10 29 TIMING GEAR ALIGNMENT 10 16 BEARINGS One bearing is pressed into the engine block and the other bearing is pressed into the crankcase cov er The bearing in the engine block can be pressed out after the oil seal is removed following section The bearing in the crankcase cover can be pulled out using a puller Clean the bearing mounting sur faces and press new bearings back in OIL SEAL Use an oil seal remover to pry the oil seal out of the engine block Clean the oil seal resting surface and lubricate surface before installing new oil seal Press new oil seal into the engine block until oil seal is flush with cylinder block boss see Figure 10 30 Lubricate the lips of the oil seal with a light coating of grease This provides initial lubrication until engine oil reaches the seal OIL SEAL CT 1093s FIGURE 10 30 OIL SEAL Redistribution or publication of this document by any means is strictly prohibited COMPRESSION RELEASE SYSTEM This engine has a compression release system that decreases the amount of effort required to start the engine and reduces engine run on when stopping The system works as follows 1 As the engine is started Figure 10 31 a spring holds in the flyweight which in turn pushes a de compression pin upward 2 The decompression pin pushes up on the ex haust tappet and opens the e
63. adjustments are required with an LP gas carburetor since there are no float or choke adjustments Mixture Screw Adjustments Mixture screws should not be adjusted until the ignition system governor and other fuel system components have been checked for correct operation If the carburetor is totally out of adjustment turn the mixture screws in until lightly seated For a preliminary adjustment turn the main adjustment screw out 4 to 5 turns and the idle adjustment screw out 2 to 3 turns Forcing the mixture adjustment screws tight will damage the needle and seat Turn in only until light tension can be felt Start the engine and allow it to run for about 15 min utes at half load Figure 8 28 shows the location of the adjustment screws Use the following procedure to adjust 1 Stop the genset and connect a voltmeter fre quency meter and load bank to the generator output leads Start the genset and apply a full load Verify that the frequency is within 60 0 5 Hz 50 1 on 50 Hz units and adjust the governor speed adjust ment nut if necessary to obtain required fre quency Turn the main adjustment screw inward until voltage or frequency drops and then outward counterclockwise 0 5 turns from the frequen cy drop If a CO meter is available follow the manufacturer s instructions for use and adjust the main adjustment screw to obtain 1 to 2 per cent CO Remove the load and verify that frequency is within 62 5 0
64. ar LPG containers or LPG burning equipment or are in an area sharing ventilation with such equip ment Keep flames sparks pilot lights electri cal arcs and arc producing equipment and switches and all other sources of ignition well away Have an ABC fire extinguisher handy LPG models are designed for a low pressure vapor withdrawal type of LPG supply system LPG supply pressure at the inlet to the demand regulator must be 9 to 13 inches water column WC when the gen set is running under full load The components of the genset LPG system include e Afuel shutoff solenoid valve A demand regulator with a built in automatic priming solenoid which allows fuel to pass through during cranking e An LPG carburetor and air filter Before servicing the LPG fuel system check to see that the LPG container s is at least half full The problem may be that there is not enough LPG to pro vide the rate of vaporization necessary to meet gen set demand especially on cold days and or when the genset is under full load 8 21 Carefully follow the instructions on Page 5 4 for dis connecting the LPG fuel line from the genset LPG sinks when it escapes into the air and can accumulate in explosive con centrations Before disconnecting the LPG fuel line close the fuel shutoff valve s at the LPG container s and move the vehicle outside and away from pits or basements or other below grade spaces where LPG could accumulate See th
65. as shown in Figure 9 5 The ohmmeter should indicate continuity be tween the 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 Test for Shorted Windings To test for shorted winding set the ohmmeter on the lowest scale Place the test prods on the slip rings as shown in Figure 9 5 A reading of less than 16 ohms at 77 F 25 C indicates shorted windings Replace rotor if winding is shorted Note Even though winding resistance is acceptable replace the Rotor if winding to ground resistance winding insulation resistance is less than 1 meg ohm An ohmmeter must indicate an open circuit or infinite resistance between the winding and ground FIGURE 9 4 GROUNDED ROTOR TEST FIGURE 9 5 OPEN OR SHORTED ROTOR TEST Redistribution or publication of this document by any means is strictly prohibited Stator Tests Use an ohmmeter for stator winding tests A megger or insulation resistance meter is preferable for grounded winding tests The stator Figure 9 6 can be tested without removing it from the generator Remove the fan see Generator Disassembly p 9 8 to gain access to the stator To perform sta tor tests carefully remove all four connector plugs from the stator A CAUTION Do not bend or flex stator wire ter minals or breakage can occur Tests for Ground Windings
66. ator AC Output Mode in the Generator Troubleshooting section START STOP SWITCH 1 CONTROL BATTERY BT1 ASSEMBLY SPARK MAGNETO PLUG E1 IGNITION G2 e IGNITION FUEL PUMP E2 COIL T1 FUEL SHUTOFF SOLENOID ON LPG MODEL FIGURE 6 6 RUN MODE 6 9 Redistribution or publication of this document by any means is strictly prohibited Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only trained and experienced personnel with knowledge of fuels electricity and machin ery hazards should perform service procedures Review SAFETY PRECAUTIONS p iii TABLE 6 4 CONTROL TROUBLESHOOTING RUN MODE Possible Cause Corrective Action Page Engine Starts and Runs Then Stops Set Restarts Immediately or After Cool Down Remote Control Run Lamp Time Meter or Battery Condition Meter Inoperative Fuel level is below genset set fuel ibus tube or oil level is low Faulty choke operation Vapor lock from high ambient temperature Contaminated or incorrect fuel Open circuit in remote control wiring If battery condition meter and run lamp work but time meter does not time meter is defective If time meter works but battery condition meter does not operate a Defective battery condition meter b Defective zener diode inside remote control Meters and switch function properly but run lamp does not illuminate Lamp internal
67. attery The control assembly A1 monitors this voltage as part of the start disconnect function e The quadrature winding Q1 Q2 output voltage is fed to the voltage regulator VR1 where it is rectified into DC voltage and fed back to the rotor through the brushes to cause further voltage buildup Voltage buildup is con trolled by the voltage regulator that senses the AC output voltage The regulator continually measures the output voltage and compares it to an internal reference voltage When the output voltage exceeds the reference the regulator causes the current in the rotor to decrease until the proper voltage is obtained e The AC windings T1 T2 provide the 120 VAC output voltage through the circuit breaker CB1 START STOP CIRCUIT SWITCH S1 BREAKER CB1 L1 LOAD r 343 O o CONTROL 120 VAC O GND O STATOR FIGURE 6 9 GENERATOR OUTPUT MODE 6 16 Redistribution or publication of this document by any means is strictly prohibited Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only trained and experienced personnel with knowledge of fuels electricity and machin ery hazards should perform service procedures Review SAFETY PRECAUTIONS p iii AC Output Voltage Too High Noisy Generator Generator Overheats TABLE 6 8 GENERATOR TROUBLESHOOTING Possible Cause Corrective Action Page 1 Engine governor out of adjustment If generator frequency is within
68. ature into brush endcap Push the four brushes toward commutator making sure springs are properly positioned on brushes Replacement brushes are supplied preas sembled in the endcap Remove brush retainers after installing armatures Make sure all brush wires are clear of commu tator 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 Place magnetic housing over armature Use a nut driver over the end of shaft to hold down ar mature and endcap IMPORTANT THIS INSULATED SHUNT MUST BE ROUTED THRU UNINSULATED SHUNT AS SHOWN TO PREVENT CONTACT WITH COMMUTATOR IN FINAL ASSEMBLY NEGATIVE BRUSH TERMINAL POSITIVE BRUSH STUD NEGATIVE T cid BRUSH TERMINAL ES 1612 2 FIGURE 8 33 BRUSH ENDCAP 8 28 Redistribution or publication of this document by any means is strictly prohibited 10 11 Place spring washer and flat washer on shaft as shown in Figure 8 34 Place mounting bracket on motor with through bolt lead ins to the inside of motor The flat near one mounting hole should line up with the positive stud on endcap so through bolt will line up Insert the through bolts and torque to 35 45 in Ib 3 4 5Nem Wipe dust from helix and gear and apply a light coat of GE Versilube 322 L on outside diameter of helix inside diameter of gear and uncham fered end of gea
69. ble 25 BTDC non adjustable DC SYSTEM Nominal Battery Voltage 12 volts Min CCA Rating SAE 32 F 0 C 360 450 above below 32 F 0 C Control Fuse INSTALLATION Noise 71 dB A Weight of Genset with muffler 111 6 Ibs 50 6 kg Weight of Genset without muffler 107 2 lbs 48 6 kg Minimum Compartment Size H x D x W 12 52 in x 18 20 in x 20 46 in 317 9 mm x 462 2 mm x 519 8 mm 24 in 155 cm 1 13 in 28 3 mm 20 in WC 1 4 in Hose Barb a E 3 o Minimum Free Air Inlet Area Muffler Outlet Collar O D Maximum Exhaust Back Pressure Gasoline Fuel Connection Maximum Gasoline Fuel Pump Lift 3 ft 1m LPG Vapor Fuel Connection 1 4 in NPTF LPG Vapor Connection Pressure 9 13 in 228 330 mm WC na typical RV installation at half load and distance of 10 ft 3 m Seethe Installation Manual for additional considerations when sizing the genset compartment 2 3 Redistribution or publication of this document by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited 3 Clearances and Dimensions ITEM INCHES MILLIMETERS CYLINDER HEAD Cylinder Head Deformation Limit 0 00394 3 39370 0 100 100 0 18 24 ftelb 25 33 Nem VALVE Valve Face Angle Intake 44 5 45 Exhaust Valve Stem Diameter Intake Exhaust Valve Guide Inside Diameter Clearance Between Valve and Guide Stem Reference Valve Intake 0 00079 0 00173 0 020 0 044 Intake
70. by means of a throughbolt The rotor is supported on the other end by the endbell which is placed over the bearing and secured to the stator housing Figure 9 1 The rotor field winding provides the rotating mag netic field which in turn generates the voltage and current in the stator windings to power the con nected loads The magnetic field is established by a 9 1 DC current flowing from the brushes through the slip rings and the field winding Generator Cooling Cooling airflow for the generator is provided by a centrifugal fan mounted on the shaft behind the bearing A portion of the airflow from the fan is di rected into the generator Part of this air flows down the rotor cooling the rotor winding and the rest flows over the stator windings cooling them Electronic Voltage Regulator The electronic voltage regulator controls the output of the generator so that the voltage remains constant under any load condition The electronic voltage regulator takes power from the excitation winding rectifies it and feeds it into the field winding through the brushes and slip rings The regulator senses the output of the power winding and its cir cuitry decides how much current should be fed into the field winding to maintain the proper output at various load levels Brushes and Brush Block The brush block is a one piece molded part that mounts inside the endbell There are two carbon brushes in the brush block which ride on th
71. carburetor main and idle adjustment screws Disassemble carburetor and clean all internal passages Adjust carburetor float level Check for proper fit of service access cover and check seal around endbell Make sure air inlet is not blocked and that it is properly sized refer to Installation Manual Make sure that air outlet is not blocked and check for recirculation of outlet air Replace air filter Clean choke and choke linkage Adjust carburetor idle and main adjustment screws Disassemble carburetor and clean all internal passages Lower oil level Drain and refill fuel tank Perform Leak Down Test Redistribution or publication of this document by any means is strictly prohibited Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only trained and experienced personnel with knowledge of fuels electricity and machin ery hazards should perform service procedures Review SAFETY PRECAUTIONS p iii Engine Hunts or Surges High Oil Consumption Note New engines can have high oil consump tion during break in TABLE 6 12 TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Possible Cause Corrective Action Page 1 Fuel supply problem caused by a Faulty fuel pump gasoline sets b Contaminated fuel supply c Vapor locking d Plugged fuel filter e Carburetor passages plugged Incorrect fuel mixture due to a Incorrectly adjusted fuel mixtur
72. ced by re pair kit in carburetor cleaner Do not soak non metal floats or other non metal parts Follow the cleaner manufacturer s recommendations Clean all carbon from the carburetor bore es pecially where the throttle and choke plates seat Be careful not to plug the fuel ports Blow out all passages with compressed air Do not use wire or other objects for cleaning They can increase the size of critical passages IDLE ADJUSTMENT THROTTLE SHAFT THROTTLE PLATE THROTTLE STOP SCREW IN MAIN NOZZLE O RINGS MAIN ADJUSTMENT SCREW CAP SPRING PLATE FIGURE 8 19 CARBURETOR OVERHAUL PRIOR TO SPEC E MODEL KV ONLY 8 17 Redistribution or publication of this document by any means is strictly prohibited 4 Check the condition of any needle valve and re place if damaged Figure 8 20 Replace float if loaded with fuel or damaged DAMAGE AND WEAR 5 Check the choke and throttle shafts for exces OCCUR HERE sive play in their bore and replace if necessary 6 Replace old components with new parts in cluded in repair kit Reassembly and Installation When carburetor ROR TO SPEC E MODEL KV ONLY parts are clean and dry reassemble as follows 1 If removed during overhaul slide in the throttle shaft and install the throttle plate using new screws if necessary Before tightening the screws the throttle plate must be centered in the bore To do so remove the throttle stop screw and complet
73. cle Removing heavy components Redistribution or publication of this document by any means is strictly prohibited REMOVING THE GENSET Some service procedures will require removing the genset from the coach While there are many varia tions Model KV and KVD genset installations are generally either compartment mount or under the floor mount Model KVD gensets have an external muffler mounted below the genset which must be removed before the genset is removed In a compartment mount installation a special compartment see Figure 5 1 is built into the coach to house the genset The compartment is constructed with a vapor tight barrier that seals off the genset from the coach interior The genset is usually fastened to the floor of the compartment which must be able to support the weight of the gen Set Access to the compartment is through a door lo cated in the exterior of the coach With the under floor mount installation see Figure 5 2 special brackets are used to suspend the gen set under the floor of the vehicle The mounting brackets bolt to special support members that are built into the vehicle framework The genset is mounted near the exterior of the vehicle Access is provided through a door located in the exterior of the vehicle Figure 5 3 illustrates the Model KVC genset instal lation Because of the wide variety of genset installations it is not possible to specify the exact removal proce dures for eac
74. component loca tions in typical genset installations Some installations may require partial removal of the genset to gain access to the battery cable fuel line and other connections Read this section before starting genset removal 1 Disconnect the vehicle and genset negative battery cables at the battery Sparks and high current could cause fire and other damage to the battery battery cables and vehicle if the loose ends of cables connected to the battery touch Always disconnect the negative battery cable from the battery before disconnecting the battery cables from the genset Disconnect the genset positive battery cable from the wire harness Disconnect the remote control wire plug from the genset housing Disconnect the generator load wires at the RV electrical system junction box Tag the RV cir cuit wires for positive identification when recon necting Loosen the conduit connector and pull the load wires and flexible conduit free of the junction box For Model KV disconnect the tail pipe For Model KVD disconnect the tail pipe and remove the muffler For Model KVC unclamp the flexible exhaust tube from the engine and loosen the two muffler hangers to remove the entire muffler tail pipe assembly Figure 5 3 Take care not to dam age the flexible exhaust tube Disconnect the fuel line from the genset Follow the applicable instructions depending on the fuel
