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0
to potentiall dangerousdiionstothe operator, serviceper-
sonnel, or e equipment. erator sets. Looseclothingandjewelry can become caught
in moving parts. Jewelry can short out electrical contacts
This symbol warns of immediate haz- and cause shock or burning.
ards whlch wi/I result In severe personal injury or 0
PURPOSE
This supplement reflects the following manual urn&
Page 1 (for units equipped with a Nikki carburetor) New -
throttle stop, mixture adjustment, and ffoat setting; in refer-
ence to like information found on pages 6-14,6-15, and
6-17.
sectkn8--
Pages 8-3and 8-4: Changes made to transformer tap
connections, and added point-to-point lead checking
note.
Page 8-77: Text changes made to assembly procedure,
transformertap connecfions (2R).
8-14: Change made to Table 8-1. Transformer Tap
Connections
SUPPLEMENT USE
Refer tothe correspondingpages of your manual and write,
'Refer to Supplemenr on them.
This supplement should not be used without reference to
the appropriate Service Manual. The Sewice Manual
should not be used without this supplement Please file or
otherwise keep the two together.
hlaMenanc8ofgeneretorsetsinvdnes
pemnm/~anddeathfmmlrazards of fuaisandrotaf-
ingpiwis. Be sum tomview ffie imptmfsafefypmau-
~cantehwdhtbasenioeM%I?lml~~q
~ o f t b a p l r o c e r k m r s ~ h d h i s ~
t
0 -
60 Hz Model 55 f 1 h e r t z / l W f 30 r/min.
0 -
50 Hz Model 45 f 1 hertz/1350 f 30 rimin.
1
Redistribution or publication of this document,
by any means, is strictly prohibited.
STANDARD
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TRANSFORMER
IGN COIL
IGN POINTS
SWPICH- LWOILPRESSURE
SWllCH-ST*RTISTW
RESISTOR-BATTERYCHARGE
K5 RELAY-UWWITHLPCDNLY
KI STARTSOLEWO
.
HI CHOKE
GI GENERATOR
FI FUSE
E3 FUEL PUMP/OR FUEL SOLENOID
IMPORTANT! Due to the possibility of E l 2 SPIRKPLLG
unit lead end ideniificationbeing out- cec2 URQllT BRELKER (Ac OUTPLITI
CR4 BRIOGE RECTIRER
of-date with the wine diagram/schematic of this sup- FRS RECTIFIER-USED WITH LPG ONLY
plement, do not Wy solely on lead markhgs by trans- CI UmcirnR
formerwhen troubleshooting. Instead check ea& lead 821 BAHERY 12V
81 STARTER
fmmpoint-&-point to confinnfhat unit is wiredpwpdy. A 3 STANDARD R W T E MHTRU
A2 DELUXE RWOTE CONTROL
AI CONTROL ASSY
Redistribution or publication of this document,
by any means, is strictly prohibited.
8-3
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TI IGN COIL
53 IGH POINTS
S2 SWITCH- LOWOILPRESSURE
SI SWITCH-STAR'l/STW
R6 RESISTOR-BATTERY CHARGE
K5 RELAY -UKOWrnH LPG ONLY
KI fTARTSOLENMD
HI CHOKE
GI GENERATOR
~I
FI FUSE
E3 FUEL PUMP/OR FUEL SOLMID
611-1177 E12 SPARKPLffi
W CIRCUIT EREAKER (IC OUTPUT)
IMPORTANl?Due to the possibility of CR4 BRIDGE RECTIFIER
CW RECTIFIER-USED WITH LPG ONLY
unit lead end idenutication behg out- CI lcApIClT0R
of-date with the wim diagmm/s&ematic of this rup- BTI I EAllERY 12'4
plement, do not rely solely on lead markings by trans-
former when troubkshooting. Instead check each lead
frompoint-to-point to confirm that unitis wlmdproperly. Redistribution or publication of this document,
by any means, is strictly prohibited.
b. Connect the CR4-AC lead wire to the trans-
former X2 (50 Hz-X3) tap and the Si lead wire to
71
Ammo' Tightening the rotor through-
bo/i to specified toque betore
the transformer X5 tap. Note: This is a prelimi- the stator assembly is installed can msult in rotor
nary connection that may requireadjustmentto shaft misalignment Follow recommended instal-
obtain the correct generator output voltage. See lation procedures to avoid any possibility ot shaft
Transformer Voltage Adjustment in this section. misalignment
c. Strip off112 inch of insu1ation"fromthe ends of
transformer primary leads H2 and H4 and from 5. Carefully lower the stator assembly over the rotor
stator leads T2 and T4. and into position for assembly to the engine. The
rotor end-bearing should fit snuggly into the bear-
d. Twist each stator lead around the end of the
corresponding transformer primary lead (T2 to ing bore hole.
H2 and T4 to H4). Place a#6 uninsulated barrel
Camless handling of the stator
connector.over the lead ends and crimp tightly can result in damage to the sta-
using a #6 staking tool.
tor windings. Do not brush the stator windings
Wire nuts or other non-crimp against the rotor as it is lowered into position.
lZBiEZl type connectors can loosen
during set operation. Use only the specified 6. Install the four nuts, locking washers, and cap-
screws that secure the stator housingto the engine-
connector and crimping tool when connecting
stator leads to transformer primary leads. to-generator adapter. Tighten capscrews to speci-
fied torque. Note that each locking washer is
installed under capscrew head.
e. Slidea 2-1 /2inch (64 mm) long pieceof braided
insulation over each connection as shown in 7. Tighten the rotor through-bolt to the specified
Figure 8-9. Use a wire tie to hold insulation torque.
. securely in place. 8. Hold the drip pan in position for mounting to the
underside of the set and install the three vibration
3. Pull each brush outward from the brush holder and isolator center screws. Tighten the rear (generator
at the same time insert a stiff piece of wire through end) center screws to the specified torque.
the small holes in the base of the holder. The wire 9. Secure ground strap to drip tray using a capscrew
holds the brushes off the slip rings during assembly. and two EIT locking washers. Note that ground
Install brush block in housing and tighten mounting strap is installed between locking washers to
screws. ensure a good electrical connection.
4. Placethe rotor in positionfor mounting on the end of
the crankshaft and install rotor through-bolt.
Tighten through-bolt just enough to hold rotor in
place.
BARREL
CONNECTOR
LATION
ES-1552
8-11
Redistribution or publication of this document,
by any means, is strictly prohibited.
TRANSFORMER VOLTAGE GENERATOR TESTING
ADJUSTMENTS This section covers the test procedures for the stator,
? generator output voltage may be adjusted by rotor, transformer, and CR4 bridge rectifier.
ingingthe connections to the transformersecondary
taps. This is necessary if the set voltagefalls outsidethe Field Voltage Test
recommended voltage range when operating at the To check the field voltage, remove the brush block
' specified frequency. Use the following procedures to cover and connect a DC voltmeter to the brush block
adjust the generator output voltage: terminals. Connectthe positive leadto the B+(outboard)
terminal and the negative lead to the B-(inboard)
, 1. Adjust thegovernor asspecified in Section 6 before terminal.
making adjustments to the transformer.
2. With the unit operating at no-load, adjust the speed Start the generator set and allow it to stabilize. Measure
adjustment nut to achieve the following frequency the field voltage with no load applied and then with full
and voltage: . load applied. Both readingsshouldfall within a range of
18 to 60 volts DC. Removetest leads and replace brush
block cover when test is complete.
I I I
I Model I AdjustSpeedNutTo: I Rotor Test
60 Hz, 120 Volts 62 Hz, 127.5 f 4.5 Volts The rotor can be tested for grounded, open, or shorted
50 Hz, 110/220 Volts 52 Hz, 233 f 9 Volts windings using an ohmmeter. Figures 8-12 and 8-13
50 Hz, 120/240 Volts 52 Hz, 225 f 9 Volts show the rotor removed from the generator for testing.
However, itis possibleto test the rotor without removing
3. Stop the set and adjust the transformertap connec- it from the generator. To obtain access to the slip rings,
tions as shown in TABLE 8-1 to increase or removethe brush block cover. Usea stiff wire to holdthe
decrease the voltage as required. brushes off the slip rings during testing. Refer to the
Brushes and Slip Rings section for the procedures to
4. Repeat the voltage check and continue to make use for inserting the wire.
adjustments until voltage is within range specified.
5. Check the no load and full load voltage and fre- Ground Test To test for grounds, set the ohmmeter for
quency as specified in Section 6 for the Governor. the highest resistance scale. Touch one test prod to the
Voltage and frequency should stay within the limits rotor shaft and hold it there. Touch the other test prodto
shown inTable 6-1. one of the slip rings. A reading less than one megohm
indicates the rotor is grounded. Replace a grounded
rotor with a new rotor.
TABLE 8-1.
TRANSFORMER TAP CONNECTIONS
VOLTAGE CR4-AC s1
ADJUSTMENT TO TO
~
To Increase x3 x4
Voltage x4
x4
Standard !joHz x3 x5
Setting -
60 Hz x2 x5
To Decrease x1 x5
Voltage x3 X6
. X6
X6
8-14
,
. SECTION TITLE . .
PAGE
SAFETY PRECAUTIONS ............................................... inside Front Cover
1. INTRODUCTION ................................................................... 1-1
About This Manual ............................ :.................................. 1-1
Model Identification................................................................ 1-1
2. SPECIFICATIONS .................................................................. 2-1
3. DIMENSIONS AND CLEARANCES .................................................... 3-1
4. TORQUE SPECIFICATIONS ......................................................... 4-1
5. PREPARINGTO SERVICE ........................................................... 5-1
Troubleshooting ............................................. ..................... 5-1
Special Tools ..................................................................... 5-1
Safely Considerations .............................................................. 5-1
SetRemoval ..................................................................... 5-2
6. .
ENGINE PRIMARY SYSTEMS .......................................................
......................................................................
Introduction
6-1
6-1
Troubleshooting Engine Primary Systems .......... .'................................ 6-1
Exhaust System .................................................................. 6-4
.. System
Cooling ................................................................... 6-7
IgnhonSystem ................................................................... 6-8
Crankcase Ventilation System ..................................................... 6-11
Governor ....................................................................... 6-11
-
Fuel System Gasoline' .......................................................... 6-12
-
Fuel System LP Gas ............................................................ 6-20
Electric Starter (Spec A).......................................................... 6-27
Electric Starter (Begin Spec 6) .................................................... 6-28
7. CONTROL ......................................................................... 7-1
......................................................................
Introduction 7-1
BGE Control Description ........................................................ 7-1
BGE Control Operation .......................................................... 7-2
BGE Control Troubleshooting .................................................... 7-4
BGELControl Description ....................................................... 7-8
BGEL Control Operation ......................................................... 7-9
BGELControl Troubleshooting .................................................. 7-11
8. GENERATOR ....................................................................... 8.1
...................................................................... 8-1
Introduction
Generator Description ............................................................. 8-1
Generator Operation .............................................................. 8-2
Generator Troubleshooting ........................... ; ............................ 8-2
Generator Service ................................................................. 8-8
Brushes and Slip Rings ........................................................... 8-12
Transformer Voltage Adjustments ................................................... 8-14
Generator Testing ............................................................... 8-14
i
Table of Contents (continued)
9; .
M I N E BOCK ASSEMBLY
General .....................................................
. .
.......................................................
:.....................
.9.$
9-1
. . : . . .
. . ..
ii
Section 1 Introduction
MODEL IDENTIFICATIoN
When contacting an Onan Dealer or Distributor,
always supply the complete Model Number and
Serial Number as shown on the set nameplate. This ONAN NAMEPLATE
information is necessary to identify your set when
ordering replacement parts.
. . . .
. . y . ..........
:* . . . . _ .. . .
ENGINE DETAILS
Displacement ...................................................... 47.7 in3 (781.8cm3)
Compression Ratio .............................................................. 6.9:l
Bore .............................................................. .3.25in. (82.55 mm)
Stroke.. ........................................................... .2.87in. (72.90mm)
Oil Capacity (With Filter) ....................... :........................... . 4 Qt (3.8L)
Ventilation (Free Area) ............................................. :..85 in2 (584.4 cm2)
Fuel: BGE ...................................................... Lead-Free or Regular
BGEL.. ....................................... LPG (Propane - Liquid Withdrawal)
GENERATOR DETAILS 50 Hz 60 Hz
Watts .................................. .3500.. ............................... .4OOO
Volts ............................ .110/220 or 120/240. ........................... 120
Amps .......................... .31.8/15.9or 29N14.6.. ........................ .33.3
Phase .................................... 10 ...................................... 10
Wires .................................... 4 ....................................... 2
Battery Charge.. ........................ 1 Amp.. .............................. .1 Amp
TUNE-UP SPECS
Spark Plug Gap .................................................... .0.025 in. (0.64 mm)
Point Gap ......................................................... .0.016 in. (0.41 mm)
Timing ..................................................................... .16O BTC
Valve Lash: intake. ............................................... .0.005 in. (0.127 mm)
Exhaust.. ............................................. .0.013 in. (0.3% mm)
2-1
Redistribution or publication of this document,
by any means, is strictly prohibited.
Section 3. Dimensionsand Clearances
MODELS BGE and BGEL
I
Piston Ring ##2 . 0.080-0.081
Groove Width (2.03-2.06 mm)
. -.. '.'....
Crankshaft Main 1.' . ... 0.0025-0.0038 .I .,;-'I <,,
Camshaft Journal ..
"'.+
. . --, ->
,
1.3740-1.3745 ..:.
,-
;. I . < _
Diameter . , . 1 . . . ,-
(34.900-34.912 mm)
. .
Camshaft Bearing 0.0015-0.0030 ' . i
Clearance s
- 1 a.
(0.038-0.076mrn) . . . .
. . - .
VALVE AND LlfTERS . Dimensions not in parentheses are in
. . . . ...
' 8
. . .. . INCHES .. .
0.7475-0.7480
Valve Lifter Diameter (18.987-18.999rnm)
3-3
Redistribution or publication of this document,
by any means, is strictly prohibited.
Section 4. Torque Specifications
~~
FOOT-POUNDS (NEWTON-METRES)
Rear Vibration.
Isolator
-Center Screw 30-33 (41-45)
Front Vibration
isolator
- Flange to Oil 19-22 (26-30)
Base Screws
I
4-1
.
Siippery Surfaces
- EkrArid short io DC wiring system - Leaking or spilled oil '
.
Develop Safe Work Habits- Unsafe actions are In a below-the-floor mount installation (see Figure
identified as the cause of most accidents involv- 5-Z),a special housing is usedto suspend the genera-
ing the use of tools and machines. Be familiar tor set from the underside of the coach. The housing
with the equipment and know how to use it safely. bolts to special support members that are built into
Use the correct tool for the job and cheek its the coach framework. The housing is mounted near
condition before starting. Observe the warnings the exterior of the coach and limited access is pro-
and cautions in this manual and take special pre- vided through a door located in the exterior of the
cautions when working around electrical equip- coach.
.
ment. Do not work alone if possible and do not
take risks. Because of the wide variety of generator set installa-
tions, it is not possible to specify the exact removal
Be prepared if an accident does occur. Numerous proceduresfor each generator set. If, after examining
agencies such as the Red Cross and your local police the installation, a satisfactory method for removing
and fire departments offer basic courses in first aid, the set cannot be determined, contact the RV coach
mouth-to-mouth resuscitation,and fire control. Take manufacturer to obtain their. recommendations
advantage of these .offerings so you are ready to before attempting to remove the set from the coach.
respond when an accident happens. Learn to be
safety conscious and make sure safe practices a part
of your work routine. ldropped
3iEM G l Generator sets are heavy and can
result in severe Dersonal iniurv if
during removal. Use adequate lifting devi-
SET REMOVAL ces fo provide sufficient supporf for the set. Keep
hands and feet clear while liffing.
Some service procedures will require that the genera-
tor set be removed from the coach. While there are Special fuel handling procedures are required when
many variations, generator set installations are removing an LP gas (propane) powered set. The fuel
generally classified as either conventional compart- system must be purged of LP gas before the set can
ment mount or below-the-floor mount. In a compart- be safely removed from the coach. Follow the purg-
ment mount installation, a special compartment (see ing procedurefollowing before attempting to remove
Figure 5-1) is built into the coach to housethe gener- an LP gas powered set. If the generator set is powered
ator set. The compartment iscontructed with a vapor by gasoline, proceed to the appropriate set removal
tight barrier that seals off the generator set from the section.
coach interior. The generator set is usually fastened
to the floor of the compartmentwhich must be able to
support the weight of the set. Access to the compart-
ment is through a door located in the exterior of the
coach.
Redistribution or publication of this document,
by any means, is strictly prohibited.
5-2
\
T
MOUNTING COMPARTMENT FLOOR
HOLES
- ks-1121
REAR
PANEL
ASSEMBL
us-1122
SUPPORTBRACKET
5-3
LP-Gas (Propane) Purging Procedure 7. Disconnect the muffler from the exhaust mani-
To purge the LP-gas from the set fuel system, close fold at the flange connection and disconnect any
the shut-off valve at the fuel tank and then start the support brackets or hangers that connect the
generatorset. Allow the generator set to operate until muffler to the set.
it runs out of fuel. Crank the set a few times after it 8. On gasoline fueled sets, turn off the fuel shutoff
stops to make sure the fuel system is completely valve in the compartment and disconnect the fuel
purged of all LP-gas fuel. lineatthe fuel pump. Securely plug the end of the
fuel line to prevent fuel leakage or an accumula-
If the generator set cannot be operated, move the RV tion of explosive gasoline vapor.
coach to an outdoor location that is well-ventilated
and is away from fire or flame. Disconnect both the
vehicle negative (-) battery cable and the generator
1- Gasoline vapor is extremely flam-
mable and can result in severe per-
set negative (-) battery cable from their respective sonal injury or death if ignited. Make certain all fuel
battery terminals. Close the fuel shutoff valves at the line openings are plugged to prevent gasoline vapor
fuel tank for both the generatorset fuel supply system from accumulating.
and the appliance (stove, heater, etc.) fuel supply
system. In addition, close the fuel shutoff valves at
each appliance. On LP gas (propane) fueled sets, disconnect the fuel
line (after purging) at the solenoid valve and plug the
E LP-G~S (Propane)is extremely flam-
mable and can result in severe per-
sonal injury or death if accidentally ignited. Eliminate
end of the fuel line to prevent entrance of dirt.
Disconnecting Set from RV Systems 1- The generator set is heavy and can
result in severe personal injury if
Disconnect the following items from the generator set
Refer to Figures5-1 and 5-2for componentlocations in dropped during removal. Use the recommended
typical generator set installations. removal techniques and keep hands and feet clear
while removing mounting bolts.
1. Disconnectthe vehicle negative (-) battery cable
at the battery terminal.
2. Disconnect the generator set negative (-) battery Removing Underfloor Mounted Set From RV
cable at the battery terminal. When the generator set has been disconnected from
the electrical, exhaust, and fuel systems, the set may
3. Disconnect the generator set positive (+) battery be partially removedfor limited service or completely
cable from the start solenoid. removed from the RV for major service. The genera-
4. Disconnectthe remote control wire plug from the tor set is mounted on a support tray which serves as
generator set control. the bottom of the underfloor housing. The inner edge
5. Disconnect the generator load wires at the RV of the support tray is hinged to the rear panel assem-
electrical system junction box. Tag the RV circuit . bly. The outer edge of the support tray is bolted to a
wires if necessaryfor positive identification when, support bracket. A front and rear panel assembly
reconnecting. serve as sides to complete the housing.
6. Loosen the conduit connector and pull the load
wires and flexible conduit free of the junction
box. Redistribution or publication of this document,
by any means, is strictly prohibited.
"5-4
The generator set is completely suspended under- Partial Set Removal: Park the recreational vehicle on
neath the RV coach by the housing assembly. To as level a surface as possible'(surface must support
avoid dropping the set during removal, follow the floor jack wheels.) Then follow these instructions
recommended set removal procedures. very carefully.
' I
DRIPTRAY
SUPPORT BRACKET
BOLTS (4)
.
FIGURE 5-3. PARTIALSETREMOVAL Redistribution or publication of this document,
by any means, is strictly prohibited.
4. Remove the four bolts from the front support 6. Removethe sidesupport to providethe clearance
bracket, and remove the support bracket itself. needed for lowering the set.
This might requireslight adjustment, either slight
raising or lowering the floor jack. 7. Remove the safety catch from the center of each
5. Once the support bracket is removed, all the hinge assembly and then remove the U-shaped
weight of the generator set on that side is on the hinge pin.
floorjack. Slowly lowerthe floorjack, being care- 8. Slowly lower the generatorset untilit is clear of all
ful to allow the floor jack to roll as the generator obstructions and can be moved out from under
set swings downward. the recreational vehicle.
6. Onan suggests wood blocks be placed under the
drip tray assembly so the floor jack can be
removed. This will allow more access room for
the maintenanceor service procedure.
. . . -... .
' i
. ..
.'
Redistribution or publication of this document,
by any means, is strictly prohibited.
Section 6. Engine Primary Systems -
INTRODUCTION
The engine primary systems include the following: The engine primary systems can often be serviced
without removing the generator set from the recrea-
0 Exhaust System tional vehicle and without major disassembly of the
" 0 Cooling System set. Use the following troubleshooting guide to help
Ignition System locate problems related to the engine primary sys-
0 Electric Starter tems. Refer to Troubleshooting Generator Set Con-
0 Crankcase Ventilation System trol for problems related to starting the generator set.
Governor
0 -
Fuel System Gasoline
0 Fuel System - LP-Gas Liquid Withdrawal
TROUBLESHOOTING ENGINE PRIMARY SYSTEMS
Engine 1. Faulty ignition due to: la. Adjust breaker point gap
Backfires a. incorrect ignition timing 1b. Reset spark plug gap
b. incorrect spark plug gap
Engine I . F.aulty ignition due to: 1a. Adjust breaker point gap
Lacks Power a. incorrect.ignition timing lb. Reset spark plug gap
b. incorrect spark plug gap
4. Incorrect fuel mixture due to: 4a. Adjust carburetor main and
a. incorrectly adjusted andidle adjustment screws
. fuel mixture screws, 4b. Adjust carburetor float
*b. incorrect float level, or level
c. dirt in carburetor 4c. Disassemble carburetor and
2: clean all internal passages
5. Exhaust system blocked or 5. Locate and remove cause
restricted of blockage
Black Exhaust 1. Rich fuel mixture due to: . ' .la. Replace air cleaner
Smoke a. dirty air cleaner, l b . Gi,ean choke and choke
*b. choke sticking, . linkage
c. incorrectly adjusted fuel mixture IC. Adjust carburetor idle and
screws 'main adjustment screws
d. dirt in carburetor
I d . Disassemble carburetor and
. . .. . . . clean ail internal passages
*'Gasoline sets only
High Oil 1. Oil viscosity too light or 1. Drain oil and refill with
Consumption oil is diluted correct viscosity oil
Low Oil 1. Oil viscosity too light or 1. Drain oil and refill with
Pressure oil is diluted correct viscosity oil
2. Low oil level 2. Add oil as required
3. Low oil pressure switch 3. Replace oil pressure switch
defective (see Engine Block Assembly
section)
4. Faulty oil bypass valve . 4. Inspect oil bypass valve and
clean or replace as required
(see Engine Block Assembly
section)
5. Excessiveengine wear or 5. See Engine Block
, defective oil pump. Assembly section
6-3
EXHAUST SYSTEM Conventional Compartment Mount Exhaust
The condition of the exhaust system is extremely System
critical on RV generator sets because of the possibil- Conventional compartment mount exhaust systems
ity of exhaust gases entering the coach. consist of the exhaust manifold, flange connector,
muffler, muffler strap, hanger, clamps, and tailpipe.
The exhaust system must be serviced immediately if inspection When service is required, disassemble and reassem-
reveals leakingjoints or connections,loosefasteners, or broken or ble as specified in the following steps.
damaged compouents.
Always replace worn components with new original Disassembly:
equipment replacementparts. Do not attempt to repaira
broken exhaust pipe or manifold by welding and do not 1. Loosenthefront muffler clamp, muffler strap, and
replace worn out components with parts that do not tailpipe hanger and remove the muffler and tail-
meet factory specifications.Contact an Onan distributor pipe assembly (see Figure 6-1).
for proper exhaust kit parts and installationinstructions.
2. Remove the screws that secure the exhaust tube
Inhalation of exhaust gases can to the exhaust manifold and remove the exhaust
ldeath.
2iSFEd result in severe' personal injury or
Modiiying the exhaust system (other than
tube and exhaust gasket.
shortening the downpipe) might allow poisonous Completion of theremainingsteps requires that the generator
exhaust gases to enter the coach. Use only original set beremovedfrom thevehicle. RefertothePREPARlNGT0
SERVICE section for the set removal procedures.
equipment replacement parts when servicing the
exhaust system. Unauthorizedmodiiicationswill also 3. Remove the cooling system noise shield and
void the warranty and cancel the UL LisfingXSA scroll (see Cooling in this section) to provide
Cerfification. Liability for injury or damages due fo access to the exhaust manifold.
unauthorized modifications becomes the responsi-
bility of the person making fhe change. 4. Removethe screw that secures the exhaust mani-
fold outlet flange to the exhaust manifold support
Two basic exhaust systems are used with Emerald ser- bracket.
ies generator sets. Figure 6-1 shows a typical exhaust 5. Remove the four exhaust manifold screwsand lift
system for a compartment mount generator set. Figure off the exhaust manifold and the two manifold
6-2 shows a typical exhaust system for an underfloor gaskets.
.mount generator set Separate sections cover the ser-
vice procedures for each exhaust system. Also refer to
specific kit installationinstructions.