75. cy Hz Typical Freq Minimum Full Load Speed r min Frequency Hz GASOLINE MODEL GOVERNOR SHAFT 50 HERTZ SPRING LOCATION 60 HERTZ SPRING LOCATION SPEED ADJUSTMENT SCREW SENSITIVITY ADJUSTMEN THROTTLE T SCREW STOP M1877 1s SPEED ADJUSTMENT SCREW Typical Freq 59 5 60 5 49 5 50 5 49 5 50 5 6 Adjust the governor sensitivity screw to give the closest regulation least speed and voltage dif ference between no load and full load without causing a hunting condition To increase the sensitivity turn the adjustment screw counter clockwise one to two turns only To decrease sensitivity turn the adjustment screw clock wise THROTTLE STOP M1877s 7 Recheck the speed setting made in Step 4 and readjust if necessary FIGURE 8 14 GOVERNOR ADJUSTMENTS 8 12 Redistribution or publication of this document by any means is strictly prohibited GASOLINE FUEL SYSTEM The fuel system must be in good condition and be properly adjusted for efficient genset operation The main components of the fuel system are the air filter assembly carburetor choke intake manifold fuel filter fuel pump and air preheater Fuel presents the hazard of fire or explosion that can cause severe personal injury or death Eliminate all possible ignition sources such as open flame sparks cigarettes pilot lights and arc producing equipment and elec trical switches from t
76. cylinder block thoroughly where gas ket rests Place head in position and follow head torque tightening sequence shown in Figure 10 4 Start out tightening all bolts to 11 ft lb 15em then tighten to the specified torque see Torque Specification section VT 1036s FIGURE 10 4 CYLINDER HEAD TIGHTENING SEQUENCE Redistribution or publication of this document by any means is strictly prohibited VALVE SYSTEM The engine uses an overhead valve design as shown in Figure 10 5 A properly functioning valve system is essential for good engine performance Access to the valve system can be gained by re moving the head cover and the cylinder head Use the following procedures to inspect and service the valve system EXHAUST VALVE INTAKE VALVE INTAKE VALVE SEAL SPRINGS VT 1037s FIGURE 10 5 OVERHEAD VALVE SYSTEM Valve Removal The valves can be removed from the cylinder head without the use of special tools Depress the valve spring retainer using a 9 16 inch crows foot on a 6 inch extension and remove keeper See Figure 10 6 Remove spring retainer and spring then re move valve Always wear safety glasses with side shields when removing springs to prevent severe eye damage 10 4 KEEPER 9 16 INCH VT 1038s FIGURE 10 6 VALVE REMOVAL Inspection Valve Face Check the valve face for evidence of burning warping out of round and carbon depos its see Figure 10 7 Burning and pitt
77. d first remove and inspect the pressure balance hose which is connected between the regulator and the fitting on the air filter end of the carburetor Figure 8 27 Replace the hose if it is plugged or kinked or not 23 to 25 inches 584 to 635 mm long For Specs E through K on Model KV the pressure balance hose must be 23 to 25 inches 584 to 635 mm long for proper engine performance Do not cut the hose to make it fit better Replace a hose that has been cut short Checking and Adjusting Regulator Lock off Pressure Lock off pressure is determined as fol lows by pressurizing the back vent side of the reg ulator diaphragm to simulate carburetor venturi vac uum 1 Connect the regulator inlet Figure 8 24 to a source of air pressure regulated to 11 inches WC 2 Disconnect from the carburetor the LPG supply hose and the pressure balance hose both of which come from the regulator 3 T in two hoses to the end of the pressure bal ance hose 1 4 inch I D if Spec E and 3 8 inch D if earlier Spec Use one hose to measure pressure by connecting it to an inclined ma nometer that reads 0 to 2 inches WC and the other to provide the test pressure 8 22 AUTOMATIC PRIMING SOLENOID INLET HOSE FITTING OUTLET HOSE FITTING Y BALANCE HOSE FITTING LOCK OFF ADJUSTMENT SCREW Beginning Spec E this screw is neither visible nor accessible for adjustment FIGURE 8 24 DEMAND REGULATOR WITH AUTOMATIC PRIMING
78. d Flash Mode Holding the Start Stop switch S1 in the Start position activates the following field flash circuit e Battery positive B is supplied through the control assembly A1 to the voltage regulator VR1 at pin 7 From pins 9 and 10 of the voltage regulator excitation voltage flows through the brushes to the rotor field winding e The excitation voltage flashes the generator field winding to ensure that there is adequate magnetism to induce generator voltage buildup START STOP SWITCH S1 BATTERY BT1 CONTROL ASSEMBLY A1 VOLTAGE REGULATOR VR1 FIGURE 6 5 START FIELD FLASH MODE 6 7 Redistribution or publication of this document by any means is strictly prohibited Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only trained and experienced personnel with knowledge of fuels electricity and machin ery hazards should perform service procedures Review SAFETY PRECAUTIONS p iii Engine Starts But Stops When Start Switch Is Released TABLE 6 3 CONTROL TROUBLESHOOTING FIELD FLASH MODE Possible Cause Corrective Action Page 1 Low oil level 2 Defective low oil level switch 2 3 No field flash voltage due to a Open circuit in wiring b Brushes not making good contact with slip rings c Slip ring surface is rough or pitted 4 Defective generator control assembly A1 or voltage regulator VR1 6 8 1a 3a Check oil level and a
79. dd oil if low Disconnect low oil level switch and check set operation Replace if defective Check wiring continuity to the brush block F1 F2 voltage regulator VR1 control assembly A1 and generator B1 B2 and Q1 Q2 windings Check connections of P5 and P6 connectors on the generator housing Check brushes for wear and for contact with the slip rings Check slip rings Perform field voltage test Redistribution or publication of this document by any means is strictly prohibited Run Mode When the engine starts release the Start Stop switch and it will return to the center Run position The following events occur e Control assembly A1 opens the circuit to the start solenoid K1 which opens the circuit to the starter motor M1 to stop cranking Control assembly A1 also opens the field flash circuit to AVR pin 7 e Voltage from the battery used to power the control assembly A1 and the fuel pump E2 is replaced with output voltage from the generator charge winding B1 B2 Refer to Battery Charge Mode following this section The control assembly senses this output for the start disconnect function e Remote run output is energized through the control assembly A1 to power the time meter battery condition meter and run lamp in the optional remote control e Voltage from the generator Q1 Q2 windings provide power to the voltage regulator VR1 to use for supplying field current to the generator Refer to Gener
80. defective as required Reset breaker Check for good wiring connections and continuity and correct as required Check for good wiring connections and continuity and correct as required Check for continuity between control connector J2 3 and voltage regulator connector P3 7 If connections are good and 12 VDC is not present at voltage regulator pin 7 during start control assembly A1 is defective Check brushes for wear and for contact Check slip rings Check capacitor and replace if defective Perform field voltage test Refer to governor adjustments Check length of brushes and replace if worn excessively Check slip rings Check for good wiring connections between the voltage regulator and the brush block and between stator connec tions Q1and Q2 Correct if required Replace electronic voltage regulator Redistribution or publication of this document by any means is strictly prohibited Generator AC Output Mode When the engine starts and begins to come up to speed AC voltage is produced in the battery charge winding B1 B2 the quadrature winding Q1 Q2 and in the AC windings T1 T2 These outputs perform the following functions e The battery charge winding B1 B2 is used to power the control assembly A1 fuel pump E2 the remote con trol and to prevent discharge of the genset starting battery during genset operation This output is not sufficient to charge a low or dead b
81. determine if voltage is being supplied to the brushes from the voltage regulator for voltage buildup Connect a DC voltmeter positive test lead into the voltage regulator plug P1 at pin 9 and connect the negative test lead into the voltage regulator plug at pin 10 The voltage regulator plug remains connected to the voltage regulator and test prods should be secured so that they are not being held during testing See Figure 9 2 Contact with rotating machinery can result in severe personal injury Keep hands hair clothing jewelry and fingers clear while servicing slip rings Electrical shock can cause severe personal injury or death Use extreme caution when working on electrical circuitry Attach and remove meter leads only when genset is not op erating Do not touch meter or meter leads dur ing testing Start the genset and allow it to stabilize Measure the field voltage with no load applied and then with full load applied Both readings should fall within a range of 18 to 60 volts DC If the genset cranks but will not run check to see that battery voltage is supplied to the voltage regulator pin 7 positive lead and ground negative lead dur ing start up If battery voltage approximately 12 volts is supplied to the voltage regulator at pin 7 there should also be battery voltage between pin 9 and ground If no voltage at pin 9 replace the volt age regulator and retest If battery voltage is not supplied to
82. e see He dentally entering the engine moving the Genset p 5 3 and remove the gen t encl re PERO 8 Remove the two screws that secure the carbu 2 Remove the choke assembly mounting bolts retor to the intake manifold and carefully sepa and disconnect the choke linkage from the car rate the carburetor from the intake manifold buretor Remove the vacuum hose from the in take manifold Assembly Assembly is the reverse of disassem bly Use new gaskets between the intake manifold and engine and between the carburetor and the in 4 Disconnect the fuel line and plug to prevent fuel take manifold Torque the mounting screws to speci leakage fications 3 Remove the governor control linkage and spring attached to the carburetor INTAKE CARBURETOR ASSEMBLY EN MOUNTING BOLTS FIGURE 8 16 CARBURETOR AND INTAKE MANIFOLD ASSEMBLY 8 14 Redistribution or publication of this document by any means is strictly prohibited Carburetor Begin Spec E Model KV All Model KVC Other than turning the altitude adjust knob shown in Figure 8 17 which changes the main fuel mixture within a limited range fuel mixture adjustments should not be attempted Nor should the carburetor be overhauled Instead a malfunctioning carbure tor should be replaced Before replacing a carbure tor however make certain 1 that all other neces sary engine and generator adjustments and repairs have been performed and 2 that the carb
83. e ignition coil is located be low the lower right corner of the access cover Dis connect the coil ground lead primary lead and spark plug lead from the spark plug The coil can be removed from the genset for testing See Figure 8 13 1 Inspect the terminal and leads for signs of cor rosion or looseness and look for cracks dents or other damage Look for evidence of electri cal leakage around the high tension connection indicated by carbon tracking Replace a coil with any defects 2 Measure the primary winding resistance Con nect one ohmmeter lead to the primary terminal and the other lead to the ground lead ring termi nal The resistance should be approximately 0 5 ohms at 75 F 24 C Replace the coil if a high or low reading is measured 3 Measure the secondary winding resistance Connect one ohmmeter lead to the spark plug connector inside the boot and the other lead to the ground lead ring terminal The resistance should be approximately 1 100 ohms at 75 F 24 C Replace the coil if a high or low reading is measured If no spark is seen and the coil windings check good proceed to the Ignition Wiring check Ignition Wiring The ignition wiring consists of the following One ground wire connected to the ignition coil T1 IGN and one ground wire connected to the magneto assembly One wire from the magneto G2 to the ignition coil primary 8 9 One ignition enable wire from the control as
84. e ignition system is suspected the spark plug can be inspected and an ignition spark check can be made without removing the genset from the vehicle Perform the spark plug ignition coil and ignition wiring checks before proceeding to the Magneto Assembly section on Page 8 10 Electrical shock can cause severe personal injury or death Do not touch electrical wiring or components during testing Discon nect electrical power by removing the starting battery negative cable before handling elec trical wiring or components Do not connect me ters while circuit is energized Use rubber insu lative mats placed on dry wood platforms over floors that are metal or concrete when testing electrical equipment Do not wear jewelry or damp clothing particularly wet shoes or allow skin surfaces to be damp when handling electri cal equipment Spark Plug E2 Remove the spark plug and inspect the electrode If the spark plug has carbon deposits use a wire brush to clean it If the spark plug is badly fouled or deformed replace it Measure and reset the spark plug gap as shown in Figure 8 12 See Sec tion 2 Specifications An examination of the spark plug can often diagnose an engine problem Refer to the following spark plug conditions s Carbon fouled Check for a poor high tension lead connection faulty choke operation rich fuel mixture or dirty air filter e Oil fouled Check for low compression s Burned or overheated C
85. e instructions on how to remove and replace the carburetor in Air Filter And Preheater Assembly on Page 8 13 and Carburetor And Intake Manifold Assembly on Page 8 14 References to preheaters and chokes are not applicable to LPG carburetors Isolating Fuel System Problem To isolate the problem to the genset or to the fuel supply system perform the following test 1 Close the vehicle gas supply tank valve and disconnect the gas hose at the carburetor fuel air mixer Connect a shop tank at least 30 Ib through a primary regulator and demand regulator ad justed for 11 inches WC If the genset can be started and runs properly the problem is in the gas supply system up to the connection at the carburetor If the genset cannot be started or does not run properly the problem is in the genset starting at the connection to the carburetor Redistribution or publication of this document by any means is strictly prohibited Demand Regulator The demand regulator assembly supplies fuel to the carburetor It is usually not the cause of fuel system problems All other possible causes should be checked out before adjusting or replacing the de mand regulator assembly Figure 8 24 illustrates the regulator with priming solenoid used prior to Spec L on Model KV or Spec B on Model KVD The demand regulator on later models does not have a priming solenoid For Specs E through K on Model KV if a fuel system problem is suspecte
86. e 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 expansion of the ring Com pression rings are marked with the word top or a mark on one side of the ring to indicate which side faces the top of the piston The top ring has a band of red paint and the bottom ring a band of white paint Follow the instructions if any for the ring set Stagger ring gaps 120 degrees apart Do not posi tion ring gaps on thrust face of cylinder CONNECTING ROD MARK CT 1091s FIGURE 10 23 ROD CAP ASSEMBLY Redistribution or publication of this document by any means is strictly prohibited Installing Piston in Cylinder When installing the piston assembly observe markings on the connect ing rod cap and splasher and assemble in correct position See Figure 10 23 1 2 Turn crankshaft to position crankpin at bottom of its stroke Lubricate piston assembly and inside of cylin der Compression rings with a ring compressor as shown in Figure 10 24 Tap piston down into bore with handle end of hammer until connecting rod is seated on crankpin Check crankpin clearance before proceeding to Step 4 see Crankpin Clearance on this page Lubricate the rod crankpin and install the con necting rod cap Tighten connecting rod bolts to specified torque The bearing cap must be tapped several times to prope
87. e retainer for wear Check for spring distortion by placing spring on a flat surface next to a square Measure height of spring and rotate it against a square to measure distortion see Figure 10 8 Re place any valve spring that is weak cracked worn or distorted E VALVE GUIDE VALVE STEM FIGURE 10 7 VALVE FACE VALVE STEM AND VALVE GUIDE INSPECTION 10 5 VT1039s FIGURE 10 8 VALVE SPRING CHECKS Reconditioning Valves and Valve Seats Valves should not be hand lapped because the sharp contact made between the valve face and valve seat will be destroyed Valve faces must be finished in a machine at 44 5 to 45 degrees Each valve must have a minimum of 1 16 inch 1 6 mm margin Figure 10 9 If the valve has less margin than this it will heat up 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 all valves can be reconditioned A badly warped valve must be replaced because the excessive grinding require 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 1 16 INCH 1 6mm MINIMUM REFER TO SPECIFICATIONS FOR CORRECT DIAMETER A 44 5 45 CHECK FOR BENT STEM VT1040s FIGURE 10 9 VALVE MARGIN Redistribution or publication of this document by any means is
88. e screws or b dirt or varnish in carburetor c Incorrect float level gasoline sets Governor problem due to a Sticking or binding governor linkage b Incorrect governor adjustment c Faulty governor spring d Governor mechanism worn excessively Carburetor icing Oil viscosity too light or oil is diluted Crankcase breather valve is dirty faulty or improperly installed Oil leaks Excessive engine wear Light loading Intake valve seal worn or defective 6 21 Check fuel pump and replace if defective Drain and refill fuel supply Let genset cool down Check for blockage air inlet or outlet or improper fuel system installation Replace fuel filter Clean passages or replace pilot jet Adjust carburetor main and idle adjustment screws Disassemble carburetor and clean all internal passages Adjust carburetor float level Check linkage alignment Make sure it does not touch other parts Clean and lubricate linkage Adjust speed and sensitivity settings Replace governor spring See Governor in Engine Block Assembly section In cold weather place air preheater in the 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 Section 10 Engine Block Assembl Do not run genset at no load for long periods of time Replace intake valve seal R
89. e slip rings and provide the means by which the controlled DC current from the regulator is conducted into and out of the rotor Each brush is kept in contact with its slip ring by a spring mounted inside the brush block behind the brush The spring exerts just the right amount of pressure to provide good contact and long brush life Wiring Harness A separate wiring harness is provided for connect ing the genset 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 must be provided by the RV manufac turer or genset installer A 1 2 inch conduit elbow is provided to facilitate installation The load wire con ductor is black the neutral conductor is white and the ground conductor is green Redistribution or publication of this document by any means is strictly prohibited GENERATOR OPERATION When the Start Stop switch is pushed to the Start position the rotor begins to rotate and is momentari ly connected to the battery This provides a current in the rotor field winding which induces a voltage in the stator windings in particular the excitation wind ing Q1 Q2 The regulator takes this voltage and rec tifies it and feeds it back into the rotor which causes the voltage to increase further This process contin ues as the engine speeds up The voltage increase is controlled by the regulator The regulator is connected to the
90. eaning when poor Remove the head cover to gain access to the cylin engine performance is noticed or to inspect the der head and valve system Use the following pro valves Use the following procedures to service cedure to service 1 Use a 10 mm socket wrench to remove head cover mounting bolts and pull off head cover See Figure 10 3 2 Clean head cover Be careful not to damage outer sealing edge where gasket fits 3 Clean cylinder head cover and cylinder head thoroughly where gasket rests Use new gas ket when reinstalling and make sure breather assembly is correctly installed in cylinder head cavity 4 Place head cover in position and torque until all bolts are tightened to the specified torque BREATHER ASSEMBLY l E GASKET i al HEAD LS 1173 FIGURE 10 3 HEAD COVER REMOVAL 10 3 1 Lift breather out of cavity in cylinder head Remove lock nut and adjusting bolts from rock er arms and push rods Remove cowling mounting bolts and lift off cowling Use a 12 mm socket wrench to remove the cyl inder head mounting bolts and lift off the head Warping can occur if the head is removed while hot Wait until the engine has cooled before removing cylinder head Clean out all carbon deposits Be careful not to damage outer sealing edge where gasket fits The head is made of aluminum and can be damaged by careless handling Use new head gasket and clean both cylinder head and
91. earing 4 Place the rotor shaft engine end down onto a 1 1 16 inch 27 mm O D steel shaft or use a plug mated to the engine end of the rotor shaft to protect the shaft taper from damage when pressing bearing into place 5 Refer to measurement taken in Step 1 Press bearing onto rotor shaft press on inner race only until it rests at the same distance from the collector ring assembly as the original bearing Do not place bearing closer than 0 14 inches 8 5 mm to the collector ring or arcing can re sult Check bearing seal for damage after installation 9 14 Redistribution or publication of this document by any means is strictly prohibited 10 Engine Block Assembly INTRODUCTION This section covers service procedures for the en gine block assembly A leak down test can be per formed to determine the condition of the engine Use the procedures in the following section to per form the leak down test Performing any major service will require genset re moval from the vehicle See Removing the Genset p 5 3 To gain access to the engine block assem bly the generator and primary engine systems must be removed Refer to the previous sections for the disassembly procedures A suggested order of disassembly for the engine block assembly follows Oil pan and oil level switch Head cover breather and cowling Rocker arms and push rods Oylinder head valve springs and valves Crankcase cover and camshaft
92. ed by coating the suspected area with a mixture of 25 percent kerosene and 75 percent light motor oil Wipe the part dry and im mediately apply a coating of zinc oxide white lead dissolved in wood alcohol If cracks are present the white coating will become discol ored at the defective area Always replace a cracked cylinder block Clean the block and proceed 2 Inspect all machined surfaces and threaded holes Carefully remove any nicks or burrs from machined surfaces Clean out tapped holes and clean up any damaged threads 3 Check cylinder head mounting area for flatness with a straight edge and a feeler gauge 10 14 Inspecting Cylinder Bore Inspect cylinder bore for scuffing scratches wear and scoring If cylinder bore is scuffed scratched scored or worn the block must be replaced When the appearance of the cylinder bore is good and there are no scuff marks check cylinder bore for wear or out of round as follows 1 Check cylinder bore for taper out of round and wear with a dial bore gauge telescope gauge or inside micrometer These measure ments should 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 10 27 A Measure and record as A the cylinder bore diameter parallel to crankshaft near the top of cylinder bore where greatest amount of wear
93. edistribution or publication of this document by any means is strictly prohibited Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only trained and experienced personnel with knowledge of fuels electricity and machin ery hazards should perform service procedures Review SAFETY PRECAUTIONS p iii TABLE 6 13 TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Possible Cause Corrective Action Page Engine Shuts Low oil level 1 Add oil as required Down and Will Not Restart Low oil level switch is defective Check low oil level switch Also see Worn spark plug Clean or replace spark plug Control Trouble Faulty fuel system flooded Refer to Fuel System section shooting table 6 4 Choke not opening Check choke operation Faulty ignition system Check for spark Engine Runs Fouled spark plug Clean or replace spark plug On After Engine carbon build up Remove carbon from engine Shutdown 6 22 Redistribution or publication of this document by any means is strictly prohibited 7 Control This section covers control operation component e Start Stop Switch S1 locations basic troubleshooting and test proce St Mee e Start Relay K1 dures The control consists of the circuitry used for y starting monitoring fault conditions instrumenta Control Fuse F1 tion battery charging and stopping e Circuit Breaker CB1 Review Control Description and
94. ely close the throttle lever pu Seat the plate then tighten screws Install the ue PIN choke shaft and plate in the same manor ON NEEDLE A VALVE 2 Install idle mixture screw assembly Turn in i screw until lightly seated and then out the num FLOAT ber of turns specified in Table 8 2 Page 8 16 E Forcing the mixture adjustment screws tight will damage the needle and seat Turn in only until light tension is felt POSITION HOOK UNDER 3 Install needle valve and seat fuel bowl gasket TAB ON FLOAT and float assembly Make sure all clips and springs are properly placed and the float moves freely without binding see Figure 8 21 FIGURE 8 21 FLOAT INSTALLATION PRIOR TO SPEC E MODEL KV ONLY 4 Invert the float and needle valve assembly and check float level by measuring between the float and carburetor at the point shown in Figure BEND TAB 8 22 The full weight of the float should be rest TO ADJUST MEASURE THIS ing on the needle valve and spring The correct DISTANCE distance is specified in Table 8 2 If the setting is incorrect remove float and bend tab to ad just Bend the float only at the point indicated Attempting adjustments with the float assembly installed can damage the inlet needle and seat Remove float assem FIGURE 8 22 FLOAT LEVEL PRIOR TO SPEC E bly before making adjustments MODEL KV ONLY 8 18 Redistribution or publication of this document by any means is strictly prohibited
95. ent tabs Figure 9 1 Squeeze screw driver handles together and carefully pull the stator straight out of the endbell If the stator will not slide out tap on the generator housing while pulling on the stator to remove Do not bend or flex stator wire terminals or damage can occur Take care not to bend flex or break the stator terminals when handling the stator or disconnecting wires Place a wooden shim between the bottom of the stator housing and the base assembly to prevent movement between the generator and the base Carefully tap on the rotor shaft with a lead hammer to free tapered rotor shaft from the crankshaft Be careful to avoid striking the collector rings Pull the rotor straight out Notice the alignment pin in the rotor shaft used to align the rotor shaft with the crankshaft Take care not to hit and damage the collector rings when removing rotor Generator Assembly Use the following procedure to assemble the gener ator 1 Prepare the genset for stator and rotor installa tion The stator and rotor must be installed while the genset is standing vertically on the en gine end for correct alignment of the rotor shaft to the crankshaft Raise the generator end of the genset and allow it to rest on the engine end Place a wooden block under the muffler to 9 10 hold the genset level Support the genset to prevent it from falling during service The genset is heavy and can re sult in severe personal i
96. er off genset Model KV only Disconnect the fuel line from the fuel pump Plug fuel lines to keep fuel from escaping Mod el KV only Fuel presents the hazard of fire or explosion which can cause severe per sonal injury or death Do not permit any flame spark arcing switch or equipment pilot light cigarette or other ignition source near the genset Keep a type ABC fire extinguisher nearby 5 Disconnect the B lead from the start solenoid 6 Remove the control panel mounting screws and loosen the control panel Model KV only Remove the two bottom mounting nuts secur ing the inlet baffle assembly Lift the inlet baffle up and move it to the side Remove the air filter cover retainer and filter Figure 8 15 on Page 8 13 Remove the scroll housing from the endbell Figure 9 1 Secure the fan hub assembly and remove the rotor through bolt and washer Figure 9 1 Re move the alignment key from the end of the ro tor shaft and save for reassembly Redistribution or publication of this document by any means is strictly prohibited 10 11 12 Remove fan hub assembly with a wheel puller Figure 9 7 Attach the wheel puller to the fan hub assembly with three 5 16 inch thread tap ping cap screws or tap fan hub with 3 8 16 inch tap and use 3 8 16 inch cap screw Prepare the brushes for endbell removal Dis connect wire harness leads from brush block and pull each brush outward from t
97. erminate the tail pipe such that it is clos er than 6 inches 153 mm to any opening such as a door window vent or unsealed compart ment into the vehicle interior Figure 8 7 Make sure a tail pipe deflector will not cause ex cessive back pressure Section 2 Specifica tions or interfere with removing a spark arrest ing screen if so equipped A CAUTION Excessive back pressure may void emissions certifications and cause en gine damage DEPARTURE ANGLE LINE ANGLE b A 3 4 INCH 19 MM SLOT BOTH SIDES FIGURE 8 4 TAIL PIPE CONNECTIONS AXLE CLEARANCE APPROACH FIGURE 8 5 APPROACH AND DEPARTURE ANGLES AND AXLE CLEARANCE 1 INCH 25 mm MINIMUM LAST TAILPIPE HANGER AS CLOSE TO END AS PRACTICAL FIGURE 8 6 TERMINATING THE TAIL PIPE NO OPENING INTO THE VEHICLE INTERIOR MAY BE CLOSER THAN 6 INCHES 153 mm TO THE END OF THE TAIL PIPE WITHIN SHADED AREA TAILPIPE FIGURE 8 7 MINIMUM DISTANCES TO OPENINGS Redistribution or publication of this document by any means is strictly prohibited COOLING SYSTEM A constant airflow is critical for engine and genera tor cooling to prevent excessive heat build up A centrifugal fan on the generator end of the genset provides the required airflow The fan draws cooling air in through the air inlet into the generator and across the engine cooling fins then discharges the heated air through the air outlet See Figure 8 8
98. et does not bog down or hunt ADJUSTMENT MAIN ADJUSTMENT SCREW FIGURE 8 18 MIXTURE SCREW ADJUSTMENT PRIOR TO SPEC E MODEL KV ONLY Redistribution or publication of this document by any means is strictly prohibited Carburetor Overhaul Prior to Spec E Model KV Only Carburetor problems not corrected by mixture or float adjustments usually result from gummed up fuel passages or worn internal parts Either replace the carburetor or overhaul it using the gaskets and replacement parts in the kits that are available See Figure 8 19 Removal and Disassembly Remove the carbure tor and intake manifold assembly as instructed in Carburetor and Intake Manifold Assembly Remove the carburetor from the intake manifold and disas semble as follows 1 Remove the main and idle mixture screw as semblies 2 Separate the lower section of the carburetor Remove the float chamber by removing the bolt from the bottom of the carburetor PILOT JET NEEDLE VALVE CLIP WASHER q O RING BOLT SPRING 4 3 Carefully note position of the float assembly parts then slide out retaining pin and remove the float and needle valve 4 Unscrew and remove the main nozzle Do not remove the choke or throttle plates shafts arms or governor link bushing unless damaged Clean and Repair When the carburetor is com pletely disassembled clean and repair as follows 1 Soak all metal components not repla
99. exhaust pipe terminates beyond the perimeter of the coach Visually and au dibly check for leaks at all connections welds gas kets and joints Also make sure that exhaust pipes do not heat surrounding areas excessively If leaks are detected correct immediately Inhalation of exhaust gases can re sult in severe personal injury or death Inspect exhaust system audibly and visually for leaks Shut off the engine and repair leaks immediate ly FUEL SYSTEM With the genset operating inspect the fuel supply line and fittings for leaks Check flexible section for cuts cracks and abrasions and make sure it is not rubbing against anything that could cause damage 11 2 Leaking fuel creates a fire hazard which can result in severe personal injury or death if ignited by flame spark pilot light ciga rette arc producing equipment electrical switch or other ignition source If fuel leaks are detected shut off the genset and correct leak immediately OUTPUT CHECK Apply a full load to make sure the set can produce its full rated output Use a load test panel to apply a pro gressively greater load until full load is reached CONTROL Stop and start the genset several times at the set control and remote control if equipped to verify that it functions properly MECHANICAL Stop the genset and inspect it for leaking gaskets loose fasteners damaged components or interfer ence problems Repair as required Inspect the
100. f open locate and correct cause of overload Replace fuse Check condition of battery and recharge or replace Clean and tighten all connections at battery K1 start solenoid and starter motor Increase starting battery cable size Check wiring continuity to the start solenoid K1 coil from control assy A1 and from ground to start solenoid Test start solenoid K1 Test Start Stop switch S1 Measure voltage between start solenoid terminal I and ground with switch S1 held in the Start position If voltage is not present and continuity and battery check OK Cont assy A1 is defective Check continuity between starter lead on start solenoid S and gnd 4 1 ohm Check wiring continuity between battery B and the start solenoid BAT Measure voltage between starter terminal and ground with switch S1 held in the Start position If voltage is not present and continuity checks OK start solenoid K1 is defective If voltage is present in step 4c starter is defective Check wiring continuity between control assembly A1 and remote Start Stop switch Test remote Start Stop switch Redistribution or publication of this document by any means is strictly prohibited Start Ignition Mode Holding the Start Stop switch S1 in the Start position activates the following ignition circuit e Control assembly A1 enables the ignition circuit this opens a ground path through the control assembly