MUFFLER STRAP
L BRACKET CUTOUT
CKET
MINIMUM
E OR AT
IMFTER OF VEHICLE)
EXS-1117
9. Run the generator set for five minutes and check 3. Place a U-bolt type automotive muffler clamp
entire exhaust system (visually and audibly) for (marked 1-114) in position on the exhaust manifold
leaks or excessive noise. Correct as required. (near elbow) prior to installing muffler.
4. Place muffler in position on set making certain
that muffler inlet pipe overlaps exhaust manifold
a minimum of 1-1/2 inches (38 mm).
Redistribution or publication of this document,
by any means, is strictly prohibited.
6-5
FIGURE 6-2. UNDERFLOOR MOUNT EXHAUSTSYSTEM
6-7
Overheating can result in engine
,NOISE SHIELD damage. To avoid Overheating,
never operate the generatorset with any ofthe cool-
ing system components removed.
fGNlTlON SYSTEM
The ignition system consists of the breaker points,
condenser, ignition coil, spark plugs, and wiring. For
reliable generator set operation, the complete igni-
tion system must be in good working order and prop-
erly adjusted. Many generator set “problems” can be
traced to an improperly maintained ignition system.
Refer to the following paragraphs when servicing or
making adjustments and the SPECIFICATIONS
(Section 2) for recommendeddimensions.
LOW TENSION
TERMINAL
Es-1529
IRON CORE
FIGURE 6-6. BREAKER POINTS
ES-1372
5. Remove the breaker points mounting screws (C)
and lift out the point assembly.
FIGURE 6-7. IGNITION COIL
6. Replace the condenser and point assembly and
install a in reverse order of removal.
7. Usean allen head wrench toadjust setscrew D to
obtain the gap setting specified in the Specifica-
tions section. Measure the point gap with a flat
thickness gauge (see Figure 6-6).
Make sure feeler gauge is clean and free of any grease, oil or
dirt.
6-9
3. To measure resistance in. the primary circuit, Chipped Insulator- Check for advanced timing.
connect one ohmmeter lead to the positive (+) Bend only side electrode when setting gap.
terminal and the other to the negative (-) terminal 0 Splash Fouled - Check for accumulated com-
on the coil. The resistance should be between bustion chamber deposits. See Cylinder Head
3.87 and 4.73 ohms. A high resistancevalue indi- section.
cates an open circuit or poor connection inside
the coil. Replace the coil if not within specifi-
0 -
Light Tan or Grey Deposits Normal plug color.
cations.
4. To measure resistance in the secondary circuit, . .
connect the ohmmeter leads to the two high ten-
sion terminals (see Figure 6-8). The resistance
measured should be between 12,600 and 15,400
ohms. A lower resistance value indicates a
shorted secondary winding. A higher resistance
value indicates the coil bas excessive internal
resistance or an open circuit. Replace coil if not
within specifications.
ES-1374
J ES-1373
Wiring
Ignition system wiring includes: (1)One positive (B+)
wire which carries the low voltage current from the
battery to the primary winding of the coil. (2) One
FIGURE 6-8. TESTING COIL SECONDARY negative (-) wire which carries low voltage to the
points and condenser. (3) Two high tension wires
that carry the high voltage current from the secon-
dary winding of the coil to the spark plugs. The spark
Spark Plugs plugs and coil secondary are all.grounded to the
Remove and inspect the spark plugs at the intervals engine making a complete circuit for thevoltage back
recommended in the operators manual. A careful to the battery. The ignition coil primary (low voltage
examinationof the plug can often pinpoint thesource side) is grounded when the breaker points close.
of an engine problem. The following covers some
common spark plug conditions and the probable Check all low voltage wiring for loose connections
cause. and cuts or breaks in the insulation. Clean all termi-
nals and connections and test for continuity with an
0 One Plug Carbon Fouled - Check for an open ohmmeter. Use a megger to check for breaks in the
ignition cable or low compression. spark plug wire insulation.
0 Black Soot Deposits - Check for faulty choke '
6-10
CRANKCASE VENTILATION SYSTEM The reed valve must be flat with no sign of a crease.
Assemble using a new gasket. Do not overtighten
The crankcase breather prevents pressure from valve cover capscrew.
building up in the crankcase. It also prevents oil con-
tamination by removing moisture or gasoline vapors Reed valve must be assembled as shown with washer on top and
and other harmful blow-by materials from the crank- breather baffle on the bottom.
case. These vapors are routed to the carburetor
where they are mixed with incomingairand burned in
the combustion chamber. Asticky breathervalve can
I - [ Over tightening fhe valve cover
can cause an air leak and allow dirt
cause oil leaks, high oil consumption, rough idle, to enter fhe engine. Be careful not to distort fhe valve
reduced engine power, a rapid formation of sludge cover when tightening.
and varnish within the engine, or oil in the breaker
point box. GOVERNOR
The governor controls engine speed which directly
Crankcase Breather Service affects the voltage output and frequency of the
If the crankcase becomes pressurized as evidenced generator. An increase in engine speed will cause a
by oil leaks at theseals, usethe following procedures corresponding increasein generator voltage and fre-
to service. quency. A decrease in engine speed will cause a
corresponding decrease in generator voltage and
Remove the breather tube from the valve cover (see frequency. The governor maintains a constant
Figure 6-10). Remove the valve cover, pack, spring, engine speed under changingload conditions so that
washer, reed valve, and breather baffle. Clean all generator voltage and frequency do not vary.
parts in parts cleaning solvent.
Governor Adjustments
VAWARNINcJMost parts cleaning solvents are
flammable and can result in severe
Before making governor adjustments, run the unit
about 10 minutes under light load to reach normal
personal injury if used improperly. Follow the manu- operating temperature. If governor is completely out
facturers recommendations when cleaning parts. of adjustment, make a preliminary adjustment at no
BREATHER HOSE load to first attain a safe voltage and speed operating
range.
6-11
5. Adjust the governor sensitivity to give the closest
regulation (least speed and voltage difference
between no load and full load) without causing a
hunting condition. To increasesensitivity (closer
SPEED ADJUSTMENT NUT regulation), turn the sensitivity adjustment screw
1 counterclockwise. To decrease sensitivity, turn
the sensitivity adjustment screw clockwise.
' 6 . Recheck the speed setting made in step #3 and
readjust if necessary.
7. Set the carburetor throttlestop screw as specified
in Fuel System of this section.
TABLE6-1.
CHECKING VOLTAGE AND SPEED/FREQUENCY
50 Hz
t
(10,4-Wire)
I101220 v 1201240 v
Voltage
Maximum No-Load 1211242 1321264
SENSITIVITY Minimum Full-Load 991198 1081216
ADJUSTMENT SCREW I
FS-I613 SpeedlFrequency
aa'mum No-Load
'Mspeed (r/min) 1575
FIGURE 6-11. GOVERNOR ADJUSTMENT Frequency (Hz) 52.5
Minimum Full-Load
62 HF 127.5f4.5 Volts .
52 Hz,233 5 9 Volts heater hose from the air cleaner housing.
52 Hz,255 +9 Volts 2. Remove the air cleaner housing center capscrew
~ ~~ ~ ~ ~ ~~ ~
6-12
CARBURETOR
AIR C W N E R
HOUSING
COVER-
FS-1-
5. Remove the three capscrews that secure the air 1. Removetheairfilterassembly asdescribed in Air
cleaner adapter to the carburetor and lift off the Filter Assembly previously.
adapter. Note that choke linkage must be disen- 2. Disconnectthe fuel lineand governor control link-
gaged from choke assembly as adapter is age from the carburetor.
removed.
3. Removethe intake manifold capscrewsand lift off
6. Remove the two capscrews that secure choke the carburetor air preheater. Lift off the carbure-
bracket to adapter and lift off choke assembly. tor and intake manifold as an assembly.
Assembly: Reverse order of disassembly. Use a new 4. Removethe two intake manifold gaskets and plug
gasket between adapter and carburetor. the intake ports with a rag to prevent loose parts
from accidentally entering ports.
Carburetor And Intake Manifold Assembly 5. Remove the two capscrews that secure the car-
buretor and choke pull-off assemblyto the intake
The carburetor and intake manifold assembly con- manifold. Disengage the choke pull-off linkage
sists of the intake manifold, choke pull-off assembly, . from the carburetor and carefully separate the
air preheaters, and carburetor (See Figure 6-13). carburetor from the intake manifold.
Disassembly: Use the following procedures to
remove and disassemble the carburetor and intake
manifold assembly.
6-13
. .'
RBURETOR
,: _. . \. \
5 .
Redistribution
FIGURE 6-14. MIXTURE SCREW or ADJUSTMENT
publication of this document,
by any means, is strictly prohibited.
TABLE 6-2. CARBURETOR ADJUSTMENT SPECIFICATIONS
1. Stop the set and connect a voltmeter, frequency General instructions for overhauling acarburetor are
meter, and load bank to the generator output given :as follows: Carefully note the position while
leads. removing all parts to ensure correct placement when
reassembling. Read through all the instructions
2. startthe generator set and apply a load'Verify
before beginning for a better of the
that the frequency is within 59 (49) *2 he* and procedures involved. Carburetor components are
adjust the governor speed adjustmentnut if neces- shown in Figure ,
6-15
1. Removetheairdeamr adapterand the automatic.
chake assertll>~y.
2. Remove thro.ttttA and choke plate retaining.
screwsythen: plates. Pulk out throttle and'&&e
shafts, being careful not to damage the t d o n
coating applied to some thlcmbshafts.
'
OCCUR HERE
3. RernouemainandidJemi>stritescrew assemblies.
4.. Separatethelowersectitmafthecarburetor: (fud
. bowl) from the upper section [fuel:bowl.cover)~of FS-1483
the cdw-1
5. Carefulty note position.of float assembly parts, F M E 6-t6. MJXTURE NEEDLE IWPECTION. '
Reassembly and lnsfallafion: When the carburetor 4. Invert the float and needle valve assembly and
parts are clean and dry, reassemble using the follow- check float level by measuring between the float
ing procedure. and gasket atthe pointshown in Figure6-18.The
full weight of the float should be resting on the
1. Slide in throttle shaft and install throttle plate needle valve and spring. The correct distance is
using newscrews, if furnished in repair kit. Before specified in Table 6-2. If the setting is incorrect,
tightening thescrews, the plate must be centered remove float and bend tab to adjust. Bend the
in the bore. To do so, back off the throttle stop float only at the point indicated.
screw as necessary and completely close the
throttle lever. Seat the plate by gently tapping Affempfing adjusfmenfs wifh
with a small screwdriver, then tighten screws. fhe floaf assembly installed
Install the choke shaft and plate in the same can damage the inlef needle and seat Remove
manner. floaf assembly before making
Redistribution adjusfmenfs.
or publication of this document,
by any means, is strictly prohibited.
6-16
The choke gets very hot during
- severe
1 burns if touched.
normal operation and can result in
Do not remove choke cover
BEND TAB
k3J53 TOADJUST while the set is operaiing.
If the engine starts but runs roughly and blows out
black smoke after a minute or two of operation, the
choke is set too rich. If the enginestarts but sputters or
MEASURETHI
DISTANC stops before itwarms up, the choke is set too lean.
6-17
PLASTIC COVER
ELEMENT COVER
4. Refer to Table 6-3 to determine the number of must point in a clockwise direction. Make sure the coil
. degrees element cover must be rotated (clockwise) sets squarely in the housing and the inner end of the
from reference position. Marks on choke housing coil engages the slot in the choke shaft. When instal-
are spaced at 5' intervals. ling the element cover, make sure the slotted tang on
5. Rotate elementcover asspecifiedand then tighten the cover engages the bi-metal strip.
cover mounting screws.
6. Move choke lever back and forth to check for
smooth operation. Lever should return automati-
cally to the free position when released from the
open position without sticking or binding.
7. Install plastic choke cover and tighten center
mounting nut.
Choke Replacement: If the choke fails to open, remove
the protective plastic cover and check to see if the OZTER
TAB
FS-1606
heatingelement is working. The heatingelement cover
should become hot after a few minutes of operation. If FIGURE 6-20. BI-METAL SPIRAL STRIP
the element cover does not get hot, start the set and
then use an AC voltmeter to check forvoltage (approx-
imately 20 VAC) at the element cover terminals. If Choke Pul/off Diaphragm Adjustments: The choke
voltage is not present, check for opens or shorts in the pulloff diaphragm partially opens thechoke plate fol-
control wiring. lowing engine startup. This helps prevent flooding
and provides for smoother engine operation as the
If the voltage is present at the heating element cover set is warming up. Use the following procedure to
terminals,stop the set and removethe heatingelement adjust.
cover. Inspect the heating element and replace if
burned out or broken. Also inspect the bi-metal spiral 1. Remove the complete air filter assembly as speci-
strip and replace if damaged, deteriorated, ordragging fied in Air Filter Assembly in thissection to provide
in the housing. access to the choke plate.