101. g time meter and the battery condition meter in the op tional deluxe remote control A2 A low oil level will cause the low oil level switch S2 to close This closes a ground path to the magneto assembly G2 eliminating ignition spark and pre venting the engine from operating If the oil level goes below the low oil level during operation the genset will shut down Charging Circuit Spec C E Model KV A 12 volt DC output one ampere maximum from the generator is used to prevent discharge of the genset starting battery during genset operation This output is not sufficient to charge a low or dead battery Stopping Pressing the Start Stop switch S1 to the Stop posi tion de energizes the ignition enable circuit and grounds the magneto assembly G2 output This causes the engine to stop running The Stop posi tion also activates the remote stop latch feature pre venting restart At the same time the fuel pump is de energized Redistribution or publication of this document by any means is strictly prohibited CONTROL COMPONENT TESTS The following control component checks can be made to verify if components are defective Discon nect the starting battery cables negative cable first before performing these tests Accidental starting or electrical shock can cause severe personal injury or death Disconnect both genset starting battery cables before performing maintenance Re move the negative battery cab
102. ge and for rec ae ee A H The engine family designation engine displacement state ommendations concerning engine lubricating oil ment of compliance with the applicable EPA and or California and fuel emissions regulations including the compliance period or category appear in this block on the actual nameplate on the f L See the Installation Manual for important recom aag J mendations concerning the installation and for a list of the installation codes and standards for safety which may be applicable See the Parts Manual for parts identification num bers and required quantities and for exploded views of the genset subassemblies Genuine Onan re placement parts are recommended for best results When contacting Onan for parts or product informa tion be ready to provide the model and serial num bers on the genset nameplate Figure 1 1 illustrates the nameplate and its location Every character in MODEL KVC these numbers is significant The last character of the model number is the specification letter which is important for obtaining the right parts FIGURE 1 1 TYPICAL NAMEPLATE 1 1 Redistribution or publication of this document by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited 2 Specifications GASOLINE __ tre __ GENERATOR 2 Pole Revolving Field Self Excited Electronically Regulated 1 Phase FUEL CONSUMPTION
103. h genset If after examining the instal lation a satisfactory method for removing the gen set cannot be determined contact the RV coach manufacturer to obtain their recommendations FUEL AND ELECTRICAL CONNECTIONS LEFT SIDE BARRIER M1723 2s FIGURE 5 1 TYPICAL MODEL KV AND KVD COMPARTMENT INSTALLATION 5 3 Redistribution or publication of this document by any means is strictly prohibited FLOOR OF COACH MOUNTING BRACKETS Y AA BARRIER qe Ao IES NS M1724 2s FIGURE 5 2 TYPICAL MODEL KV AND KVD UNDER FLOOR INSTALLATION 5 4 Redistribution or publication of this document by any means is strictly prohibited AIR SEAL PANEL STEEL ENCLOSURE AND COOLING AIR PLENUM THAT SEALS TIGHT AROUND SIDES TOP AND FRONT TO PREVENT AIR RECIRCULATION FRONT ACCESS COVER MUST ALSO SEAL TIGHT COACH MANUFACTURER THE DOTS REPRESENT LOCATIONS REQUIRING AC CESS FOR OPERATION AND PERIODIC MAINTENANCE UNCLAMP THE FLEXIBLE EX HAUST TUBE AT THE ENGINE AND LOOSEN THE TWO MUF FLER HANGERS TO REMOVE THE ENTIRE MUFFLER TAILPIPE ASSEMBLY iiia HOT AIR DISCHARGE VEHICLE FRAME GENSET OUTRIGGERS MUFFLER TAILPIPE AND 2 OF 4 MOUNTING BOLTS ASSEMBLY FIGURE 5 3 MODEL KVC INSTALLATION 5 5 Redistribution or publication of this document by any means is strictly prohibited Disconnecting Set from RV Systems Disconnect the following items from the genset Re fer to Figures 5 1 5 2 or 5 3 for
104. he ignition coil If no spark was seen in the Ignition Spark Check and all accessible ignition wiring checks good perform the Magneto Assembly Check Magneto Assembly Check Use a known good new ignition coil 1 Make sure the cranking circuit and battery are in good condition Disconnect the J2 harness connector from the control assembly A1 Measure the resistance between J2 pin 4 and ground If the resistance is 100 ohms or more proceed to Step 3 If zero resistance is measured the low oil level switch is grounding the magneto output due to a low oil level or a defective low oil level switch S2 Correct this problem before proceeding to Step 3 The oil level switch is covered in the Oil Pan and Oil Level Switch section on Page 10 2 Remove the spark plug reconnect the spark plug lead and ground the plug side electrode to bare metal on the engine Do not touch the plug or plug wire during test ing Crank the engine and observe the plug A 8 10 good spark should be observed If no spark is observed the magneto or wires connected to the magneto are the most likely cause Refer to the Generator Disassembly section on Page 9 8 for generator disassembly to access the magneto assembly CRANKCASE VENTILATION The crankcase breather prevents pressure build up in the crankcase It also prevents oil contamination by removing moisture or gasoline vapors and other harmful blow by materials from the crankcase These
105. he holder and at the same time insert a piece of wire into the small hole in the endbell at bottom of brush block See Figure 9 8 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 The brushes will be damaged during disassembly if not held off the slip rings Make certain wire is in place before removing the generator endbell Remove the two starter mounting bolts that se cure the starter to the endbell Remove the choke assembly from the generator endbell and disconnect the leads attached to the resis tor at the top of the endbell Remove endbell mounting screws and remove the endbell Se cure springs for reinstallation Sharp edges can cause severe personal injury Wear gloves when handling components with sharp edges Careless handling of rotor or stator can damage the insulation on the windings Do not allow windings to be brushed or scraped during removal 9 9 PULLER FIGURE 9 7 PULLING THE FAN HUB ASSEMBLY BRUSH BLOCK END BELL c A SS Y f S Cet K FIGURE 9 8 BRUSH BLOCK Redistribution or publication of this document by any means is strictly prohibited 13 Remove each of the wire connectors from the stator assembly Wear gloves when handling the stator for protection from sharp edges In sert two 6 inch screw drivers into the holes on opposite sides of the stator laminations next to the alignm
106. he work area and rooms with common ventilation Keep a type ABC fire extinguisher nearby Air Filter and Preheater Assembly The air filter and preheater assembly consists of the air filter cover air filter scroll assembly preheat door and preheat linkage See Figure 8 15 If a problem exists with operation of the preheat door remove the genset see Removing the Genset p 5 3 and remove the enclosure assembly Model KV Check preheater linkage and adjust as re quired If the problem is within the scroll assembly follow the Generator Disassembly procedures on Page 9 8 through the scroll removal step and repair or replace as required 8 13 PRE HEATER CONTROL LEVER AIR FILTER RETAINER FIGURE 8 15 AIR FILTER AND PREHEATER ASSEMBLY TYPICAL ALSO OF MODEL KVC Redistribution or publication of this document by any means is strictly prohibited Carburetor and Intake Manifold 5 Remove the two bottom intake manifold mount ing bolts that connect the intake manifold to the The carburetor and intake manifold assembly con cylinder head sists of the intake manifold carburetor choke pulloff and governor control linkages See Figure 8 16 6 Remove the carburetor and intake manifold as an assembly Removal To remove and disassemble the carbure tor and intake manifold assembly 7 Remove the intake manifold gaskets and plug the intake port to prevent loose parts from acci 1 Remove the genset from the vehicl
107. heck for leaking in take manifold gasket lean fuel mixture or incor rect spark plug type e Splash fouled Check for accumulated com bustion chamber deposits p 10 3 Light tan or gray deposits Normal plug color 8 8 If the spark plug is in good condition proceed to the Ignition Coil section Ignition Coil T1 The ignition coil is a transformer that steps up the magneto output voltage to about 20 000 volts for spark plug firing The coil consists of a primary and a secondary winding Perform the following checks Ignition Spark Check Gasoline vapor is extremely flammable and can result in severe person al injury or death if ignited Make certain that no gasoline or other flammable fumes are present Park the vehicle in a well venti lated area and leave the genset compart ment door open for several minutes before performing this test 1 Make sure the engine oil is adequate and that the genset is level Remove the spark plug reconnect the spark plug lead and ground the plug side electrode to bare metal on the engine Do not touch the plug or plug wire during test ing Crank the engine and observe the plug A good spark should be observed If no spark is observed proceed to the coil winding check SPARK PLUG GAP SEE SPECIFICATIONS ES 1462 FIGURE 8 12 MEASURING PLUG GAP Redistribution or publication of this document by any means is strictly prohibited Coil Winding Check Th
108. hem To disas semble remove the snap ring from the governor center pin and slide governor gear assembly off mounting shaft being careful not to lose outer wash er See Figure 10 15 To install governor assemble in reverse order of removal see inset drawing Fig ure 10 15 for position of flyweight and sleeve To remove the governor shaft remove the retainer clip outside the block then lower the governor shaft into the crankcase SNAP RING RUBBER WASHER BEGIN FLYWEIGHTS 42 7 43 3 MM 1 68 1 70 INCH FIGURE 10 15 GOVERNOR PISTON ASSEMBLY REMOVAL AND SERVICE The piston assembly consists of the piston piston pin and connecting rod assembly After piston re moval all parts must be carefully inspected for dam age and wear before replacing Remove the carbon from the top of the cylinder bore and check for a ridge Remove ridge with a ridge reamer see Figure 10 16 before attempting piston removal Remove the piston as follows Improper use of a ridge reamer can damage the cylinder bore Follow tool manufac turer s instructions and be careful when using a ridge reamer CT 1090s FIGURE 10 16 REMOVING WEAR RIDGE 1 Remove two bolts from connecting rod Mark direction of assembly for connecting rod cap and splasher 2 Lift the rod cap from the rod and push the piston assembly out of the top of the cylinder with the handle of a ham
109. iD E ERE RE fep ETE FERMER REG ES 10 3 Gylinder Head zo morerei kapne Scr ta Gee Ene e pas Mie Son tet qe ae elas 10 3 Valve System ccu a RE SEL ee RIEN rad ERI ER PRIN m ER RE EE RTREdE i 10 4 Crankcase Cover enc edocti elu roba cu lee ok ots te M ede c 10 7 Camshaft and Tappet Removal esee 10 7 COVE MO A a AM UU COP EN M EUN 10 8 Piston Assembly Removal and Service o 10 8 Crankshaft a Sa cat N T e UD de do 10 13 Cylinder BIOCK 556 ex e T nl Dag usd ie eie Dr ipu usce spese 10 14 Timing Gears cerca A Re E ides Se Peewee ees 10 16 Bearings me 10 16 Oll Seal coc ek ERE SERT UIS ERR SENE Rib a RT RE EU a ER 10 16 Compression Release System eese 10 17 TI SERVICE CHECK LIST suo ioe ee I9 eEXqO MERE REED ada ES VE 11 1 12 WIRING DIAGRAMS sondear cca et aee t a et eie e alla 12 1 Redistribution or publication of this document by any means is strictly prohibited SAFETY PRECAUTIONS Thoroughly read the OPERATOR S MANUAL before operating the genset Safe operation and top performance can be obtained only when equipment is operated and maintained properly The following symbols in this manual alert you to po tential hazards to the operator service person and equipment alerts you to an immediate hazard which will result in severe personal injury or death alerts you to a hazard or unsafe practice which can result in severe personal in jury or death alerts you to a hazard or unsafe practice which can re
110. ies the fol lowing outputs and results Energizes the start solenoid K1 causing the start solenoid contacts to close energizing the starter The starter begins to crank the engine to initiate starting Energizes the fuel pump E2 the fuel pump begins pumping fuel to the carburetor for en gine operation e Flashes the generator field winding to ensure that there is adequate magnetism to induce generator voltage buildup e Enable the ignition circuit this opens a ground path through the control assembly to the mag neto assembly G2 so output from the magne to will energize the ignition coil T1 The igni tion coil energizes the spark plug E1 for igni tion Run Mode When the engine starts release the Start Stop switch and it will return to the center Run position The following control assembly functions occur e Voltage from the battery is replaced by output voltage from the generator when the engine 7 4 comes up to speed so the control remains en ergized e Start solenoid K1 is de energized opening the circuit to the starter motor M1 to stop cranking The start disconnect is activated at approximately 2000 rpm Fuel pump E2 remains energized during the run condition Field flash is no longer required and is turned off gnition enable remains on Output from the magneto assembly G2 energizes the ignition coil T1 to provide spark e Remote run output energizes the runnin
111. ing Diagram 50 Hertz 12 15 625 4345 Model KVD Wiring Diagram and Schematic cee eee eee 12 16 12 1 Redistribution or publication of this document by any means is strictly prohibited P Br CRI START BI CS DO av RA 5 SORS SF M Ed E s S T VRI REGULATOR VOLTAGE Esos TIR COIL IGNITION S2 SWITCH LOW OIL LEVEL RI RESISTOR BATTERY CHARGE r ma E2 K2 SOL REGULATOR LP 4 KI RELAY STARTER 4 le ES G2 MAGNETO IGNITION A 5 GI GENERATOR TTT a Bf KI A UT ER EXTR ner E2 FUEL PUMP FUEL SOL LP v 9 EN BA so El SPARK PLUG aon EE moe 5 FUEL PUMP OUTPUT e CAPRCITOR 2 5 B PI 16 CRI RECTIFIER BRIDGE Ze CB CIRCUIT BREAKER AC OUTPUT ES BT BATTERY 12V S EN 62 i B OTOR STARTER u l 2 l A3 REMOTE CONTROL STANDARD 9 P T A2 REMOTE CONTROL DELUXE E x 5 START SOL OUTPUT Al CONTROL ASSY E PI 3 ITEM DESCRIPTION E IGN ENABLE OUTPUT 5 ac Ka lt P2 4045 gt Eg BA SR 42 Ao Q amp BATTERY GND INPUT o S PI 7 a 2 n E z El ee m TI IGN 6 E El VRI Fe NAA F S P3 ERR UH B2 E 250s ve on 3 a S 3 96 99 0 TI al CBI LI LOAD 20V L2 NEUT GND FIGURE
112. ing 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 warping and misalignment Warping occurs mainly due to exposure to intense heat Out of round wear follows when the seat is pounded by a valve whose head is not in line with the stem and guide If a valve face is burned or warped or the stem worn install a new one Too much clearance in the intake guide admits air and oil into the combustion chamber affecting car buretion increasing oil consumption and making heavy carbon deposits Clean metal is a good heat conductor but carbon insulates and retrains the heat This increases combustion chamber tempera ture which causes warping and burning Redistribution or publication of this document by any means is strictly prohibited 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 Stems and Guides Always check stems and guides for wear as shown in Figure 10 7 Use a hole gauge to measure the valve guide When clearance with stem exceeds original clearance by 0 002 inch 0 05 mm replace the valve or cylinder head which includes the valve guide or both Springs Check valve springs for cracks worn ends and distortion If spring ends are worn check valv
113. ink Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist seek medi cal attention Shut down the unit and do not operate until it has been in spected and repaired Never sleep in the vehicle with the genset running unless the vehicle interior is equipped with an operating carbon monoxide detector Protection against carbon monoxide inhalation also includes proper exhaust system installa tion and visual and audible inspection of the complete exhaust system at the start of each genset operation GENERAL After the genset has been serviced and reinstalled in the vehicle inspect the installation and test the set to confirm that the genset will operate properly and produce its full rated load capacity Check each of the following areas before putting the set into ser vice over hot sharp or rough surfaces and are not kinked or worn Check each of these connections Load wires e Control wires e Ground strap e Battery cables MOUNTING INITIAL START ADJUSTMENTS Voltage frequency sensitive Examine all mounting bolts and supporting mem bers to verify that the genset is properly mounted All fasteners should be tightened securely to pre vent them from working loose when subjected to vibration LUBRICATION If the engine oil was drained fill the crankcase with oil of the recommended classification and viscosity Refer to the appropriate operator s ma