2. Disconnect diaphragm hose from intake mani-
When installing a new bi-metal strip, maintainthe orig- fold and apply4 to 18 inches (102 to457 mm) Hg
Redistribution or publication of this document,
inal direction of spiral (see Figure 6-20). The outer tab vacuum to the diaphragm. by any means, is strictly prohibited.
6-18
Pump Test (forunits built June 1986 and before): Test
CHOKE LEVER
the fuel pump by checking the pump outlet pressure.
Use the following procedure.
C
-H
,OKE PLATE CLOSED
/-- PULL OFF LINKAGE
1. Removethefuel linefromthepumpoutletandinstall
PULL OFF DlAPliRAGM
a pressure gauge.
2. Press the START switch and hold it for several
seconds until pressure reading is constant
3. The pressure reading for a good pump should fall
within 4 to 5 psi (27.5 to 34.4 kPa). The pressure
should stay constant or drop off very slowly.
A low pressure readingwith little or no pressuredrop
indicates a weak or broken diaphragm or diaphragm
DISTANCE
I LDIAPHRAGM
MTG BRKT
BEND HERE
spring, worn linkageor leaky check valves. If pressure
is above maximum, the pump diaphragm is too tight
or the diaphragm (or plunger) return spring is too
strong. Any of the above conditions are cause for
repair or replacement of the pump.
Fuel Pump Repair (for units built June 1986 and
beiore)sServiceofthe fuel pump is limitedto the bottom
cover, plunger tube, and plunger assembly. All parts of
FS-1603
the electric system are hermetically sealed in a gas
atmosphere and are not serviceable. If electrical failure
occurs, replace the pump.
FIGURE 6-21. CHOKE PULLOFF DIAPHRAGM Do not iamper with the seal ai the
1- center of the mounting bracket on
the side of the pump as it retains the dry gas which
surrounds the electrical system. Electrical system
3. Apply light finger pressure against the choke lever components are not serviceable.
to take up all freeplay in the pulloff linkage (see
Figure 6-21). Use the following procedurefor servicing the pump:
4. Check alignment (as viewed from the top) of diaph-
ragm stem, pulloff linkage, and slot in choke lever. 1. Using a5/8-inch wrench, loosenthe pump cover,
Correct alignment as required. then remove by hand.
5. Measure distancebetween choke plateand bottom 2. Remove the filter, magnet and cover gasket
of carburetoratthe point indicated in Figure 6-21. If (Figure 6-22).
necessary, bend diaphragm mounting bracket to
Later models do not have a filter assembly.
obtain 0.39 to 0.43 inches (9.9 to 10.9 mm) clear-
ance.
6. Movechokeleverbackand forth tocheckforfree
movement. Verify that choke does not bind or
stick.
PUMP ASSEMBLY
7. Remove vacuum supply from diaphragm and
install filter assembly on carburetor.
Fuel Pump
All gasoline fueled generator sets are equipped with an
electric fuel pump. AI1 fuel pumps have an integral shu-
toff valve that prevents fuel flow to the carburetor when
the set is not in operation. If the pump malfunctions or
insufficient fuel delivery is suspected, use the approp-
riate following procedureto test, and repairireplacethe
Pump.
Do not substitute automotive type
@@@@d electric fuel pumps for standard
Onan supplied electric pumps. The output pressure FS-1487
is much higher and can cause carburetor flooding or
fuel leakage, creaiing a fire hazard. FIGURE 6-22. FUEL PUMP ASSEMBLY
(June 1986
Redistribution and before)of this document,
or publication
by any means, is strictly prohibited.
6-19
3. Using a thin nose pliers, remove the retainer Pump Test (forunifsbuiltJune 7986andaffer):Testthe
spring from the plunger tube. Remove the fuel pump by checking the pump outlet pressure. Use
washer, 0 ring seal, cup valve, plunger spring, the following procedure.
and plunger from tube (see Figure 6-23).
1. Removethe fuel linefrom the pump outletand install
a pressure gauge.
PUMP ASSEMBLY
2. Press the START switch and hold it for several
seconds until pressure reading is constant
3. The pressure reading for a good pump should fall
within 3-112 to 5 psi (l7.2ts34.4kPa).The pressure
should stay constant or drop off very slowly.
CRANKCASE
BREATHER HOSE
AIR CLEANER HOUSING
J
,,I AIR FILTER
XFS-1612
CARBURETOR AIR CLEANER ADAPTER
Overhauling the carburetor includes complete dis- FIGURE 6-26. CARBURETOR OVERHAUL
assembly, thorough cleaning, and replacement of
worn parts. Carburetor repair kits are available that
supply new gaskets and replacement parts for the CIeanandRepair: When the carburetor is completely
components subject to wear. disassembled, clean and repair using the following
procedures.
Note the position of all components while removing
to ensure correct placementwhen reassembling.See 1. Soakall metal components not replacedby repair
Figure 6-26 for component designations. kit in carburetor cleaner. Do not soak any non-
metal partsorthey may bedamaged bythe clean-
Removal and Disassembly: Remove the carburetor ing solution. Follow the cleaner manufacturer's
from the intake manifold as specified in the Carbur- recommendations.
etor, Air Filter,And Intake Manifold Assembly section. 2. Clean all carbon from throttle bore, especially
Use the following procedure to disassemble the where the throttle plate seats. Be careful not to
carburetor. plug the idle or main fuel ports.
Mosf parts cleaning solvenfs are 3. Blow out all passages with low pressure (30
AWARN~NG flammable and can resulf in severe psi/207 kPa) compressed air. Do not use wire or
personal injury if used impropriy. Follow the manu- other objects for cleaning that might increasethe
facturers recommendafions when cleaning parts. size of critical passages.
4. Check the condition of the mixture screws (see
1. Remove the throttle stop collar and throttle stop Figure 6-27) and replace if worn or damaged.
lever from the end of the throttle shaft. 5. Replace all old components, seals, and gaskets
2. Remove the throttle plate retaining screws and' with new parts included in the kit.
throttle plate. Remove dust seals from throttle
shaft and carefully pull out throttle shaft.
3. Remove main and idle mixture screw assembly.
4. Separate lower section (bowl) of carburetor from
the upper section (bowl cover).
6-23
The regulatorwill normally require very little attention
if the set is used on a regular basis and operated on
clean high quality fuel. Most regulator malfunctions
can be traced to the following two sources:
0 Hardened diaphragms and seats due to extended
IDAMAG
AND WEAR periods of non-operation.
OCCUR HERE
0 Dirt or foreign matter embedded on valves and
valve seats.
FS-1453
6-24
3. If the primary seal is sound, the gauge should
read approximately 1-1/2 psi (10.3 kPa) and the
pressure should remain constant. A fluctuating
pressure reading indicates a bad primary seat.
4. Close the air pressurevalve and observethe pres-
sure gauge. The pressure should remain con-
stant. If the pressure reading drops, the sec-
ondary seat is leaking.
SECONDARY
DIAPHRAGM
/y 6SECONDARY
VALVE
If the regulator does not pass either test, it must be
rebuilt or replaced.
PRIMARY
VALVE
- PRIMARY
DIAPHRAGM FS-1599
XFSlwO
6-25
Fuel Filter 5. Wipe the center stud magnet clean of any rust or
The fuel filter (see (Figure6-31) removessolid impuri- scale particles that have collected.
ties such as rust or scale from the LP gas before they 6. Install clean filter element using new gaskets (2)
can clog the regulator or carburetor. A magnet within
and securely tighten center stud nut.
the filter housing traps iron or rust particles while a
filter element traps nonmagnetic particles. The fuel 7. Place a new O-ring in the filter bowl sealing
filter operates at container pressure and must be groove.
careful!y assembled to prevent leakage. Use the fol- 8. Align reference mark on filter bowl with reference
lowing procedures to disassemble and clean: mark on filter body and install capscrews (4) and
lock washers (4). Tighten capscrews to 56 to 74
1. Remove the four capscrews and lock washers in-lbs (6.5 to 8.3 Nom) torque. When fuel system
that secure the filter bowl to the filter body. is pressurized, check filter for leaks.
2. Separate filter bowl from filter body and discard
the O-ring seal. Solenoid Valve
3. Removenut and washer from center stud and pull The solenoid valve (see Figure 6-32) providesa positive
out the filter element. fuel shutoff whenever the generator set is stopped. The
solenoid must be energized before fuel will flow to the
4. If filter element is clogged, wash element in kero- regulator. Service is limited to replacing the complete
sene and blow dry with low pressure (30 psi/207 valve assembly if it does not operate properly. Thevalve '
kPa) compressed air. Replace filter element if may be bench tested by connecting battery positive(B+)
damaged. to the top terminal and battery negative (B-)to the
grounded terminal. The plunger assemblyshould with-
draw and open the valve when the solenoid is ener-
FILTER ELEMENT gized. Replace the solenoid valve if it does not operate
properly.
OdtNG SEAL-
0
Disassembly,
Use the following procedures to remove and disas-
semble the starter.
STOP NUT
GROWLER
BRUSH SCREWS
/ I ~ ~STUD
J T
END CAP NUT
. ES-1334
ES-1002
6-27
Testing For Opens: Touch an ohmmeter lead to a 5. Apply a thin film of silicone base grease (GEVer-
commutator bar and then systematically touch the siiube 322-L or equivalent) to theportions of the
other leadto each of the remaining commutator bars. armature shaft that contact the bearings. Apply a
A high resistance reading indicates an open circuit heavy coat of silicone base grease to the starter
between the commutator bars and armature wind- drive section of the shaft.
ings. Replace an open armature with new part. 6. Install the pinion gear stop nut and tighten to 20
to 25 ft-lbs (27to 34 Nom) torque.
Brush Inspection: Measurebrushes (see Figure6-36)
and replace if worn to less than 1/4 inch (6.4 mm). 7. Place the armature end cap in position on the
Check to see that brushes move smoothly in the starter housing and then carefully insert the
brush holders. Replace brushes that are burned. armature into the housing. Install starterthrough-
bolts and tighten securely. b
Housing Inspection: Inspect the inside of the starter 8. Mount starter on generator stator housing and
housing. Magnets are glued to the housing and must secure using hex head capscrews, lockwashers,
be secure and free of cracks. and nuts. Tighten mounting screws to 30 to 33
ft-lbs (41 to 45 Nom) torque.
9. Connect generator set positive (+) battery cable
to starter lug terminal.
10. Connect generator set negative (-) battery cable
to generator set starting battery.
--I
0.25 IN
6-28
r
STAmEFi
RETAINER THROUGHBO1
;d
SUPPORT PLASnC
RETAINER WllH tO1/8"
A VISE OR OTHER
SOLID SURFACE
USE CARE NOT TO
HAVE SPRING RETURN
"LEG BETWEENTHE p u s n c
RETAINER & SUPPORT WHEN
DRMNG OUT ROLL PIN.
6-11
6-29
Testing Armature for Grounds: Touch one ohmmeter Testing for Opens; Touch one ohmmeter lead to a
lead to a commutator bar and then touch the other lead commutator bar and then systematically touch the other
to armatureshaftand core 1aminations.Alow resistance lead to each of the remaining commutator bars. A high
reading indicates a grounded armature. Replace resistance reading indicates an open circuit between
grounded armature with 8 new part See Figure 6-39. the commutator bars and armature windings. Replace
an open armature with a new part
Brush Inspeclion: Measure brushes (Figure 6-41) and
replace if worn less than 0.425 (11 mm).
0.425 INCH
(11.mm)WEAR UMlT NEW 0.570 INCH '
(t4.5mm) '
SlU4
I I
FIGURE 6-40. TESTING ARMATURE FOR SHORTS Redistribution or publication of this document,
by any means, is strictly prohibited.
6-3Q
-
TORQUETO 5-10 IN-LBS (.S1.13 N W
6-31
6. If the brushes are at least 0.430 inch (10.9 mm) long, 9. Place magnetic housing over armature. Use a nut
rest the brush springs against the sides of brushes driver over the end of shaft to hold down armature
to keepthem clear during armature installation. See and endcap.
Figure 6-43. 10. Place spring washer and flat washer on shaft as
7. Place washer on commutator end of shaft and put shown in Figure 6-44.
armature into brush endcap. Push the four brushes 11. Place mountingbracket on motor with exposedend
toward commutator, making sure springs are prop- of sleeve bearing and through-bolt “lead-ins”to the
erly positioned on brushes. Recheck to be sure inside of motor. The “flat” near one mounting hole
spring is pushed all the way down on mounting tab. should line up with the positive stud on end cap so
8. Make sure all brush wires are clear of commutator through-bolts will line up.
and that uninsulated portions of insulated wires do 12. Insert the through-bolts and torque to 35-45 Ib-in
not touch inside diameter of housing. Uninsulated (3.96-509 Nom).
portions of wires must also not touch adjacent
brush boxes. 13. Wipedustfrom helixandgearandapplyalightcoat
of GE Versilube 322-Lon outside diameter of helix,
inside diameter of gear and unchamfered end of
gear. Place clutch and helix assembly on motor
shaft with flats engaged in dutch hole.
6-32
WASHER
METAL
R€IURN SPRING
THROUGH
BOLT
a1r1t
14. /i Return Spring is Unassembled; D. Place spring cover over top of plastic retainer,
then the return spring on top of the retainer.
A. Place 1-1/16 inch O.D. washer over end of E With washer placed over point of plastic
shaft retainer, push metal retainer into hole of plastic
B. With chamfered side of shaft hole up, place plas- retainer as far as it will go.
tic retainer on shaft and line up hole with hole in
shaft 15. Mount starter on generator stator housing using
C. Support the plastic retainer with a vise or other capscrews, lockwashers and nuts. Tighten mount-
solid surface. Using a 5/32 to 118 inch nail set ing screws to 30-33Ib-ft (41-45 Nom).
and hammer, drive in a new roll pin. The pin 16. Connect generator set positive (+) battery cable to
should be driven in about 1/loth of an inch (2.5 starter terminal. Connect generator set negative (-)
mm) from the edge of the plastic retainer or so it terminal to generator set starting battery.
is evenly spaced from each side.
6-33
A
.. .
Section 7. Control
INTRODUCTION
The control system includes all functions that relate The PC board assembly is designed so it will not be
to starting, monitoring forfault conditions, instrumen- damaged by reversed battery polarity or by a short in
tation, battery charging, and stopping. This section the lead wires from the board or remote start control.
covers how the control operates, where the compon- The relays are sealed and filled with dry nitrogen for
ents are located, and basic troubleshooting proced- maximum contact life.
ures. Separate control systems are used for the BGE
and BGEL series generator sets. Each system is Start/Run/Stop Switch
covered separately in this section. The Start/Run/Stop switch (SI) is a single pole, dou-
ble throw (SPDT) rockertypeswitch usedforstarting
or stopping the generator set. Placing the switch in
BGE CONTROL DESCRIPTION either the Start or Stop position will initiate the
The generator set control consists of the following appropriate control function. The switch will auto-
components: matically return to the center (Run) position when
released. The switch is mounted on the control panel
Printed Circuit Board Assembly and is removable for service replacement.
Panel Mounted Start/Run/Stop Switch (Sl)
Start Solenoid (Kl) Start Solenoid
The K1 start solenoid is used for opening or closing
Battery Charge Resistor (R6) the circuit between the starter motor and the battery.
Optional Remote Start Control Because of the high current loads imposed during
starting, the start solenoid is designed with heavy
The following sections provide a general description duty contacts rated to withstand 300 amperes. A sin-
of each component and how it functions: gle small terminal providesaconnection pointforthe
12volt DCsolenoidcoil.Thesolenoid is mounted inside
Printed Circuit Board Assembly the control. The large stud that protrudes through the
The printed circuit board assembly is the center of control housing is for battery B+ connection, while B-
the generator set control system. The PC board cir- cable connects to ground position on tray.
cuitry controls the start, starter disconnecthn, stop,
and battery charging functions. The primary compo- Battery Charge Resistor
nents of the PC board include three relays, one power The battery charge resistor is a fixed value (2.5 ohm,
rectifier, two diodes, one capacitor, five resistors, and 50 watts) resistorthat limits the battery charge rate to
a 5-ampere fuse. The o n l y s e r v i c e a b l e no more than 1 ampere. The charge rate may not be
component is the fuse which is removable from the altered. The resistor mounts betweenthe left cylinder
front of the control panel. connections to the PC (as viewed from flywheel end) and the engine to
board are made through an eight pin connector (Pl). generator adaptor.
mounted on the board and through the six leadwiring
harness. The PC board assembly mounts on the back
of the control panel.
7-1
Optional Remote Start Control Closing the K3-9,15 contacts (which parallel the
The remote start control is an optional accessorythat K4-2,8 contacts) provides an alternate pathway for
allows the generator set to be started, monitored, and supplying B+ to the T1 ignition coil and E3 fuel
stopped from a remote location. The deluxe control Pump.
includes a running time meter and battery condition Opening the K3-1,8 contacts disconnects B+ (CR4
meter. Remote control panels are usually mounted positiveterminal) from the generatorfield windings.
on the vehicle dashboard.
Closing the K3-2,8 contacts connects B+ to the run
BGE CONTROL OPERATION light, time meter, and battery condition meter.
This operation description applies to BGE series Opening the K3-9,16 contactsdisconnects B+from
generator sets. The schematic diagram shown in Fig- the K4 start relay causing it to de-energize.
ure 7-1 is intended as an example to help follow the
circuit description. Always refer to the specific wiring De-energizingthe K4 relay opens the K4-2,8 and K4-
diagram that corresponds to the m-ode1 and spec 9,15 relay contacts. Opening the K4-2,8 contacts has
number of the generator set when troubleshooting no effect since they are in parallel with the closed
problems. K3-9,15 contacts which connect B+ to the ignition
Starting . coil and the fuel pump. Opening the K4-9,15 contacts
Placing the Start/Run/Stop switch in the Start posi- disconnects 6+ from the K1 start solenoid. De-
tion connects battery ground (B-) to the K4 start energizing the K1 start solenoid disconnects B+ from
relay. This energizes the K4 relay which closes two the starter motor which stops cranking.
sets of contacts (K4-2,8 and K4-9,15) that connect
battery positive (B+) to the generator field windings When the S1 switch is placed in the RUN position, the
through (CR4 +), T1 Ignition coil, E3 fuel pump, and engine continues to run. Relays K2 (generator relay)
K1 start solenoid. Connecting B+ as deschbed pro- and K3 (run relay) are energized while relays K1 (start
duces the following control responses: solenoid) and K4 (start relay) are de-energized.
Generator voltage is rectified to DC by the CRl power
Flashes the field to ensure there is adequate resid- rectifiers and supplied to the battery through the
ual magnetism to induce voltage buildup. charge resistor (R6). This charges the battery at a
0 Energizes the ignition coil (Tl) so it can begin pro- constant rate (1 ampere maximum) during set
ducing an ignition spark when the breaker points operation.
begin to open and close.
0 Energizes the fuel pump (E3) which begins pump-
ing fuel to the carburetor.
0 Energizes the K1 start solenoid to close the K1
contacts.
Starter Lockout-Run
When the engine starts, the low oil pressure switch
(S2) closes to connect battery ground (B-) to the K3
run relay. As the engine comes up to speed, AC output
voltage from the generator is supplied to the choke
heaterelement(HI) and to the K2generator relay.This
activates the heating element (which opens the choke)
and also energizes the K2 relay. Energizing the K2
relay closes one set of contacts (K2-25) that connect
B+ to the K2 run relay. This energizes the K3 relay
which opens two sets of contacts to produce the fol-
lowing control responses:
Stopping
Placing the Start/Stop/Run switch (Sl)in the Stop the engine stops. As the generator output voltage
position grounds the output of resistors R1 and R2to drops, the K2 generator relay also de-energizes. All
remove B+ from the K3 run relay. This de-energizes components return to theirde-energized position fol-
the K3 relay which opens the K3-2,8 and K3-9,15 relay lowing set shut-down. CR1 prevents the battery from
contacts to disconnect B+ from the ignition coil, fuel discharging through the generator windings while
pump, run light, and meters. Without ignition or fuel, . the set is stopped.
Engine . 1. If engine cranks at set but la. Check for continuity and
Does Not not at remote control panel, and correct if circuit is
Crank fault is due to: open
a. open circuit in remote control 1b. Replace remote start
b. remote start switch faulty control switch
2. If engine cranks at remote 2a. Check for continuity and
control panel but not at set, correct if circuit is open
fault is due to: . 2b. Replace S1 switch
a. open circuit in wiring between
S1 ,switchand PC board, or
b. faulty S1,switch
6. If voltage is not present as described 6a. Check for continuity and correct if
in step 5 test, fault is due to: circuit is open
a. open circuit between K1 relay 6b. Replace control PC board
and control PC board, or
b. defective control PC board
Engine Starts 1. Low oil pressure switch not closing la. Check oil level and add oil if low
But Stops due to: 1b. Check for continuity and correct if .
When Start a. low oil level circuit is open '
Switch is b. open circuit between switch and IC. Replace low oil pressure switch
Released control Id. Refer to Lubrication system
c. defective low oil pressure switch section for test and service
d. low oil pressure. procedures
Engine Starts 1. Fuel level is below generator 1, Check fuel and oil levels
And Runs; Then set fuel pickup tube or and refill as necessary
Stops. Set oil level is low.
. . Restarts
Immediately or 2. Faulty choke operation due 2. Refer to Fuel System
Set Restarts to sticking chok-e linkag.e, . ,... section for testing and
After Cooling incorrect choke adjustment, service procedures
Down open circuit in wiring
between choke heater and . -
generator, or defective
choke heater.
7-6
TROUBLESHOOTING THE BGE CONTROL
, Low Battery 1. Disconnect the negative (-) battery 3a. Refer to Generator section
(Continued) cable at the battery and for testing and service
remove control lead P1-6 procedures.
from the battery positive (+) 3b. Replace control PC board
terminal on the K1 start
solenoid. Connect a DC
ammeter and 5 ampere fuse in
series between the P1-6 lead
wire and the stud terminal
on the K1 solenoid. With set
running, the ammeter should
read between 0 and 1 ampere.
If meter shows battery is
discharging, fault is due to:
a. defective generator charge
winding
b. CR1 power rectifier open.
Run Lamp, Time Open circuit between 1. Check for continuity and
Meter, or terminal 6 or remote connector correct if circujt is open
Battery plug and terminal 6 on
Condition Meter Start/Run/Stop switch.
Does Not
Operate Open circuit between ground 2. Check for continuity and
terminals on lamp or meters correct if circuit is open
and terminal 1on remote
Start/Run/Stop switch.
7-7
PC BOARD
A/
CONTROL PANEL ASSEMBLY
\
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REAR VIEW
1
' P3 12
561521
7-8 .
BGEL CONTROL OPERATION Closing the K3-9,15 contacts (which parallel the K4-
This operation description applies to BGEL series 2,8 contacts) provides an alternate pathway for
generator sets. The schematic diagram shown in Fig- supplying B+ to the T1 ignition coil and E3 fuel
ure 7-4 is intended as an example to help follow the solenoid valve.
circuit description. Always refer to the specific wiring
diagram that corresponds to the model and spec Opening the K3-1,8 contacts disconnects B+ (CR4
number of the generator set when troubleshooting positive terminal) from the generator field
problems. windings.
Starting Closing the K3-2,8 contacts connects B+ to the
Placing the Start/Run/Stop switch in the Start posi- run light, time meter, and battery condition meter.
tion connects battery ground (B-) to the K4 start
relay. This energizes the K4 relay which closes two Opening the K3-9,16 contacts disconnects B+ from
sets of contacts (K4-2,8 and K4-9, 15) that connect the K4 start relay causing it to de-energize.
battery positive (B+)to the generator field windings
(CR4 +), T1 ignition coil, E3 fuel solenoid valve, K5 De-energizing the K4 relay opens the K4-2,8 and K4-
stop relay, and K1 start solenoid. Connecting B+.as 9,15relay contacts. Opening the K4-2,8 contacts has
described producesthe following control responses: no effect since they are in parallel with the closed
K3-9,15 contacts which connect B+ to the ignition coil
Flashes the field to ensure that there is adequate and the fuel solenoid. Opening the K4-9,15 contacts
residual magnetism to induce voltage build up. disconnects B+ from the K1 start solenoid. De-
energizing the K1 start solenoid disconnects B+ from
0 Energizes the ignition coil (Tl) so it can begin pro- the starter motor which stops cranking.
ducing an ignition spark when the breaker points
open and close. When the S1 switch is placed in the RUN position, the
engine continuesto run. Relays K2 (generatorrelay),
Energizes the fuel solenoid valve (E3) which opens K3 (run relay), and K5 (stop relay) are energized.
to allow fuel to flow to the carburetor. while relays K1 (start solenoid) and K4 (start relay)
are de-energized. Generatorvoltage is rectified to DC
0 Energizes the K5 stop relay to open the K5 by the CR1 power rectifierand supplied to the battery
contacts. through the charge resistor (R6). This charges the
battery at a constant rate (1 ampere maximum) dur-
0 Energizes the K1 start solenoid to close the K1 ing set operation.
contacts.
Starter Lock-out-Run
When the engine starts, the low oil pressure switch
(S2)closes to connect battery ground (B-) to the K3
run re1ay.A~theenginecomes uptospeed, ACoutput
voltage from the generator is suppliedto the K2 gener-
ator relay. This energizes the K2 relay which closes
one set of contacts (K2-23)that connect B+ to the K3
run relay.This energizesthe K3 relay which opens two
sets of contacts and closes two sets of contacts to
produce the following control responses.