114. into the bearing Install the crankcase cover and check to see that the crankshaft turns freely Checking Endplay With the crankcase cover installed check the crank shaft endplay at the point shown in Figure 10 26 Refer to the Dimensions and Clearances section for the recommended crankshaft endplay If necessary add or remove shims as required and recheck end play Verify that the crankshaft turns freely without binding IE as O gt 2 A CT1124s FIGURE 10 26 CHECKING ENDPLAY 10 13 Redistribution or publication of this document by any means is strictly prohibited CYLINDER BLOCK Cleaning After removing the piston crankshaft cylinder head etc inspect the block for cracks and extreme wear If the block is still serviceable prepare it for cleaning as follows 1 Scrape all old gasket material from block 2 Remove grease and scale from cylinder block by agitating in a bath of commercial cleaning solution or hot soapy washing solution 3 Rinse block in clean hot water to remove clean ing solution Inspecting Block When rebuilding the engine thoroughly inspect block for any condition that would make it unfit for further use This inspection must be made after all parts have been removed and block has been thor oughly cleaned and dried 1 Make a thorough check for cracks using any standard method of crank detection One meth od of crank detection follows Minute cracks may be detect
115. ion e 10 20 Percent leak down Normal condition e 20 30 Percent leak down Near service limit If leakage is greater than 30 percent the engine could need major service work With the tester still connected listen for air leakage at the points listed in Table 10 1 and note probable cause of engine problem AIR LEAKAGE REGULATOR M1907s FIGURE 10 1 TYPICAL LEAK DOWN TESTER Redistribution or publication of this document by any means is strictly prohibited TABLE 10 1 LEAK DOWN CHECK POINTS AIR LEAKAGE AT PROBABLE CAUSE 1 Dipstick hole or Broken ring Breather valve Worn cylinder bore rings 2 Carburetor throat Intake valve stuck Broken intake valve Damaged intake valve seat 3 Muffler Exhaust Exhaust valve stuck pipe outlet open Damaged exhaust valve Damaged exhaust valve seat OIL LEVEL OIL PAN AND OIL LEVEL SWITCH SWITCH Remove the oil plug and drain the crankcase oil if not previously drained Remove the oil pan mounting bolts and remove pan see Figure 10 2 Remove oil level switch mounting bolts and remove switch OIL PLUG Clean oil pan and use new gasket when reinstalling piis Torque all mounting bolts to the specified mounting torque see Section 4 Torque Specifications FIGURE 10 2 OIL PAN REMOVAL 10 2 Redistribution or publication of this document by any means is strictly prohibited HEAD COVER CYLINDER HEAD Remove the cylinder head for cl
116. ircuit to the fuel pump E2 and to the remote control START STOP SWITCH S1 CONTROL ASSEMBLY SPARK MAGNETO PLUG E1 IGNITION G2 C IGNITION COIL T1 STATOR FIGURE 6 8 STOP MODE 6 13 Redistribution or publication of this document by any means is strictly prohibited Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only trained and experienced personnel with knowledge of fuels electricity and machin ery hazards should perform service procedures Review SAFETY PRECAUTIONS p iii TABLE 6 6 CONTROL TROUBLESHOOTING STOP MODE Possible Cause Corrective Action Page Genset 1 If set can be stopped from set control Check wiring continuity between Does Not Stop but not from remote control panel control assembly A1 and remote When Switch fault is due to Start Stop switch Is Pushed To a Open circuit between control assy Check remote Start Stop switch Stop A1 and remote Start Stop switch b Remote Start Stop switch faulty Always remove the load a few If set can be stopped from remote Check Start Stop switch S1 minutes before control but not from set fault due to stopping the Start Stop S1 switch on control set to allow assembly A1 cool down 6 14 Redistribution or publication of this document by any means is strictly prohibited TROUBLESHOOTING GENERATOR Use the following troubleshooting guide to help lo cate problems related t
117. ity Infinity Infinity Infinity B2 to Ground Q1 to Ground Q2 to Ground T1 or T2 to B1 or B2 B1 or B2 to Q1 or Q2 T1 or T2 to Q1 or Q2 TABLE 9 3 STATOR WINDING RESISTANCES RESISTANCE OHMS TEST LEAD LOCATION AT 77 F 25 C 60 HERTZ STATOR 0 191 TO 0 233 0 191 TO 0 233 0 024 TO 0 030 0 024 TO 0 030 0 615 TO 0 751 0 615 TO 0 751 50 HERTZ STATOR 1 013 TO 1 238 1 013 TO 1 238 0 073 TO 0 089 0 073 TO 0 089 0 738 TO 0 902 0 738 TO 0 902 FIGURE 9 6 STATOR ASSEMBLY Redistribution or publication of this document by any means is strictly prohibited GENERATOR SERVICE This section covers generator disassembly and as sembly procedures Refer to Figure 9 1 to identify the various generator components described in each sub section Generator Disassembly Use the following procedure to disassemble the generator 1 Drain the engine oil while the genset is still mounted in the vehicle Hot oil can cause severe burns if spilled or splashed on skin Keep hands clear when removing oil drain plug and wear protective clothing 2 Remove the genset from the vehicle and place it on a sturdy workbench See Removing the Genset p 5 3 The genset is heavy and can re sult in severe personal injury if dropped during removal Use the recommended re moval techniques and keep hands and feet clear while removing mounting bolts 9 8 3 Remove side mounting screws from the enclo sure cover and lift cov
118. lay if coil winding resistance is not 3 to 5 ohms On Model KV remove the attached leads and measure resistance between terminals I and S Figure 7 4 On Model KVC measure resist ance between terminal S and ground internally grounded If the coil checks good and a problem with the relay is still suspected remove the leads from the side terminal posts An open circuit should be measured between the side terminal posts with the coil de en ergized With 12 VDC applied across the coil termi nals I and S on Model KV and terminal S and ground on Model KVC the solenoid should be ener gized and continuity should be measured between the side posts TERMINAL POSTS FIGURE 7 4 START RELAY CHECK Redistribution or publication of this document by any means is strictly prohibited Diode Bridge CR1 Spec C E Model KV The diode bridge consists of four diodes connected in a bridge circuit Figure 7 5 The diode bridge can be checked with a diode checker Remove all of the leads from the diode bridge and check each diode individually Continuity should be indicated in the forward bias direction and an open circuit should be indicated in the reverse bias direction refer to your meter instruction manual If any of the diodes check bad replace the diode bridge With the leads removed also check between each terminal and ground to make sure a diode is not shorted to ground If shorted and not replaced this could damage the B1
119. le first and connect it last to reduce the risk of arcing Control Assembly A1 The Control Assembly consists of a printed circuit board with components relays and the Start Stop switch S1 soldered to the board It is difficult to iso late individual components on the control assembly for testing Use Section 6 Troubleshooting to identi fy possible problems in the control circuit If a prob lem with the Control Assembly is suspected use the control circuit board tester if available or check the control outputs with a voltmeter Start Stop Switch S1 If the genset can be started and stopped from the re mote control but not from the genset control panel check the Start Start switch on the circuit board Disconnect the J1 harness connector from P1 the Control Assembly connector Continuity should be measured between pin P1 6 and P1 7 when the switch is held in the Start position Continuity should be measured between pin P1 5 and P1 7 when the switch is held in the Stop position An open circuit should be measured between each of pins P1 5 P1 6 and P1 7 when the switch is in the center Run position Figure 7 3 If the switch tests bad replace the control assembly A1 If the switch checks good connect the P1 con nector back to the harness connector J1 and check continuity through each connector pin to make sure good contact is made Repair any poor or intermit tent connections 7 5 START STOP SWITCH 1 ES209
120. ler gauge as shown in Figure 10 19 Replace the piston when the side clearance of the top compression ring reaches 0 0039 inch 0 1 mm Redistribution or publication of this document by any means is strictly prohibited Replace piston showing signs of scuffing scoring worn ring lands fractures or damage from pre igni tion Connecting Rod Inspection Replace connecting rod bolts and nuts with damaged threads Replace connecting rod 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 pin that is cracked scored or out of round more than 0 002 inch 0 05 mm Piston Clearance CT 1061s Proper piston tolerances must be maintained for satisfactory operation Use a micrometer to mea sure the piston diameter at the point shown in Figure 10 21 When the cylinder bore is measured see Cylinder Block section on Page 10 14 subtract the piston diameter from the cylinder bore diameter to obtain the piston pin to cylinder wall clearance Re CYLINDER fer to Section 3 Dimensions and Clearances for the WALL recommended piston clearance FIGURE 10 19 CHECKING RING LAND PISTON RING IMPROPER
121. m may be within the governor mechanism see the Governor section on Page 10 8 Governor Adjustments Adjustments to the governor should be made in the following sequence 1 The carburetor fuel mixture screws must be correctly adjusted before governor adjust ments are made If the carburetor needs ad justing refer to Carburetor Mixture Screw Ad justments on Page 8 16 before making any ad justments to the governor Set the carburetor throttle stop screw as speci fied in Carburetor Mixture Screw Adjustments on Page 8 16 Redistribution or publication of this document by any means is strictly prohibited 3 Check the governor linkage for binding or ex cessive looseness Check the motion spring for bending or damage and straighten or replace as needed With unit operating at no load adjust the speed adjustment screw see Figure 8 14 on the gov ernor linkage to obtain 62 5 0 5 Hz at be tween 120 and 126 volts on 60 hertz units Set 50 hertz units to obtain 52 0 0 5 Hz at be tween 220 and 231 volts for 220 volt units and 240 to 252 volts for 240 units Check the frequency and voltage first with a load applied and then with no load applied The frequency and voltage should stay within the limits shown in Table 8 1 TABLE 8 1 CHECKING VOLTAGE AND SPEED FREQUENCY Voltage Maximum No Load Typical No Load Minimum Full Load Typical Full Load Speed Frequency Maximum No Load Speed r min Frequen
122. means is strictly prohibited 6 10 11 Prepare endbell for installation Place springs on studs and lubricate O ring Verify that brushes are held in holder with piece of wire See Figure 9 8 Install endbell onto rotor bear ing and secure with endbell mounting screws The brushes will be damaged during assembly if not held off the slip rings Make certain wire is in place before installing the generator endbell Remove the piece of wire holding the brushes off the slip rings Connect the F lead wire to the outboard brush terminal and the F lead wire to the inboard brush terminal Install fan hub onto rotor shaft and align key slot on fan hub with key slot in end of rotor shaft Install alignment key Insert washer on rotor through bolt and install into rotor shaft Verify alignment of rotor shaft and fan hub Secure the fan hub assembly and tighten the rotor through bolt to the specified torque Lower the generator end of the genset and al low it to rest on base Install two starter mounting bolts through end bell and attach starter at specified torque At tach connectors to resistor on endbell Attach fan to fan hub with three bolts and install scroll housing Install air filter retainer and filter cover 9 11 12 13 14 15 16 17 Install air inlet baffle assembly and tighten mounting nuts to specified torque Connect fuel line to fuel pump and inspect the fuel supply li
123. means is strictly prohibited Start Stop Switch S1 The Start Stop switch S1 is a single pole double throw SPDT rocker type switch that is mounted on the Control Assembly A1 circuit board Holding the switch in the Start position will initiate engine crank ing Pushing the switch to the Stop position will initi ate the stop function The switch will automatically return to the center Run position when released Start Solenoid K1 The start solenoid K1 is used for closing and open ing the circuit between the battery and the starter motor The start solenoid has heavy duty contacts that handle the high current draw of the starter dur ing cranking Control Fuse F1 A 5 amp fuse provides protection for the control wir ing and remote wiring from a short circuit The con trol fuse is mounted on the side of the control panel Circuit Breaker CB1 The standard 25 amp circuit breaker protects the generator AC windings from a short circuit or over load The circuit breaker is located on the control panel If an overload occurs the breaker can be re set after all loads are removed from the genset Control Assembly A1 The control assembly consists of a printed circuit board with the Start Stop switch S1 and other components and relays mounted on the board The 7 3 control assembly is mounted behind the service ac cess panel or inside the control box Figure 7 1 or 7 2 The control provides the follo
124. mer Be careful not to scratch the crankpin or the cylinder wall when remov ing Redistribution or publication of this document by any means is strictly prohibited The piston is fitted with two compression rings and one oil control ring Remove these rings from the piston using a piston ring expander as shown in Fig ure 10 17 Remove the piston pin retainer from each side and push the piston pin out Remove dirt and deposits from the piston surfaces with an approved cleaning solvent Clean the piston ring grooves with a groove cleaner Figure 10 18 or the end of a piston ring filed to a sharp point Care must be taken not to re move metal from the groove sides Using caustic cleaning solvent or wire brush for cleaning pistons will damage pis ton Use only parts cleaning solvent When cleaning the connecting rod in solvent include the rod bore Blow out all passages with low pressure compressed air CT 1059 1s FIGURE 10 17 REMOVING PISTON RINGS 10 9 Most parts cleaning solvents are flammable and can result in severe personal in jury if used improperly Follow the manufactur er s recommendations when cleaning parts S FIGURE 10 18 CLEANING RING GROOVES CT 1060s Inspection The following covers inspection procedures for pis ton and connecting rod Piston Inspection Inspect the piston for fractures at the ring lands skirt and pin bosses Check for wear at the ring lands using a new ring and fee
125. ne for cuts cracks and abrasions Model KV only Make sure fuel supply line does not rub against anything that could cause breakage Leaking fuel will create a fire hazard which can result in severe personal injury or death If leaks are detected correct immediately Replace worn fuel line compo nents before leaks occur Connect the B lead to the start solenoid Install the control panel Inspect assembly check all electrical and mechanical connec tions for correct fit and location Place enclo sure cover on genset and secure with side mounting screws Install the genset in the vehicle and securely fasten all mounting screws and hardware Con nect the fuel line exhaust system and electrical systems in reverse order of disassembly See Removing the Genset p 5 3 Fill the crankcase with oil of the correct classifi cation and viscosity refer to the operator s manual Redistribution or publication of this document by any means is strictly prohibited BRUSHES AND SLIP RINGS Brushes Remove the fan see Generator Disassembly p 9 8 Inspect the brushes and brush block for burn marks or other damage lf the brushes appear to be in good condition use a piece of wire modified as shown in Figure 9 10 to check for excessive brush wear Insert the painted end of the wire through the hole above each brush Make sure the wire is resting on the brush and not on the spring If the painted part of the wire is not visible
126. njury if dropped during service Support the genset during service to prevent it from falling Check the generator housing for burrs in the aluminum slots that the stator slides into Re move burrs and clean housing if required Position the stator so the output connector ter minals face outward from generator housing and orient stator lamination alignment tabs with mounting grooves in housing as shown in Fig ure 9 1 Carefully lower stator into generator housing If necessary the stator can be lightly tapped on the lamination mounting tabs until the stator seats into the housing Careless handling of the stator can damage the insulation on the stator windings Be careful not to brush windings against the housing or strike windings dur ing installation Align pin in the rotor shaft with the slot in the crankshaft and lower rotor onto crankshaft Make sure that the rotor is seated Misalignment of the rotor shaft and the crankshaft can cause damage to the rotor and stator assembly Use care when installing the rotor shaft to align the pin on the rotor shaft with the slot in the crank shaft Attach the stator wire harness connectors to the stator Be careful not to bend connector ter minals or damage may occur Refer to Section 12 Wiring Diagrams for wiring locations Use wire ties to secure stator leads away from rotor and fan hub to prevent rubbing Redistribution or publication of this document by any