7-9
Sl-Start/Run/Stop switch El-Spark plug
SWow oil pressure cut-out switch E2-Spark plug
S3-Breaker points E3-Fuel solenoid
CR1-Power reclifier RG-Battery charge resistor
CRiGField rectifier K1-Start solenoid
F1-Fuse KIGenerator relay (AC)
01-Starter motor K3-Run relay
GlGenerator KdSIart relay
E-Stop relay
. .
Stopping
Placing the Start/Stop/Run switch (Sl)in the Stop Without ignition or fuel, the engine stops. As the
position grounds the K3 run relay. This de-energizes generator output voltage drops, the K2 generator
the K3 relay which opens the K3-2,8 and K3-9,15 relay relay also de-energizes. All components return to
contacts to disconnect B+ from the ignition coil, fuel their de-energized position following set shutdown. +
solenoid, run light, meters, and K5 solenoid. De- CR1 prevents the battery from discharging through
energizing the K5 relay closes the K5-30, 87A con- the generator windings while the set is stopped.
tacts which holds the K3 relay grounded. This pre-
vents the set from restarting if the S1 switch is
released from the Stop position.
Redistribution or publication of this document,
by any means, is strictly prohibited.
7-10
BGEL CONTROL TROUBLESHOOTING
Use the troubleshooting guide to help bcate problems The troubleshooting guide is divided into six set-
related to the BGEL control. Figures 7-5 and 7-6 show tions. After identifying the problem, referto the guide
the location of most of the Control components. Refer to for the possible cause and the recommendedcorrec-
the wiring diagram in Figure7-8for location of all termi- tive action.
rial connectiois.
Engine 1. If engine cranks at set but 1a. Check for continuity and
Does Not not at remote control panel, and correct if circuit is
Crank fault is due to: open
a. open circuit in remote control l b . Replace remote start
wiring control switch
b. remote start switch faulty
7-12
TROUBLESHOOTING THE BGEL CONTROL
Engine Starts 1. Low oil pressure switch not 1a. Check oil level and add
But Stops When closing due to: oil if low
Start Switch a. low oil level, lb. Check for continuity'and
Is Released b. open circuit between correct if circuit is open
switch and control, 1c. Replace low oil pressure
C. defective low oil pressure switch, switch
d. low oil pressure. 1d. Refer to Lubrication system
section for test and
service procedures
Engine Starts 1. Oil level is low 1. Check fuel and oil levels
And Runs; Then and refill as necessary
Stops. Set
Restarts
Immediately or 2. Dirty fuel filter restricting 2. Clean fuel filter. Refer
Set Restarts fuel filter causing to Fuel System section for
After Waiting filter to freeze up. service procedures
Several Minutes
3. Breaker points sticking 3. Replace breaker points
Low Battery 3. Disconnect the negative (-) 3a. Refer to Generator section
(Continued) battery cable at the battery for testing and service
and remove control lead P1-6 procedures.
from the battery positive (+) 3b. Replace control PC board
terminal on the K1 start
solenoid. Connect a DC
ammeter and 5 ampere fuse in
series between the P1-6 lead
wire and the stud terminal
on the K1 solenoid. With set
running, the ammeter should
read between 0 and 1 ampere.
If metershows battery is
discharging, fault is due to:
a. defective generator charge
winding or
b. CRl power rectifier open.
4. If time meter works but 4a. Replace battery condition ' '
REAR VIEW
I
STOP GND STRT
CR5 DIODE COMPONENTSIDE
SC-1523
7-15
Redistribution or publication of this document,
by any means, is strictly prohibited.
Section 8. Generator
INTR0DUCTION Rotor
The 4-pole rotor provides the rotating magnetic field
The BGE and BGEL generator sets have a 4-pole, that is required for generating an AC voltage poten-
revolving field generator with transformer voltage tial in the stator windings. The DC current required
regulation. All AC load connections are made for field excitation is supplied through two slip rings
through long generator lead wires that connect that mount on the rotor shaft.
directly to a customer supplied junction box. A circuit
breaker provides overcurrent protection for the The inner end of the rotor is connecteddirectly to the
generator and also functions as an on/off switch in engine crankshaft using a tapered seavshaft cou-
the load circuit. pling and through-bolt. The outer end of the rotor is
supported by asingle bearingthat is pressed onto the
GENERATOR DESCRIPTION rotor shaft. The bearing fits inside the generator
housing bearing.
The generator consists of the following major
components: Cooling airflow for the generator is provided by a
centrifugal fan that mounts on the inner end of the
Stator and Housing rotor shaft. The fan also serves as a mount for the
Rotor starter ring gear.
0 Voltage Regulating Transfomer
0 Field Current Rectifier Voltage Regulati ng Transformer
Brushes The voltage regulating transformer helps to provide
Wiring Harness stable generator output voltage under varying load
conditions. Voltage transformers are constructed
Stator and Housing with two primary windings and a single secondary
During generator set operation, AC current is pro- winding. Each primarywinding (Hl-H2and H3-H4) is
duced in the windings of the stator. All stators have connected in series with one of the generator AC
two AC output windings (T1-T2 and T3-T4) for pow- output windings. The transformer secondary winding
ering the load and a separate winding (61-62) for is connected in series with the field current circuit.
battery charging. On 4.0 kilowatt sets, the AC output Taps on the secondary allow for field current
windings are wired. in parallel (T1 connected inter- adjustments.
nally to T3) to produce 120 volts only. All stators also
The voltage regulatingtransformer mounts on the out-
have two lead wires (SIand S2)that are used with the
side of the generator housing and is enclosed with a
voltage regulating transformer.
special cover. The cover must be in place during oper-
ation for transformer cooling.
The stator mounts inside the generator housing and
is held in position with four clamps and four cap-
screws. A series of air-intake openings in the end of
the housing allow cool air to be drawn inside the
housing for generator cooling. The housing also pro-
vides a mounting point for the starter, rear bearing,
brushes, control, fuel pump, and voltage regulating
transformer. The complete stator and housing
assembly bolts to the engine-to-generator adapter.
8-1
. Field Current Rectifier (CR4) To prevent an excessive voltage drop when a load is
The CR4 rectifier is a full wave bridge rectifier used to applied to the generator, a method for regulating the
rectify a portion of the generator AC output voltage to AC output voltage is required.Thevoltage regulating
DC for field excitation. The positive and negative transformer allows the generator to provide a stable
terminals of the rectifier are connected to the genera- AC output voltage under varying load conditions.
tor brushes. The rectifier mounts insidethe generator Each transformer primary winding (HI-H2and H3-
set control and may be accessed by removing the H4) is connected in series with one of the stator AC
control panel. output windings. The full AC output current pro-
duced by the generator flows through these two
Brushes primary windings. Increasing or decreasin the cur-
The brush block assembly consists of a single brush rent output from the transformer winding zoduces a
block with two brushes. The brush block mounts corresponding increase or decrease in the current
inside the generator housing and can be accessed by produced in the secondary winding. The secondary
removing the small plate at the rear of the housing. winding is connected in series with the circuit that
supplies AC current for rectification to DC field
current.
Wiring Harness
A separate wiring harness is provided for connecting During operation, adding load increases the current
the generator set to the RV electrical system. All lead flow through thetransformer primary windingswhich
wires are stranded copper wire to withstand vibra- causes a corresponding increase in the current out-
tion. The lead wires must be protected with flexible put from the transformer secondary winding. This
conduit which must be provided by the RV manufac- boosts the DC field current to a higher level to offset
turer. A 3/4 inch conduit elbow is provided to facili- the voltage drop that would normally occur when a
tate installation. The load wire conductors are black, load is applied. In the same manner, decreasing the
the neutral conductors are white, and the ground load reducesthe DC field current to offset the voltage
conductor is green. The exit point forthe wiring har- rise that would normally occur when a load is
ness is near the voltage regulating transformer. removed. Continuously adjusting the field current as
the load changes is how voltage regulation is
GENERATOR OPERATION achieved.
Generator operation involves the control, stator,
rotor, voltage regulating transformer, brushes, and GENERATOR TROUBLESHOOTING
full wave bridge rectifier. The schematic shown in Use the following troubleshooting guide to help
Figure 8-1 is intended as an example to help follow locate problems related to the generator. Figures 8-3
the generator operating description. Always refer to and 8-4 show the location of most of the generator
thespecificschematic that correspondsto the model components. Refer to the wiring diagram in Figure
and spec number of the generator set when trouble- 8-2 for the location of all terminal connections. The
shooting problems. troubleshooting guide is divided into four sections.
After identifying the problem, refer to the guide for
When theStart/Run/Stop button is placed in the Start the possible cause and the recommendedcorrective
position, the rotating field (rotor) is momentarily action. ,
connected to battery positive (B+)to ensure ade-
quate residual magnetismforvoltage build-up. As the
engine starts and speed increases, the rotating field
induces a voltage build-up in the stator windings. A
portion of the AC current generated in the stator
windings is rectified to DC by the CR4 bridge recti-
fier. The DC current is supplied to the rotating field
windings tocreatethe strong magneticfield required
for generating the rated current. The AC voltage
build-up stabilizes at approximately 128 volts when
the engine reaches governed speed.
8-2
REMOTEPANELS
WIRING DIAGRAM
I A3
I REMOTE
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S3 IGN PDINTS
S2 SWITCH- LOW OIL PRESSJRE
SI SWllCH-START/STW
R6 RESISTOR-BATTERY CHARGE
K5 RELAY-SEDWrlHLPCffllY
KI STARTSMENOlD
HI WOK€
GI GENERATOR
FI FUSE
E3 NELPWPlOR N W S O W O I D
E l 2 SPIRKPLUG
t852.QIcuITBREAlw (Ac OUTPUT)
nl-ll74pr)
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8-4
TROUBLESHOOTING THE GENERATOR
. condition may
cause the
generator set to
2. Open circuit between brush
block an CR4 rectifier
2. Check for continuity and
correct if circuit is open
stop when the 3. Brushes stuck in holder or 3. Release brushes if jammed
Start switch is not making good contact with in holder. Clean slip
released. slip rings rings if dirty.
8-5
W171-1
8-6
TROUBLESHOOTING THE GENERATOR
SoHz
-\ I
8-7
GENERATOR SERVICE
This section covers generator disassembly and
assembly procedures. Refer to Figures 8-3 and 8-4 to
locate and identify -the various generator compo-
nents described.in each sub-section.
I
Generator Disassembly
Use the followjng procedures to disassemble the
generator:
Refer to Fuel System (Section 6) for detailed FIGURE 8-5. BRUSH BLOCK
reinova4 procedures.
5. Disconnect the lead wires fronthe charge resis-
tor (quick-disconnect type connections), the low
oil pressure cutoff switch, and the B+,terminal on
the ignition coil.
JBCAUTION) The brushes will be damaged
during disassembly if not held
6. Remove the brush block cover and disconnect . off the slip rings. Make certain wire is in place
the B+ (outboard) and 6-(inboard) lead wires ' before removing stator assembly.
from the brush block terminals-
8. Remove the transformer cover and if the set is
7. Pull each brush outward from the holder and at the '
LP-gas fueled, disconnect the fuel line at thevap-
same time insert a piece of stiff wire into the small orizer coupling.
hole in the end of the stator housing (see Figure
8-5). Carefully guide the wire through the brush 9. Attach the special lifting plate (see Figure8-6) to
block and then release each brush. Verify that each the end ofsthestator housing using four -5/16-18
brush is held off the slip rings by the wire. x 1 capscrews.
10. Place a pad in front of the engine to cushion and
protect the scroll. Attach a hoist or other suitable
lifting device to the lifting plate. Lift the set as -
shown in Figure 8-6 until it is completely vertical
and resting on the scroll. Remove lifting plate -
when complete.
11. Remove the capscrew and two EIT lock washers
. that secure the ground strap to the drip pan.
12. Removethe three vibration isolator center screws
from theunderside of the drip pan and lift away
. from the drip pan.
8-8
18. Carefully lift the rotor assembly off the end of the
engine crankshaft and remove rotor tool.
19. Remove the brush block mounting screws and
carefully lift out the brush block assembly.
LIFTING PLATE
CAPSCREW
n /
/ 6-1176
8-9
21. Use the following procedure to remove the stator
from the stator housing:
a. Remove stator lead wires from the trans-
former primary leads and secondary taps as
described in steps 20a through 20c.
b. Cut off the wire ties that secure the stator lead
wires to the inside of the housing.
, Cut only wire ties, not the tie supports.
Generator Assembly
Use the following procedures to assemble the
generator:
1. If the stator was removed from the housing during
disassembly, use the following procedures to
install the stator in the housing:
a. Position the stator so the output leads are
. oriented as shown in Figure 8-3; then carefully
0-1175
lower the stator into the stator housing.
FIGURE 8-8. ROTOR TOOL
Carelesshandling of fhesfa-
latheCAUTl O NI tor can result in damage to
sfator windings. Donot brush the stator
20. Use the following procedure to remove trans- windings againsf the housing as it is fowered
former from housing: into position.
a. Remove the braided insulating material from b. Install the four clamps and.capscrews that
the transformer primary lead wire (T2-H2 and secure thestatorto the housing-Tightencap-
T4-H4) connections. screws to specified torque.
b. Cut off the crimped barrel connectors and c. Route stator lead wiresthrough holes in sta-
separate the transformer primary leads from tor housing as specified in Figure 8-3. Fasten
the stator leads. wiring harness to inside of housing using wire
c. Disconnect the lead wiresfrom the transformer ties.
secondary taps. d. If transformer was not removed during disas-
d. Removethefourscrewsthatsecurethetrans- sembly, followsteps2c through 2e to connect
former to the stator housing and lift off the stator output leads to transformer.
transformer assembly. 2. If the transformer was removed from the stator
housing during disassembly, use the following
(QCAUTIONI The fransformer air gap ’
procedures to install the transformer on the stator
might be alferedif fhe mount- housing:
ing bracket is removed from the transformer.
Do not loosen or remove any screws thatpass a. Hold transformer in position for mounting on
through the transformer laminations. the stator housing. Install the two mounting
screws and tighten securely.
1ATION
3.
ES-15i2
8-11
10. Attach the special lifting plate (see Figure 8-6) to I BRUSHES AND SLIP RINGS
theend ofthestator housing usingfour5/16-18~
1 capscrews. This section covers brush replacement and slip ring
11. Attach a hoist or other suitable lifting device to
service.
the lifting plate. Carefully tilt the set back until it is
resting on the drip tray. Removelifting plate when
Brush Replacement
Remove the brush block cover and inspect the
complete.
brushes and brush holder for burn marks or other
12. km-~ovethe Piece of Wire that is holding the damage. If the brushes appearto be in good condition,
s the Slip rings- Check the bru&'~esto
b ~ s h e off usea piece of wire (modified asshown in Figure8-10)
verify that they are c ~ ~ t e r on e dthe Slip rings- If to check for excessive brush wear. Insert the wire
brushes are not centered, loosen the brush block through the hole above each brush. Make sure the
mounting screwsand adjust. Retighten mounting wire is resting on the brush and not on part of the
screws when complete. spring. If the painted partof the wire is notvisible, the
13. Connect the B+ lead wire to the outboard brush brush is excessively worn and must be replaced.
terminal and the B- lead wireto the inboard brush Always replace the brush springs when installing new
terminal. Install brush block cover and tighten brushes to insure that proper tension is maintained.
cover mounting screws. Use the following procedure to replace the brushes.
14. Connect the appropriate lead wires to the charge
resistor, low oil pressure cut-off switch, and igni- 1. Disconnect the negative (-) battery cable at the
tion coil B+ terminal. battery terminal.
15. Place new intake manifold gaskets on the engine 2. Remove the air cleaner cover and air cleaner filter
biock and install the carburetor and intake mani- element.
fold assembly. Tighten the intake manifold 3. Disconnect the B+ (outboard) and B-(inboard)
screws to the specified torque. Connect the pre- lead wires from the brush block terminals.
heater tube, crankcase breather hose, fuel lines,
thrcttle linkage, and choke heater wires. Refer to 4. Remove the brush block mounting screws and lift
FuelSystem (Section6) for detailed assembly proce- out the brush block.
dures.
16. Install the noise shield, flywheel guard, and trans-
former cover.
17. Install the generator set in the vehicle and
securely fasten all mounting screws and hard-
ware. Connect the fuel, exhaust, and electrical
systems in reverse order of disassembly. Refer to
the Set Removal section.
18. Fill crankcasewith oil of the recommendedclassi-
fication and viscosity.
E1174
E1179
8-13
TRANSFORMER VOLTAGE GENERATOR TESTING
ADJUSTMENTS
The generator output voltage may be adjusted by This section coversthe test proceduresfor the stator,
changing the connections to the transformer secon- rotor, transformer, and CR4 bridge rectifier.
dary taps. This is necessary if the set voltage falls
outside the recommendedvoltage range when oper- Field Voltage Test
ating at the specified frequency. Use the following To check the field voltage, remove the brush block
procedures to adjust the generator output voltage: cover and connect a DC voltmeter to the brush block
terminals. Connect the positive lead to the B+
1. Adjust the governor as specified in Section 6 for the (outboard) terminal and the negative lead to the B-
Governor before making adjustments to the trans- (inboard) terminal.
fanner.
2. With the unit operating at no-load, adjust the speed Start the generator set and allow it to stabilize. Meas-
adjustment nut.to achieve the following frequency ure the field voltage with no load applied and then
and voltage: with full load applied. Both readingsshouldfall within
a range of 18 to 60 voits DC.Remove test leads and
replace brush block cover when test is complete.
I Model I Adjust SpeedNutTo: I Rotor Test
60 Hr, 120 Volts ’ 62 Hz, 127.5 f4.5 Volts
50 Hz, 110/220 Vale 52 Hz, 233 f9 Volts The rotor can be tested for grounded, open, or
50 Hz,12O/240 Volts 52 Hz, 255 f9 Volts shorted windings using an ohmmeter. Figures 8-12
~ ~ ~ and 8-13 show the rotor removed from the generator
3. Stop the set and adjust the transformer tap connec- for testing. However, it is possible to test the rotor
tions as shown in TABLE 8-1 to increaseor decrease without removing it from the generator. To obtain
-the voltage as required. access to the slip rings, remove the brush block
cover. Use a stiff wire to hold the brushes off the slip
4. Repeat the voltage check and continue to make rings during testing. Refer to the Brushes And Slip
adjushents until voltage is within range specified. Rings section forthe procedures to use for inserting
5. Check the no load and full load voltage and fre- the wire.
quency as specified in Section 6 for the Governor.
Voltage znd frequency should stay within the limits Ground Test: To test for grounds, set the ohmmeter
shown in Table 6-1. for the highest resistancescale. Touch one test prod
to the rotor shaft and hold it there. Touch the other
test prod to one of the slip rings. A reading less than
TABLE 8-1. one megohm indicatesthe rotor is grounded. Replace
TRANSFORMER TAP CONNECTIONS a grounded rotor with a new rotor.
I I I
1 VOLTAGE
ADJUSTMENT
I I
To increase x3 x4
Voltage x4
x4 ,
To Decrease x1 x5
Voltage X6
X6
X6
8-14
Open Or Shorted Windings Test: To test for open
windings, set the ohmmeterforthe highest resistance
scale. Place test prods on the slip rings as shown in
Figure 8-12. Ohmmeter should indicate continuity OHMS OF
kW STACK LENGTH RESISTANCE
between slip rings. A high resistance reading indi- (*lW
cates a poor connection or an open winding. Check
the connection betweenthe slip rings and rotor lead 4.0 75 mm 7.62
wires. Replace rotor if rotor winding is open.
3.5 92 mm 8.90
(soHz)
Stator/Transformer Test
The stator and transformer can be testedfor grounded
or open windings using an ohmmeter. Testing for
shorted windings requires a digital-type ohmmeter
than can read to within 0.01 ohms.
U I
ES-1559
FIGURE 8-13 TESTING ROTOR FOR OPENS OR SHORTS Redistribution or publication of this document,
by any means, is strictly prohibited.
8-15
If the open circuit is between T1, T3 and one of the
transformer primary lead wires (H1 or H3), the source of
the open could be either the stator windings or the
transformer primary windings. To isolate, disconnect
the transformer primary leads from the stator leads (T2
from H2 or T4from H4). Test each winding separately as
specified in Table 8-4 to locate the source of the open.
Replace the stator or transformer if test indicates an
open winding.
LEADS LOCATION
T1,T3 Stator
B1 Stator
x1 Transformer
. * -
TABLE 8-4
RESISTANCE VALUES
FOR STATORS AND TRANSFORMERS
OHMS OF
Kw STACK TEST RESISTANCE
LENGTH WINDING
WHZ
STATOR ONLY
TRANS ONLY
H4 to H3 0.03 0.03 0.03
H2 to H1 0.03 0.03 0.03
8-17
Redistribution or publication of this document,
by any means, is strictly prohibited.
Section 9. Engine = Block Assembly
Inspection
Valve Face: Check the valve face for evidence of burn-
ing, warpage, out-of-round, and carbon deposits (see
Figure 9-4).
‘ VALVE RETAINER :
‘ I I vr-1019 ’
REFER TO SPECIFICATIONSFOR
T E C
YT-1022
9-3
Installation: Run a small polishing rod with crocus
cloth through valve guide holes to clean out carbon USENWVALMSEATTO
ADJUSTPUUERMPM
and other foreign materials. Place a new gasket on
the intake valve guide and coat the outer edge of each
new guide with oil. Place guide, notch up, in cylinder
block and piess in until shoulder of guide rests
against the cylinder block. A suggested method of
installation is shown in Figure 9-8.
NUT
(2REQUIRED)\
VT-1023
Valve.Seat
Inspect valve seat inserts. If seats are loose, cracked,
or severely pitted, new inserts must be installed.
Remove valve seat inserts using a valveseat removal
tool.
9-4
Replacement: After the old seat has been removed.
clean out any carbon or metal burrs from the seat
insert recess. Use a valve seat insert driver and a
hammer to install the insert.
Insert the pilot of the tool into the valve guide hole in
the cylinder block. Quickly drive the valve seat insert
in so that the insert goes evenly to the bottom of the
recess in the cylinder block. Make certain that the
valve seat insert rests solidly on the bottom of the
recess all the way around its circumference (Figure
9-10).
The valve seat must be stakedto ensure a tight fit and
eliminate the danger of its loosening in the bore.
CHECK THIS SURFACE
GOVERNOR
GOVERNOR ARM
GOVERNOR SHAFT
VI-1027
9-6
TIMING GEARS AND CAMSHAFT
c3J4" If replacement of either the crankshaft gear or the
WHEN GOVERNOR
IS PROPERLY camshaft gear becomesnecessary, it is recommended
ASSEMBLED THE that both gears be replaced.
DIMENSIONSHOWN
ON DRAWING WILL To remove the crankshaft gear, first remove the snap
BE AS INDICATED
ring and retainerwasher; then attachthe gear pulling
ring using two No. 10-32 screws (Figure 9-14).
Tighten the screws alternately until both are tight.
Attach a gear puller to the puller ring and remove the
gear.
CENTERPIN -I
The camshaft and gear are removed as an assembly.
Before removing the camshaft and gear assembly,
SNAP RING remove the cylinder head and valve assemblies. Then
remove the operating plunger for the breaker points
and tappets.
GOVERNOR CUP
Each timing gear is stamped with " 0near the edge.
GOVERNOR FLYBALL The gear teeth must mesh so that these marks exactly
coincide when the gears are installed in the engine.
When installing the camshaft gear and shaft assembly,
B VT-1028 be sure that the thrust washer is properly in place
behind the camshaft gear. Then install the crankshaft
retaining washer and lock ring.
FIGURE 9-13. GOVERNOR CUP
GOVERNOR CUP
With the gear cover removed, the governor cup can
be taken off after removing the snap ring from the
camshaft center pin, see Figure 9-13. Catch the fly-
balls while sliding the cup off.
The governor cup and flyballs are easily installed THESE MARKS MUST
ALIGN WHEN INSTALLINC
when the camshaft assembly is removed from the TIMING GEARS
engine. If necessary, the engine may be tilted up to
install the cup and flyballs. Put the flyballs between
the spacer arms and install the cup on the center pin.
VT-1029
Lock the cup in place with the snap ring.
FIGURE 9-14. TIMING GEAR REMOVAL AND INSTALLATION
The camshaft center pin extends out 3/4-inch (19
mm) from the end of the camshaft. This distance.
provides an in and out travel distance of 7/32-inch
(5.6 mm) for the governor cup, as illustrated. Hold the
cup against the flyballs when measuring. If the dis- LUBRICATION SYSTEM
tance is less, the engine may race, especially at no All generator set engines use an oil pump to providea
load. Remove the center pin and press in a new pin constant flow of oil to theengine parts.The oil supply
the specified amount. Do not hammer the new pin collects in the oil base where it is picked up by the oil
into place or it will be damaged. The camshaft center pump pick-up cup. A bypass valve is used to controt
pin cannot be pulled outward or removed without oil pressure. Drain the oil before removing the oil
damage. If the center pin extendstoo far, the cup will base and always use a new gasket when replacingthe
not hold the flyballs properly. oil base. Redistribution or publication of this document,
by any means, is strictly prohibited.
9-7
Oil Pump
Theoil pump (Figure9-15) ismounted on the frontof
the crankcase behind the gear cover and is driven by
the crankshaft gear. The inlet pipe and screen
assembly is attached directly to the pump body. A
discharge passage in the cover of the pump registers
with a drilled passage in the crankcase. Parallel pas-
sages distribute oil to the front main bearing, rear
.
main bearing and pressure control bypass valve.
LS-1110
9-8
Remove dirt and deposits from the piston surfaces
with an approved cleaning solvent. Clean the piston
ring grooves with a groove cleaner or the end of a
piston ring filed to a sharp point (Figure 9-19). Care
must be taken not to remove metal from the groove
sides.