127. ns if touched Allow the genset to cool down before handling the choke assembly Choke Adjustment See Figure 8 23 Check the choke linkage to make sure it is not bent or rubbing Rotate the choke lever on the carburetor The choke shaft should move freely and it should return to its original position when released To readjust the choke 1 Let the genset cool down overnight in an am bient of 60 80 F 15 27 C 2 Loosen the two choke adjustment plate lock screws 8 19 CHOKE COIL HOUSING CHOKE ADJUSTMENT PLATE CHOKE LINKAGE LOCK SCREWS THE CHOKE LEVER MUST BE PARALLEL TO THE CARBURETOR FLANGE AT 70 F 21 C FIGURE 8 23 CHOKE ASSEMBLY TYPICAL ALSO OF MODEL KVC Redistribution or publication of this document by any means is strictly prohibited 3 Rotate the choke adjustment plate until the choke lever on the carburetor is parallel to the carburetor flange This is the position the choke lever should be in when the ambient tempera ture is 70 F 21 C If the ambient is cooler the choke adjustment plate may be rotated slightly in the counterclockwise direction and if warm er clockwise Tighten the lock screws Move the choke lever back and forth to check that it does not bind or stick Start the genset and observe choke and engine operation Proper engine cooling requires that the access cover be secured during op eration D
128. nual for the specific recommendations and procedures WIRING Verify that all wiring connections are tight and installed properly Make certain that wires do not run 11 1 equipment such as VCRs televisions comput ers etc can be damaged by power line frequen cy variations Some solid state devices are powered whenever connected to an AC outlet even if the device is not in actual operation For this reason disconnect all devices that are volt age or frequency sensitive before attempting any carburetor governor adjustments If dis connecting the devices is not possible open the circuit breaker s at the distribution panel or at the genset If the fuel system was worked on check that the idle and main adjustment screws are adjusted as de scribed in the Fuel System section before starting the set Reinstall adjustment screw limiter caps Redistribution or publication of this document by any means is strictly prohibited Start the set then immediately adjust the governor speed for a safe no load operating speed With no load applied listen for unusual sounds or vibrations Warm up the genset for at least 15 minutes at 50 to 75 of rated load and check that the choke is completely open Adjust the carburetor and gover nor as specified in the Fuel System and Governor sections EXHAUST SYSTEM With the genset operating inspect the entire ex haust system including the muffler and exhaust pipe Make certain that the
129. o not run the genset for more than two minutes with the access cover off or when it is already at operating temperature Bimetal Coil Replacement If the choke does not open properly replace the bimetal coil in the choke housing as follows 1 Remove the adjustment screw and washer from the choke coil housing Remove the housing Straighten the tab from the adjustment plate to release the bimetal coil Remove choke linkage from the bimetal coil and install the linkage on the new coil Assemble the new coil to the adjustment plate and bend the tab on the adjustment plate to the secure coil Install the choke coil housing and secure it with screw and washer Perform the choke adjustment procedure Gasoline Fuel Filter The fuel filter is located below the carburetor Shut off the fuel supply valve if equipped and let the genset run until it is out of fuel Allow the genset to cool down before replacing the fuel filter 8 20 Fuel presents the hazard of fire or explosion that can cause severe personal injury or death Do not permit any flame spark arcing switch or equipment pilot light lit cigarette or other ignition source near the fuel system Keep a type ABC fire extinguisher nearby Fuel Pump An electric fuel pump is used to supply fuel to the carburetor If the pump malfunctions or insufficient fuel delivery is suspected use the following proce dures to test the fuel pump Do not substitute a
130. o the generator Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only trained and experienced personnel with knowledge of fuels electricity and machin Figure 6 1 or 6 2shows the location of the generator components Refer to the wiring diagram in Section 12 Wiring Diagram tor wiring connections ery hazards should perform service procedures Review SAFETY PRECAUTIONS p iii Possible Cause Corrective Action Page 1 Locate cause of overload and correct No AC Output Voltage Note this condition may cause the genset to stop when start switch S1 is released AC Output Voltage Too Low TABLE 6 7 GENERATOR TROUBLESHOOTING 1 Open circuit breaker Open circuit between voltage regulator and brush block Open circuit between stator connec tions Q1 or Q2 and voltage regulator This condition will produce approx 15 to 30 VAC output Open circuit between battery Pos and voltage regulator pin 7 for field flash Brushes not making good contact with slip rings Slip ring surface is rough or pitted Capacitor C1 shorted Defective generator control assembly A1 or voltage regulator VR1 Engine governor out of adjustment Brushes worn or not making good contact with slip rings Poor wiring connections to voltage regulator If generator frequency is within specified limits but voltage is incorrect voltage regulator is
131. ol with coated bristle tips to produce a crosshatch pattern in the cylinder bore 3 The deglazing tool should be driven by a slow speed drill Move deglazing tool up and down in cylinder rapidly enough to obtain a cross hatch pattern as shown in Figure 10 28 Never use gasoline or commer 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 sur faces of all lubricated parts 4 Clean cylinder bore thoroughly with soap wa ter and clean rags Continue cleaning until a clean white rag shows no discoloring when wiped through cylinder bore PRODUCE CROSS HATCH SCRATCHES AVOID THIS FOR FAST RING FINISH SEATING C 1091s FIGURE 10 28 CROSSHATCHING 10 15 Redistribution or publication of this document by any means is strictly prohibited TIMING GEARS If replacement of either the crankshaft gear or the camshaft gear becomes necessary it is recom mended that both gears be replaced Each of these gears are pressed on The crankshaft gear requires a gear separator and puller to remove and the cam shaft gear requires a press to remove Both gears can be installed using a press These gears use a Woodruff key to provide correct positioning on the shaft Each timing gear is stamped with an O near the edge The gear teeth must mesh so that these marks ex
132. on due to worn or fouled spark plug faulty plug wire faulty ignition coil or magneto Sticking choke or carburetor mixture screws incorrectly adjusted Fuel pump E2 not working due to a Fuel pump defective b Open circuit between fuel pump and control assembly A1 or control assembly is defective Faulty fuel solenoid priming solenoid or regulator on LPG models Governor linkage stuck or binding Oil level switch S2 closed due to a Low oil level b Defective low oil level switch 6 6 a Add fuel if tank is low Open fuel supply valve if equipped Replace clogged fuel filter and check fuel supply for contamination Refer to gnition System for test and service procedures Regap LPG sparkplug to 0 020 inch Refer to Fuel System for adjustments Measure voltage between fuel pump connector and ground with the engine cranking If B voltage is not present proceed to 4b If voltage is present min 6 VDC fuel pump is defective Check continuity between control assembly and fuel pump If connections are good and voltage was not measured in 4b replace control assembly A1 Refer to LPG Fuel System Section 8 for service procedures Check governor arm movement See Governor section 7a Check oil level and add oil if low 7b Check low oil level switch Redistribution or publication of this document by any means is strictly prohibited Start Fiel
133. ool down before servicing Loosen the clamp securing the tail pipe to the muffler and pull the tail pipe away Figure 8 2 If muffler service is required remove the genset from the vehicle and remove the outer housing See Genset Removal p 5 3 Remove the nuts securing the muffler flange to the engine Remove the bolts securing the mounting brack ets to the muffler Model KV Assembly EXHAUST GAS IS DEADLY To prevent exhaust leaks install gaskets clamps straps and hardware as specified Inspect all components even if not replaced or worked on Install a new exhaust gasket making sure to re move and discard the old one Mount the muf fler flange to the engine and torque the nuts to specifications Install muffler support bracket mounting bolts and secure to the specified torque Install the genset housing and reinstall the gen set See Tail Pipe if replacing the tailpipe Run the genset for five minutes and look and listen for exhaust system leaks and excessive noise Shut down the genset immediately and correct any problems TYPICAL SIDE EXHAUST TAIL PIPE NOT FURNISHED BY TYPICAL REAR EXHAUST y Je 6 TAIL PIPE NOT oh FURNISHED BY ONAN FIGURE 8 2 MODEL KV EXHAUST TAILPIPE Redistribution or publication of this document by any means is strictly prohibited Model KVD Disassembly 1 Allow the exhaust system to cool down before servicing 2
134. operat ing the genset in a confined area e Disable the automatic genset starting feature of an inverter charger or other automatic starting device before storing the vehicle or parking it in a garage or other confined space s The exhaust system must be installed in accor dance with the genset Installation Manual s Engine cooling air must not be used for heating the working or living space or compartment FUEL IS FLAMMABLE AND EXPLOSIVE s Do not smoke or turn electrical switches ON or OFF where fuel fumes are present or in areas sharing ventilation with fuel tanks or equip ment Keep flame sparks pilot lights arc pro ducing equipment and switches and all other sources of ignition well away e Fuel lines must be secured free of leaks and separated or shielded from electrical wiring MOBILE 7 e Leaks can lead to explosive accumulations of gas Natural gas rises when released and can accumulate under hoods and inside housings and buildings LPG sinks when released and can accumulate inside housings and base ments and other below grade spaces Prevent leaks and the accumulation of gas BATTERY GAS IS EXPLOSIVE Wear safety glasses Do not smoke To reduce arcing when disconnecting or recon necting battery cables always disconnect the negative battery cable first and reconnect it last MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Disable the automatic genset starting feature of an inverter
135. overnor arm 8 11 attachment bolt to 60 to 70 in lbs 6 8 to 7 9 Nem Release the governor shaft and check for a gap between the stop on the throttle shaft and the carburetor body of approximately 0 003 to 0 006 in 0 076 to 0 152 mm If a gap is not present repeat steps one thru three and in crease the torque on the governor shaft before securing the governor arm Before making governor adjustments run the unit about 15 minutes under 50 percent load to reach normal operating temperature If the governor is completely out of adjustment make a preliminary adjustment at no load to first attain a safe voltage and speed operating range An accurate voltmeter and frequency meter should be connected to the generator in order to correctly adjust the governor accuracy of 0 396 on frequency and 0 5 on voltage A small speed drop not no ticeable without instruments will cause an objection able voltage drop A binding in the governor shaft governor linkage or carburetor throttle will cause erratic governor action or alternate increase and decrease in the engine speed hunting A rich or lean carburetor adjust ment can cause hunting and a fouled spark plug can cause missing and hunting Springs tend to lose their calibrated tension through fatigue and after long usage and may require replacement If the governor action is erratic after adjustments are made replace the spring If this does not improve operation the proble
136. power output leads L1 L2 and constantly measures the output voltage comparing it to an internal reference volt age When the output voltage exceeds the refer ence the regulator causes the current in the rotor to decrease until the proper voltage is obtained During genset operation the regulator constantly monitors the output voltage When additional load is applied to the generator the output voltage starts to decrease The regulator senses this decrease and it increases the field current until the reference volt age and the output voltage match Similarly when the load is decreased the output voltage begins to increase and is again sensed by the regulator In this case the regulator decreases the amount of current to the field until the output voltage again matches the reference voltage In this manner the electronic voltage regulator keeps the voltage of the generator constant with varying load conditions ALIGNMENT STATOR SCROLL HOUSING N ROTOR THRU BOLT STATOR 4 HOUSING BRUSH BLOCK ASSEMBLY MAGNETO ASSEMBLY ED SEE ASSEMBLY FAN ASSEMBLY G1211s FIGURE 9 1 GENERATOR Redistribution or publication of this document by any means is strictly prohibited VOLTAGE REGULATOR TESTS Confirm that voltage regulator VR1 is faulty before replacing it Use a meter with a diode checking func tion Fluke Model 73 or equivalent Multimeter to perform the following tests 1 Disengage the
137. r Place clutch and helix as sembly on motor shaft with flats engaged in clutch hole If Return Spring is Unassembled A Place 1 1 16 inch O D washer over end of shaft See Figure 8 34 B With chamfered side of shaft hole up place plastic retainer on shaft and line up hole with hole in shaft CLUTCH amp SPLINE ASSEMBLY ROLL PIN METAL SPRING RETAINER amp WASHER 13 14 15 16 AT WASHER SPRING MOUNTING BRACKET m ENS E Es E RETURN SPRING SPRING WASHER RETURN COVER C Support the plastic retainer with a vise or other solid surface Using a 5 82 to 1 8 inch nail set and hammer drive in a new roll pin The pin should be driven in about 1 10th of an inch 2 5 mm from the edge of the plas tic retainer or so it is evenly spaced from each side D Place spring cover over top of plastic re tainer then the return spring on top of the retainer E With washer placed over point of plastic re tainer push metal retainer into hole of plastic retainer as far as it will go Carefully mount the starter on the end bell and tighten the mounting bolts and rear support bracket mounting bolt and nut to the specified torque Connect the positive cable to the starter lug terminal Mount outer housing on the genset and install genset into vehicle Reconnect genset starting battery negative cable last WASHER WASHER THROUGH BOLT MAGNETIC HOUSING B
138. r Mounted Set from RV When the genset has been disconnected from the electrical exhaust and fuel systems the genset may be removed for major service work The genset is mounted on support brackets that are bolted to the underside of the floor on the vehicle or trailer and to the genset housing The genset is completely suspended underneath the floor of the RV by the support brackets To avoid dropping the genset during removal follow the rec ommended genset removal procedures The genset is heavy and can cause severe personal injury if dropped during remov al Use the recommended removal techniques and keep hands and feet clear while removing mounting bolts Park the recreational vehicle on as level a surface as possible Then follow these steps very carefully 1 Put the vehicle in its park position lock the brakes and remove the keys if applicable Make sure no one moves the vehicle while per forming this procedure Dropping the genset can result in severe personal injury or death Make sure no one moves the vehicle during this procedure and that the procedure is per formed very carefully and only as instructed Redistribution or publication of this document by any means is strictly prohibited Use a forklift truck to support the weight of the genset at the points shown in Figure 5 4 Raise the forklift just so it makes contact with the bottom of the genset housing then put a little upward pressure under
139. re loose cracked or severely pitted should be re placed by replacing the cylinder head assembly Both the valve stem guides and the valve seats are available only as part of the cylinder head assembly Valve Lash Adjustment The engine is equipped with adjustable valve tap pets Adjust the valve clearance when the engine is at ambient temperature Proceed as follows 1 Follow head cover removal instructions this section Inspect valve stems for proper align ment with tappets 2 Advance the engine until both the valves are closed and there is no pressure on the valve lift ers piston at top dead center Redistribution or publication of this document by any means is strictly prohibited 3 Clearances are shown in the Specifications section For each valve the gauge should just pass between the top of the valve stem and the rocker arm see Figure 10 12 4 Check the cylinder head mounting bolt torque see Cylinder Head this section before per forming valve lash adjustment 5 To correct the valve clearance place a 14 mm wrench on the adjusting nut and a 10 mm wrench on the outer locking nut Loosen the outer locking nut and turn the adjusting nut as needed to obtain the correct clearance Tighten locking nut after adjustment is made 6 Recheck the valve clearance after adjustment has been made and also check the rocker arm bolts to see that they have not loosened as a re sult of adjusting the valve lash
140. require cleaning since LP gas vaporizes completely before reaching the carburetor and leaves no residue However a bad fuel supply may allow dirt or oil to collect in the car buretor This may require that the carburetor be cleaned to restore satisfactory operation Cleaning the carburetor includes complete disas sembly thoroughly cleaning and replacement of parts and gaskets ELECTRIC STARTER A 12 volt electric starter with negative ground is used for cranking the genset When the starter is en ergized an inertial engagement system causes the ROLL PIN STARTER SPRING RETAINER SUPPORT PLASTIC RETAINER WITH A VISE OR OTHER SOLID SURFACE USE CARE NOT TO HAVE SPRING RETURN LEG BETWEEN THE PLASTIC RETAINER amp SUPPORT WHEN DRIVING OUT ROLL PIN starter pinion gear to engage the ring gear on the fan hub assembly As the starter spins the starter pin ion gear drives the ring gear causing the genset to crank Because the starter is an integral part of the genset control system check the complete control before servicing the starter Use the following proce dures to disassemble inspect and assemble the starter It is necessary to remove the genset from the ve hicle before the starter can be serviced see Re moving the Genset p 5 3 Disassembly 1 Verify that the genset starting battery has been disconnected negative cable first before proceeding Remove the genset outer housing and disconnec
141. rly align it with the connecting rod Clearance varies on the crankpin if this is not done Crank the engine by hand to see that the crankshaft turns freely without binding CT 1066 2s FIGURE 10 24 INSTALLING PISTON 10 12 Crankpin Clearance 1 Mark parts so they can be installed in their origi nal positions and wipe all parts clean of any oil or grease Place a piece of the correct size Plasti gage across the full width of the rod cap about 1 4 inch 6 mm off center Install the rod cap and tighten to the specified torque Do not rotate the crankshaft after the cap is in place Remove the rod cap and leave the flattened Plasti gage on the part to which it adheres Compare the widest point of the flattened Plas ti gage with the graduations on the envelope see Figure 10 25 to determine the crankpin clearance Redistribution or publication of this document by any means is strictly prohibited ENVELOPE GRADUATION SCALE CT 1092s FIGURE 10 25 MEASURING CRANKPIN CLEARANCE CRANKSHAFT Remove the crankshaft after the connecting rod and piston have been removed carefully pull the crank shaft out of the oil seal and bearing Inspection Check the crankpin O D and finish If it is worn or scored and cannot be smoothed out by polishing or if it exceeds the allowable size limit the crankshaft should be replaced Installation Lubricate the bearings with engine oil Slide the crankshaft
142. rly wired battery bring battery up to full charge Load connected to battery while set Reconnect and check battery connec is turned off tion Too much DC load on genset Disconnect load and recharge starting battery battery Remove other DC loads from genset starting battery Genset charging circuit not Check all wiring connections between functioning due to the generator B1 B2 windings and the a Open in circuit between generator Battery B connection including all B1 B2 winding and battery B connections to the diode bridge CR1 b Open charging resistor R 1 and battery charge resistor R1 c Diode bridge CR1 defective Remove wires from the charge resistor d Generator B1 B2 defective R1 and measure its resistance A normal reading is 4 to 6 ohms Refer to diode bridge CR1 test Refer to generator test section NOTE The battery charging circuit is designed to maintain the genset starting battery The charging cir cuit will not charge a low or bad battery A low battery should be fully charged with a battery charger 6 12 Redistribution or publication of this document by any means is strictly prohibited Stop Mode Momentarily pushing the Start Stop switch S1 to the Stop position begins the stop mode with the following results e Control assembly A1 de energizes the ignition enable circuit grounding the magneto G2 ignition circuit to stop the engine e Control assembly A1 also opens the c
143. rom 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 lubri cant from the cylinder walls and diluting the crank case oil An overly lean mixture results in a loss of power flat spots in acceleration and a greater ten dency to burn valves and spark plugs Mixture screw adjustment should be checked with every engine tune up and whenever a carburetion problem is suspected Before adjusting be sure the ignition system is working properly and the governor is correctly set The limiter cap on the main mixture screw should not be removed unless the carburetor is totally out of adjustment or has been overhauled With the limiter cap removed use the mixture set tings in Table 8 2 for preliminary adjustments Turn the mixture screws in until lightly seated then turn out the specified number of turns TABLE 8 2 CARBURETOR ADJUSTMENT SPECIFICATIONS MIXTURE SETTING IDLE 1 3 4 1 4 Forcing the mixture adjustment screws tight will damage the needle and seat Turn in only until light tension can be felt FLOAT LEVEL 1 1 2 1 4 9 16 1 16 In 14 2 mm Start the engine and allow it to run for about 10 min utes The location of the adjustment screws is shown in Figure 8 18 Use the following procedure 1 Stop the genset and connect a voltmeter fre quency meter and load bank to the generator output leads 2 Start the
144. rounded Service as necessary Start the genset f the fuse blows the rotor has a flying ground short caused by centrifu gal force Replace the rotor Redistribution or publication of this document by any means is strictly prohibited 9 11 Ifthe genset continues to run measure sta tor winding voltages If winding voltages are as specified in Table 9 1 the generator windings brush block and slip rings are probably okay See Voltage Regulator Tests and Field Voltage Tests in this section for further tests Service as necessary if there is no output from a winding If the genset starts but stops disconnect the power supply and connect an ohmmeter across pins P3 9 and P3 10 The resistance should be approximately 18 ohms Push and hold the start switch down and watch the ohm meter as the engine runs up to speed If the ro STATOR tor winding opens goes to infinite resistance as the engine runs up to speed the rotor has a flying open caused by centrifugal force Re place the rotor Hold the start switch down just long enough to check whether the winding is open at operating speed Prolonged op eration with the starter engaged can dam age the starter overrunning clutch TABLE 9 1 OUTPUTS AT 24 VDC EXCITATION PSPINS WINDING VOLTAGE Tia v 11 12 Q1 Q2 96 VAC VOLTMETER OHMMETER PINS 11 12 96 VAC PINS 2 3 126 VAC PINS 9 10 18 OHMS lt 24VOLT GO
145. s All threads must be clean and lubricated with new engine oil The cylinder head mounting bolts must be tightened in the proper sequence refer to Section 10 Engine Block Assembly TABLE 4 1 TORQUE SPECIFICATIONS TORQUE FOOT POUNDS NEWTON METERS SPECIFICATIONS Housing Mounting Screws 6 9 8 12 Engine Cooling Shrouds 6 Fan Mounting Screws Gearcase Cover Generator Housing to Engine Mounting Nuts Intake Manifold Carburetor Mounting Nut Muffler Bkt to Engine Muffler Flange to Engine Oil Base and Generator Housing to Mounting Stud Oil Base to Engine Oil Drain Plug Oil Watch Bolt Rotor Through bolt Spark Plug Starter Bkt to Engine Starter Bkt to Starter Starter Flange to Endbell Mounting Screws Governor Lever Nut Speed Adjust Lever Nut Vibration Isolators 4 1 Redistribution or publication of this document by any means is strictly prohibited When engine torques are not specified in Table 4 1 tighten the screws and nuts according to Tables 4 2 and 4 3 The grade numbers are indicated on top of the screw or bolt head TABLE 4 2 METRIC BOLT TORQUE SPECIFICATIONS NO GRADE OR 8 8 GRADE SIZE FOOT POUNDS NEWTON METERS CS TABLE 4 3 METRIC BOLT TORQUE SPECIFICATIONS 10 9 GRADE SIZE FOOT POUNDS NEWTON METERS 4 2 Redistribution or publication of this document by any means is strictly prohibited 5 Preparing for Service TROUBLESHOOTING Before starting to service the genset
146. s document by any means is strictly prohibited Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only trained and experienced personnel with knowledge of fuels electricity and machin ery hazards should perform service procedures Review SAFETY PRECAUTIONS p iii Engine Overheats Black Exhaust Smoke White or Blue Exhaust Smoke TABLE 6 11 TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Possible Cause Corrective Action Page Restricted airflow due to dirt debris or insulation blocking air inlet or outlet Dirt or oil on engine cooling fins Cooling fan plugged or broken Lean fuel mixture due to a Incorrectly adjusted fuel mixture screws b Dirt or varnish in carburetor c Incorrect float level gasoline sets Loose or missing service access cover or improper seal around the endbell assembly Improper installation due to a Insufficient air inlet size b Air inlet location allowing recirculation Rich fuel mixture due to a Dirty air filter b Choke sticking gasoline sets c Incorrectly adjusted fuel mixture Screws d Dirt or varnish in carburetor Oil level too high Contaminated fuel Excessive engine wear 6 20 Clean air inlet and outlet areas Do not store anything in compartment area Clean all dirt and oil from engine cooling fins Inspect cooling fan clean or replace as needed Adjust
147. s document by any means is strictly prohibited Tail Pipe 1 For the tail pipe use 18 gauge 1 1 8 inch I D aluminized steel tubing or material of equiva lent heat and corrosion resistance Do not use flexible tubing which is neither gas tight nor du rable Use U bolt muffler clamps available from Onan for tail pipe connections Overlapping pipe should be slotted Figure 8 4 Support the tail pipe near its end and at inter vals of 3 feet 0 9 m or less Use automotive type tail pipe hangers available from Onan Tail pipe hangers must hang straight down Otherwise the hanger will pull the tail pipe to side front or back causing noise and or dam age to the muffler and tail pipe Do not route the tail pipe near fuel lines and fuel tanks or closer than 3 inches 76 mm to com bustible material wood felt cotton organic fi bers etc unless it is insulated or shielded The temperature rise above ambient on adjacent combustible material must not exceed 117 F 65 C To prevent damage to the tail pipe while the ve hicle is moving keep it out of the approach and departure angles and above the axle clearance line Figure 8 5 Do not terminate the tailpipe underneath the vehicle Extend it a minimum of 1 inch 25 mm beyond the perimeter of the vehicle Fig ure 8 6 Support the end of the tail pipe such that it cannot be pushed in and up under the skirt of the vehicle Do not t
148. sider the safety aspects of any service procedure Servicing gensets presents several haz ards that the service technician must be aware of to safely complete the job Study SAFETY PRECAU TIONS p iii and familiarize yourself with the haz ards listed in Table 5 1 Approach the job in a safety conscious manner Being safety conscious is the most effective way to avoid injury to yourself and to others Reduce the risk of an accident by adopting the following safeguards Safeguards to Avoid Hazards Use personal protection Protect your body by wearing the appropriate safety equipment such as e Safety shoes Gloves e Safety glasses e Hard hats e Ear plugs Do not wear rings jewelry or loose clothing these can get caught on equipment or conduct electricity Reduce the hazard A safe orderly work area and well maintained equipment reduce the risk of haz ard Leave all guards and shields in place on ma chinery and maintain equipment in top condition Store flammable liquids in approved containers away from fire flame spark pilot light arc produc ing equipment and other ignition sources Keep the work area clean well lighted and well ventilated Keep fire extinguishers and safety equipment nearby and be prepared for any emergency Develop safe work habits Unsafe practices are the cause of most accidents involving tools or ma chinery Be familiar with your tools and machines and learn how to use them safely Use the righ
149. sult in personal injury or equipment damage Electricity fuel exhaust moving parts and batteries present hazards which can result in severe personal injury or death GENERAL PRECAUTIONS Keep children away from the genset s Do not use evaporative starting fluids They are highly explosive To prevent accidental or remote starting while working on the genset disconnect the nega tive battery cable at the battery Keep the genset and its compartment clean Excess oil and oily rags can catch fire Dirt and gear stowed in the compartment can restrict cooling air e Make sure all fasteners are secure and torqued properly Do not work on the genset when mentally or physically fatigued or after consuming alcohol or drugs e You must be trained and experienced to make adjustments while the genset is running hot moving or electrically live parts can cause se vere personal injury or death Used engine oil has been identified by some state and federal agencies as causing cancer or reproductive toxicity Do not ingest inhale or contact used oil or its vapors Benzene and lead in some gasolines have been identified by some state and federal agencies as causing cancer or reproductive toxicity Do not to ingest inhale or contact gaso line or its vapors Keep multi class ABC fire extinguishers handy Class A fires involve ordinary combustible ma terials such as wood and cloth Class B fires combustible and
150. t the positive cable from the starter lug STARTER POSITIVE 4 TERMINAL STARTER THROUGH BOLTS ndi TM U E SUPPORT FIGURE 8 29 DRIVING ROLL PIN OUT 8 26 Redistribution or publication of this document by any means is strictly prohibited 2 Remove the starter mounting bolts Remove the rear support mounting nut and loosen the rear starter support bracket mounting bolt 3 Carefully disengage the starter from the end bell 4 Use a 1 8 to 5 32 inch nail set to remove the roll pin from the armature shaft Remove the return spring gear and clutch assembly as required When reassembling always use a new roll pin See Figure 8 29 5 Remove the starter through bolts and carefully separate the brush end cap housing and arma ture assembly Electrical Tests Testing Armature for Grounds Touch one ohm meter lead to a commutator bar and then touch the other lead to armature shaft and core laminations A low resistance reading indicates a grounded arma ture Replace grounded armature with a new part See Figure 8 30 Testing for Shorts Use a growler Figure 8 31 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 arma ture while slowly rotating armature in growler A shorted armature will cause the blade to vibrate and be attracted to the core Replace a shorted arma ture with a new part Testing for
151. t tool for the job and check its condition before starting Follow all warnings and cautions in this manual and take extra precautions when working around electri cal equipment Avoid working alone and do not take risks Do not work when tired or after consuming any alcohol or drug that makes the operation of equip ment unsafe Be prepared for a potential accident The Red Cross and public safety departments offer courses in first aid CPR and fire control Use this informa tion to be ready for an accident Be safety con Scious and make safety procedures part of the work routine TABLE 5 1 HAZARDS AND THEIR SOURCES eFire and explosions Leaking or spilled fuel Hydrogen gas from charging battery Oily rags improperly stored Flammable liquids improperly stored Any fire flame spark pilot light arc producing equipment or other ignition sources e Burns Hot exhaust pipes Hot engine and generator surfaces Hot engine oil Electrical short in DC wiring system ePoisonous gases Carbon monoxide from faulty exhaust Operating genset where exhaust gases can accumulate 5 2 e Electrical shock AC Improper genset load connections Faulty RV wiring Faulty electrical appliance Faulty genset wiring Working in damp conditions Jewelry touching electrical components e Rotating Machinery Jewelry or loose clothing catching in moving parts e Slippery Surfaces Leaking or spilled oil e Heavy Objects Removing genset from vehi
152. the brush is excessively worn and must be replaced Always re place the brush springs when installing new brushes to maintain proper tension on the brushes Clean carbon deposits from brushes and slip rings see Slip Ring Service on Page 9 13 Use the fol lowing procedure to replace the brushes 1 Remove the brush block mounting screws and lift out the brush block 2 Remove brushes and springs from holder and replace with new parts see Figure 9 9 3 Pull each brush outward from brush holder and insert a stiff wire through the small hole in the base of the holder See Figure 9 8 The wire holds the brushes off the slip rings during as sembly Inspect slip rings before installing brush block See Slip Ring Service this page 4 Install brush block in endbell but do not tighten mounting screws 5 Remove the wire holding the brushes off the slip rings Adjust the brush block so that the brushes are centered on the slip rings then tighten mounting screws 6 Follow the Generator Assembly procedure on Page 9 10 to reinstall fan hub and remaining generator components 9 12 SPRING aT B Ww DI LD Ec Uf FIGURE 9 10 BRUSH WEAR CHECK Redistribution or publication of this document by any means is strictly prohibited Slip Rings Remove the fan see Generator Disassembly p 9 8 Inspect the slip rings for grooves pits or other damage A Scotch Brite pad can be used to re move light wear and for
153. tions so output voltage and frequency will not vary Contact with moving parts can cause severe personal injury Keep clothing hair jewelry hands and fingers clear while ad justing the governor A hot genset can cause severe burns Always allow the genset to cool before touching any components or removing any parts Voltage frequency sensitive equipment such as VCRs televisions comput ers etc may be damaged by power line frequen cy variations Some solid state devices are powered whenever connected to an AC outlet even if the device is not in actual operation For this reason disconnect all devices which are voltage or frequency sensitive before attempt ing any carburetor governor adjustments If dis connecting the devices is not possible open the circuit breaker s at the distribution panel or at the genset if so equipped If the governor arm has been removed for service or if the there has been a loss of governed power reset the governor arm to governor shaft position before proceeding to the governor adjustments Governor Arm to Governor Shaft Adjustment 1 Loosen the bolt that secures the governor arm to the governor shaft Figure 8 14 2 Turn the governor shaft back and forth several times Also move the governor arm from closed to wide open throttle to verify free movement 3 Turn the governor shaft to the fully clockwise position and apply 2 to 5 in lbs 0 23 to 0 56 Nem of torque Tighten the g
154. to the magneto assembly G2 so that output from the magneto will energize the ignition coil T1 e With the engine cranking a permanent magnet in the flywheel rotates at the proper time past the magneto to induce a voltage that flows to the ignition coil T1 that fires the spark plug E1 for ignition e Battery positive B is supplied to the fuel pump E2 or fuel shutoff solenoid E2 and regulator K2 on LPG models Schematic for gasoline fueled model shown BATTERY BT1 START STOP SWITCH 1 CONTROL ASSEMBLY START RELAY K1 des IG a a 3 4 e STARTER MOTOR B1 OIL LEVEL INTERNALLY SWITCH S2 GROUNDED ON KVC SPARK 1 MAGNETO PLUG E1 IGNITION G2 FUEL PUMP E2 IGNITION FUEL SHUTOFF SOLENOID COIL T1 ON LPG MODEL Hi a gt FIGURE 6 4 START IGNITION MODE 6 5 Redistribution or publication of this document by any means is strictly prohibited Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only trained and experienced personnel with knowledge of fuels electricity and machin ery hazards should perform service procedures Review SAFETY PRECAUTIONS p iii TABLE 6 2 CONTROL TROUBLESHOOTING IGNITION MODE Possible Cause Corrective Action Page Engine Cranks 1 But Does Not Start Restricted fuel supply due to a Fuel level below pickup tube in tank b Fuel line supply valve closed c Fuel filter clogged Faulty igniti
155. tribution or publication of this document by any means is strictly prohibited Model KVC Disassembly First allow the exhaust system to cool down Then unclamp the flexible exhaust tube from the engine exhaust tube and loosen the two muffler hangers to remove the entire muffler tailpipe assembly Fig ure 8 1 Take care not to damage the flexible ex haust tube Model KVC Assembly 1 If the genset has been removed first install the genset in the vehicle 2 Assemble the flexible exhaust tube to the muf fler with a new flange gasket if they have been disassembled 3 Lift the muffler assembly up to the engine ex haust tube making sure the split collar on the flexible tube overlaps the engine exhaust tube approximately 1 inch 25 mm 4 Secure the two muffler hangers one on each end so that the flexible tube hangs straight 5 Secure the clamp at the engine exhaust tube 6 See Tail Pipe for important consideration re garding routing and termination 7 Run the genset for five minutes and look and listen for exhaust system leaks and excessive noise Shut down the genset immediately and correct any problems ENGINE EXHAUST TUBE MUFFLER CLAMP HERE MUFFLER HANGARS HERE MUFFLER TAILPIPE ASSEMBLY FIGURE 8 1 MODEL KVC EXHAUST SYSTEM 8 2 Redistribution or publication of this document by any means is strictly prohibited Model KV Disassembly 1 Allow the exhaust system to c
156. uretor c Incorrect float level gasoline sets d Vacuum leak Mechanical engine defect intake valve defect Faulty ignition due to incorrect spark plug gap 6 18 Check and replace if necessary Drain fuel tank clean the fuel system and refill with fresh fuel Adjust carburetor main and idle adjustment screws Adjust carburetor float level Disassemble carburetor and clean all internal passages Replace filter Locate and correct leak Replace gasket Replace spark plug Check magneto and coil connections Perform Ignition Spark Check Check spark plug wire and boot Rotor or fan hub improperly installed In cold weather place air preheater in the winter position Adjust carburetor main and idle mixture screws Disassemble carburetor and clean all internal passages Adjust carburetor float level Locate and correct leak Perform Leak Down Test Reset spark plug gap Redistribution or publication of this document by any means is strictly prohibited Many troubleshooting procedures present hazards that can result in severe personal inju ry or death Only trained and experienced personnel with knowledge of fuels electricity and machin ery hazards should perform service procedures Review SAFETY PRECAUTIONS p iii Engine Backfires Through Muffler When Running Engine Lacks Power TABLE 6 10 TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Possible Ca
157. uretor is actually malfunctioning by carefully following the troubleshooting procedures in Section 6 Trouble shooting See the instructions on how to remove and replace the carburetor under the subheadings Air Filter And Preheater Assembly and Carburetor And Intake Manifold Assembly in this section A throttle stop screw is provided for adjusting the closed position of the throttle plate to obtain proper governor response when loads are being discon nected See Governor Adjustments on Page 8 11 To adjust the throttle stop screw 1 Connect a frequency meter and start and run the genset until it has warmed up to normal op erating temperature 2 Disconnect all loads Pull the governor linkage toward the front of the genset so that the tang on the throttle lever bears against the throttle stop screw Adjust the stop screw to obtain a frequency of 44 to 46 Hz on 60 Hz gensets 36 to 38 Hz on 50 Hz gensets 8 15 THROTTLE STOP SCREW THROTTLE LEVER ALTITUDE ADJUST KNOB TAMPER RESISTANT PLUG OVER IDLE MIXTURE NEEDLE ALTITUDE SCALE FIGURE 8 17 CARBURETOR ADJUSTMENTS BEGIN SPEC E MODEL KV ALL MODEL KVC Redistribution or publication of this document by any means is strictly prohibited Carburetor Mixture Screw Adjustments Prior to Spec E Model KV Only The most common cause of poor carburetion is un satisfactory adjustment of the idle or main mixture adjustment screws Significant variation f
158. use Corrective Action Page 1 Rich fuel mixture due to a Incorrectly adjusted fuel mixture screws b Choke sticking or out of adjustment 2 Mechanical engine defect exhaust valve defect 3 Faulty ignition due to incorrect spark plug gap 1 Dirty air filter 2 Restricted fuel flow due to a Plugged fuel filter or b faulty fuel pump c LPG regulator or fuel solenoid dirty or defective 3 Exhaust system blocked or restricted 4 Carburetor air preheater set incorrectly 5 No load speed set too low 6 Incorrect fuel mixture due to a Incorrectly adjusted fuel mixture screws b Dirt or varnish in carburetor c Incorrect float level gasoline sets 7 Incorrect valve lifter clearance or defective valve 8 Excessive engine wear 1a 1b Adjust carburetor main and idle mixture screws Check choke assembly Perform Leak Down Test Reset spark plug gap Replace air filter Replace fuel filter Test fuel pump and replace if faulty Refer to LPG Fuel System Locate and remove blockage clean spark arrester screen In cold weather place air preheater in the winter position Adjust governor setting Adjust carburetor main and idle adjustment screws Disassemble carburetor and clean all internal passages Adjust carburetor float level Adjust valve clearance if problem continues inspect valves Perform Leak Down Test Redistribution or publication of thi
159. utomotive type electric fuel pumps for standard Onan supplied electric fuel pumps The output pressure is much higher and can cause carburetor flooding or fuel leakage creating a fire hazard Fuel Pump Test Test the fuel pump by checking the pump outlet pressure as follows 1 Remove fuel line from carburetor inlet and install a pressure gauge Press start switch and hold it for several sec onds until pressure reading is constant Beginning Spec F the pressure for a good pump will be 2 5 to 4 0 psi 17 to 27 kPa Prior to Spec F the pressure for a good pump will be 3 to 5 psi 20 7 to 34 5 kPa unless the pump has been replaced with a later Spec F pump The pressure should stay constant or drop off very slowly e f the pressure is below 2 5 psi 17 kPa replace the fuel pump If pressure reading is at zero stop engine cranking and check electrical connections Press the Start switch and recheck pres sure reading There are no serviceable components in the fuel pump Replace complete fuel pump assembly if defective Replacement pumps are lower pressure 2 5 to 4 0 psi 17 to 27 kPa pumps Redistribution or publication of this document by any means is strictly prohibited LPG FUEL SYSTEM LPG is flammable and explosive and can cause asphyxiation NFPA 58 Section 1 6 requires all persons handling LPG to be trained in proper handling and operating proce dures Do not smoke if you smell gas or are ne
160. vapors are routed to the air inlet where they are mixed with incoming air and burned in the com bustion chamber A sticky breather valve can cause oil leaks high oil consumption rough idle reduced engine power and a rapid formation of sludge and varnish within the engine Crankcase Breather Service If the crankcase becomes pressurized as evi denced by oil leaks at the seals use the following procedures to service Remove the head cover and the gasket see the Head Cover section on Page 10 3 then remove the breather assembly from the cylinder head and in spect it The reed valve must be flat with no sign of creases or other damage If the breather is defec tive replace it If the breather is dirty clean it in parts cleaning solvent Most parts cleaning solvents are flammable and can result in severe personal in jury if used improperly Follow the manufactur er s recommendations when cleaning parts Check breather tube and air passages for clogging and clean as required Redistribution or publication of this document by any means is strictly prohibited GOVERNOR The governor controls engine speed which directly affects the generator voltage output and frequency An increase in engine speed will cause a corre sponding increase in voltage and frequency A de crease in engine speed will cause a corresponding decrease in voltage and frequency The governor maintains a constant engine speed under changing load condi
161. wing functions Local starting and stopping e Starter solenoid output Fuel pump output e AVR field flash output e Remote running output e Ignition enable Rectifier Bridge CR1 Spec C E Model KV The rectifier bridge consists of four diodes con nected in a bridge circuit to form a full wave voltage rectifier The bridge circuit rectifies the AC voltage from the generator battery winding B1 B2 to sup ply DC voltage for battery charging Battery Charge Resistor R1 Spec C E Model KV The battery charge resistor limits the battery charge rate to a maximum of one ampere Optional Remote Control A2 A3 The remote control is an optional accessory that al lows the genset to be started monitored and stopped from a remote location The deluxe control A3 includes a running time meter and a battery condition meter Remote control panels are mounted inside the vehicle Redistribution or publication of this document by any means is strictly prohibited CONTROL OPERATION The schematic diagram in Figure 12 1 on Page 12 2 can be used to help follow the circuit description Al ways refer to the specific wiring diagram that corre sponds to the model and spec number of the genset when troubleshooting Start Mode Holding the Start Stop switch S1 in the Start posi tion activates the control assembly A1 by closing the start signal input circuit While the Start Stop switch is held the control assembly suppl
162. wiring connector and remove the voltage regulator Figure 9 2 With the meter on Diode Check test between connector terminal pairs 5 9 7 9 10 9 11 9 12 9 10 5 5 11 5 12 and 5 3 Figure 9 2 It is important that the positive lead of the meter be connected to the first terminal of each pair VOLTAGE REGULATOR VR1 Sos TTT D CONNECTOR P3 3 Replace the voltage regulator if any reading in dicates a short or open except for pair 10 5 which should indicate an open Short is indicated by zero or a number very near ly zero Meters of different make indicate open differently Read the meter instructions If in doubt compare with readings of a regulator of the same part number known to be good 4 f the regulator checks good there is a small chance that it may still be bad Recheck it on a genset Also check that the connector pins are secure in both connector ends Also check ca pacitor C1 located behind the control panel with a capacitor checker Refer to the capacitor housing for the capacitance value KVC BOTTOM VIEW FIGURE 9 2 VOLTAGE REGULATOR LOCATION AND CONNECTOR P3 9 3 Redistribution or publication of this document by any means is strictly prohibited FIELD VOLTAGE TESTS A voltage check can be made to
163. xhaust valve mo mentarily to release compression and make starting easier 3 As the engine speeds up the flyweight is forced outward by centrifugal force and the decom pression pin moves down so that it no longer opens the exhaust valve 4 When the engine is stopped engine speed drops and the flyweight pulls in and the decom pression pin moves up The pin opens the ex haust valve again releasing compression The most common cause of problems with this sys tem is a faulty spring the spring may be too long or it may not be connected A spring that is too long will reduce the decompression cutoff speed Make sure that the spring is properly attached if a problem with the cutoff speed is still suspected replace the spring 10 17 ENGINE START POSITION CAM GEAR TAPPET FLYWEIGHT CAMSHAFT SPRING ENGINE RUNNING POSITION CT 1121s FIGURE 10 31 COMPRESSION RELEASE SYSTEM Redistribution or publication of this document by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited 11 Service Check List EXHAUST GAS IS DEADLY Exhaust gases contain carbon monoxide an odorless and colorless gas Carbon monoxide is poisonous and can cause unconsciousness and death Symptoms of carbon monoxide poisoning can include e Dizziness e Throbbing in Temples e Nausea e Muscular Twitching e Headache e Vomiting e Weakness and Sleepiness e Inability to Th
164. y prohibited 2 If available use a small puller with grips that will fit between the bearing and the collector ring assembly Cover the end of the rotor shaft with a steel plate to prevent deformation of the shaft during removal The bearing casing is made of hardened steel When struck it will shatter into small pieces and can cause severe per sonal injury Use protective eye wear and clothing when replacing the rotor bearing Heating the rotor bearing for re moval or installation can cause damage to the bearing and the collector ring housing Do not heat the rotor bearing 3 If a suitable puller is not available wrap the col lector ring with a cloth for protection and cut off the outer race of the bearing using a small hand grinder with a cutting wheel Be careful to avoid cutting the collector ring assembly Remove the bearings and make two cuts approximately halfway through the inner race 180 apart See Figure 9 12 Place rotor with one cut face down on a hard surface and center a cold chisel on the other cut and strike to split apart Be careful not to damage the rotor shaft The bearing cas ing is made of hardened steel that can shatter into small pieces Use protective eye wear and clothing to protect yourself from injury when striking the bearing casing COLD CHISEL FIGURE 9 12 ROTOR BEARING REMOVAL Inspect the rotor shaft for dirt or corrosion If necessary clean with emery cloth before instal ling new b

Service Manual

Contents

Download Pdf Manuals

Related Search

Related Contents