Lift the rod bearingcap from the rod and push the rod
and piston assembly out the top of the cylinder with
the handleendof a hammer. Be careful not to scratch
the crankpin or the cylinder wall when removing
these parts. W
Markeach plrtonandrod assemblysotheycan beretumedtolheir
rerpectlve cyllnden after overhaul. Keep connecting rod bearing
caps with their respective rods.
Inspection
-1059 The following covers inspection procedures for pis-
tons and connecting rods.
FIGURE 9-18. REMOVING PISTON RINGS
Piston Inspection: Inspectthe pistons for fractures at
the ring lands, skirts and pin bosses. Check for wear
Mark each piston to make sure the rod will be at the ring lands using a new ring and feeler gauge as
assembled on the piston from which it was removed. shown in Figure 9-20. Replace the piston when the
Remove the piston pin retainer from each side and side clearance of the top compression ring reaches
push the pin out. 0.008 inch (0.20 mm).
Redistribution or publication of this document,
by any means, is strictly prohibited.
9-9
Plsfon Pln Inspection; Replace piston pins that are
cracked, scored, or out of round morethan 0.002 inch
(0.05 mm).
Bearing Inspecfion: Inspect bearings for burrs,
breaks, pitting and wear. Replace bearing insertsthat
are scored, have the overlay wiped out, show fatigue
failure, or are badly scratched. If bearings appear to
be serviceable, check them for proper clearance.
Piston Clearance
Proper piston tolerances must be maintainedfor satis-
factory operation. Use a micrometer to measure the
pistondiameter atthe point shown in Figure9-22. When
the cylinder bore is measured (see Cylinder Block sec-
fion).subtractthe pistondiameter from the cylinder bore
diameter to obtain the piston to cylinder wall clearance.
Refer to the Dimensions and Clearances section for the
recommended piston clearance.
. (3-1061
. .
c , .
CYLINDER, 13-1063
WALL
9-10
lnsfalling Piston in CylinrfecWhen installingthe piston
assembly, the raised lines (witness marks) on the rods
and caps must be aligned, see Figure 9-24. Also, note
that the connecting rod bolt is offset to one side of the
cap. When assembled on the crankshaft, the thin sideof
the cap should be next to the cylinder block. The rod and
cap stamped #Eshould be installed next to the bearing
plate.
NG IN
BORE
1. Turn crankshaft to position rod bearingjournal at
bottom of its stroke.
2. Lubricate piston assemblyand inside of cylinder.
Compress rings with a ring compressor as shown
FEELER GAGE
in Figure 9-25. Install bearing insert in rod.
9-11
Place a piece of the correct size Plasti-gage Position the crankshaft so the crank throw is aligned
across the full width of the bearing cap about 1/4 with the notch at the rear of the crankcase and install
inch (6 mm) off center. the crankshaft. Make sure the front thrust washer did
Install the bearing cap and tighten to the speci- . not slip out of place during installation.
fied torque. Do not rotate the crankshaft after the
cap is in place. Place the oil seal loader on the oil seal guide and
Remove the bearing cap and leave the flattened driver and insert into the rear bearing plate. Remove
Plasti-gage on the part to which it adheres. Com- the seal guide and driver leaving the loader ‘in the
pare the widest point of the flattened Plasti-gage bearing plate. The loader prevents the seal from
with the graduations on the envelope (see Figure being cut on the crankshaft keyway during installa-
9-26) to determine the bearing clearance. tion of the rear bearing plate.
.--- - Use oil or gear lubricant to hold the shim@)and rear
thrust washer in position on the rear bearing plate (see
3 . 0 Figure 9-31.The shim goes against the bearing plate
and theflatsurfaceofthethrustwashergoesagainstthe
shim.
Place the bearing plate gasket in position on the
block, making sure the oil hole on the back of the
block is exposed. install the rear bearing plate and
fasten with two nuts (or capscrews) tightened to the
specified torque. Make sure the rear thrust washer
and shim(@did not slip out of place during installa-
tion. The crankshaft should turn freely by hand.
Checking Endplay
After tightening two rear bearing plate nuts (or cap-
screws) to the specified torque, check the crankshaft
.- endplay at the point shown in Figure 9-27 using a
feeler gauge. Lightly tap the front of the crankshaft
CT-1067
with a plastic-faced hammer to take up the freeplay.
Refertothe DimensionsandClearances sectionforthe
FIGURE 9-26. MEASURING BEARING CLEARANCE recommended crankshaft endplay. If necessary,
removethe rear bearing end plate and add or remove
CRANKSHAFT shimsas required. Installthe end plate and tighten all
nuts (or capscrews) to the specified torque. Make
To remove the crankshaft, loosen the rear bearing sure the shim and thrust washer are in place, and
plate screws and remove the bearing plate, gasket, recheck crankshaft endplay. Verify that the crank-
thrust washer, and shims. Turn the crankshaft so the
shaft turns freely without binding.
crankthrow is aligned with the notch in the rear open-
ing of the crankcase. Carefully slide the crankshaft
out of the crankcase.
7’-
Inspection
Inspect the rod and main bearingjournals. If they are
worn or scored and cannot be smoothed out by pol-
ishing, either the journals should be reground to use
FRONT
one of the standard undersize bearings or the crank-
shaft should be replaced. Remove only as much
metal as is required,to restore the journal surface
while maintaining the recommended bearing
clearance.
Installation - 1
Lubricate the front and rear main bearings with
engine oil. Use,oil or gear lubricant to hold the front
MEASURE ENDPLAY HERE
(REFER TO DIMENSIONS
AND CLEARANCES)
J CT-1068
9-12
CYLINDER BLOCK
The cylinder block is the main support for all other 1. Makeathorough check for cracks. Minutecracks
basic engine parts. Crankshaft and camshaft are may be detected by coating the suspected area
supported by the block, assuring alignment of the with a mixture of 25 percent kerosene and 75
crankshaft and cylinder bores. percent light motor oil. Wipe the part dry and
immediately apply a coating of zinc oxide (white
Cleaning lead) dissolved in wood alcohol. If cracks are
After removing pistons, crankshaft, cylinder heads, present, the white coating will become discolored
etc., inspect block for cracks and extreme wear. If at the defective area. Always replace a cracked
block is still serviceable, prepare it for cleaning as cylinder block.
follows: 2. Inspect all machined surfaces and threaded
holes. Carefully remove any nicks or burrs from
1. Scrape all old gasket material from block. machined surfaces. Clean out tapped holes and.
Remove oil bypass to allow cleaning solution to clean up any damaged threads.
contact inside of oil passages. 3. Check top of block for flatness with a straight
2. Remove grease and scale from cylinder block by edge and a feeler gauge.
agitating in a bath of commercial cleaning solu-
tion or hot soapy washing solution. Cylinder Bore Inspection: Inspect cylinder bores for
3. Rinse block in clean hotwaterto remove cleaning scuffing, scratches, wear, and scoring. If cylinder
solution. bores are scuffed, scratched, scored, or worn, they
must be rebored and honed for the next oversize
piston.
Inspection
When rebuilding the engine, thoroughly inspect When the appearance of cylinder bores is good and
block for any condition that would make it unfit for there are no scuff marks, check cylinder bore for wear
further use. This inspection must be made after all or out of roundess as follows:
parts have been removed and block has been tho-
roughly cleaned and dried. 1. Check cylinder bore for taper, out-of-round, and
wear with a cylinder bore gauge, telescope
gauge, or inside micrometer. These rneasure-
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 measurementstaken at top and bottom of
piston travel as follows (see Figure 9-28).
9-13
A. Measure and record as “A” the cylinder bore
diameter (parallel to crankshaft) near the top
of cylinder bore where greatest amount of
wear occurs.
B. Also measureand record as “B”cylinder bore
diameter (parallel to crankshaft) at the bot-
tom of piston travel.
C. Measure and record as “C’cylinder bore
diameter (perpendicular to crankshaft) near
the top of cylinder bore where greatest
amount of wear occurs.
D. Also measure and record as“D”cy1inder bore
diameter (perpendicularto crankshaft) at the
bottom of piston travel.
E. Reading“A’subtracted from reading “B” and
. reading “C” subtracted from reading “D”
indicates cylinder taper.
TOP END OF CYLINDER
F. Reading “A” compared to reading “ C and
reading “B” compared to reading ‘ID”indi-
cates whether or not cylinder is out-of-round.
If out-of-round exceeds 0.003 inch (0.08 mm),
the cylinders must be rebored and honed to RING
the next oversize. A reboring machine is used WEAR
when going to oversize pistons. The following AREA
repair data covers honing to oversize by use
of a hone.
9-14
3. Clean base of boring bar before bar is set up. Deglazing Cylinder Bores
Deposits under boring bar will cause it to tilt, and Deglazethe cylinder bores if there are no scuff marks
the cylinder will be distorted after boring. and no wear or out of round beyond specifications
4. Makean initial rough cut’followed byafinish cut. before installing new rings. Deglazing gives a fine
Then hone cylinder bore to the specified over- finish but does not enlarge cylinder diameter, so the
size. original pistons with new rings may still be used.
Honing Cylinders (Using Precision Hones) The reason for deglazing a cylinder is to provide
Refer to hone manufacturer’s recommended grit cavities to hold oil during piston ring break-in.
size to producespecified surfacefinish of 20 to40
RMS.Too rough of afinishwill wearoutthe rings 1. Wipe cylinder bores with a clean cloth which has
and too smooth of a finish can retard piston ring been dipped in clean, light engine oil.
seating. 2. Use a brush type deglazing tool with coated bris-
tle tips to produce a crosshatch pattern in the
1. Position block solidly for either vertical or horiz- cylinder bore.
ontal honing. Use either a drill press or heavy- 3. The deglazing tool should be driven by a slow
duty drill which operates at approximately 250 to speed drill. Move deglazing tool up and down in
450 rpm. cylinder (10 to 12 complete strokes) rapidly
2. Follow hone manufacturer’s instructions for the enough to obtain a crosshatch pattern as shown
use of oil or lubricant on stones. Do not use lubri- in Figure 9-29.
cants with a dry hone.
3. Insert hone in bore and adjust stone to fit snugly
to the narrowest section. When adjusted cor-
rectly, the hone should not shake or chatter in
cylinder bore, but will drag freely up and down
when hone is not running.
4. Connect drill to honeand start drill. Feel out bore
for high spots, which cause an increased drag on
stones. Move hone up and down in bore with
short overlapping strokes about 40 times per
minute. Usually bottom of cylinder must be
worked out first because it is smaller. As cylinder PRODUCECROSS HATCH AVOID THIS FINISH
takes a uniform diameter, move hone up and SCRATCHES FOR FAST
RING SEATING c-1091
down all the way through cylinder bore.
5. Check diameter of the cylinder regularly during
honing. A dial bore gauge is the easiest method,
but a telescoping gauge can be used. Check size FIGURE 9-29. CROSSHATCHING
at six places in bore; measure twice at top, mid-
dle, and bottom at 90-degree angles.
6. Crosshatchformed by the stones should form an ’
9-15
BEAR1NGS
Front Bearing: :Locktite Bearing Mount is used when
Removal of the camshaft or crankshaft bearings installing the front bearing. Use the towelette fur-
requires complete disassembly of the engine. Use a nished with the bearing kit to clean the outside of the
combination main and cam bearing removal tool and bearing and the bearing bore in the block. Apply the
a press to drive out the bearings. Support the casting Locktite Bearing Mount to the mating surfaces of the
to avoid distorting or damaging the bearing bores. bearing and bearing bore. Allowthree to four minutes
for drying.
Camshaft Bearings
Replacement camshaft bearings are precision type Breathing vapor from towelette and
and do not require line reaming or line boring after prolonged contact with skin can be
U
installation. Coat the bearing with lubricating oil. harmful. Be sure area is well-venfilafed.
Position the front bearing so the oil hole in the bear-
ing is aligned with the oil hole (see Figure 9-30) in the Use the combination main and cam bearing driver
block. Position the rear bearing so the elongated slot and a press to install the front bearing. Push the ,
is aligned with the breaker point plunger hole in the bearing in to the depth allowed by the flange on the
top of the block. driver. Wipe off any excess Locktite and allow one
hour for hardening at room temperature.
Engines shipped from the factory have separate thrust washers
and main bearings for both front and rear of engine. Front bearing
replacement part is one piece bearing (with attached .thrust
washer) as shown in Figure 9-32. Do not add an additional thrust
washer to this front bearing.
Crankshaft Bearings
?d
New crankshaft main bearings are precision type
which do not require line reaming or line boring after
installation. They are available in standard size,
0.002,0.010,0.020 or 0.030 inch undersize.
THRUST WASHER Use an oil seal guide and driver to press or drive the b
rear seal into the rear bearing plate until it bottoms
against the shoulder of the plate (see Figure 9-33).
BEARING M-3475 Press or drive the front oil seal into the gear cover
PRECISIONTYPE.- DO NOT LINE BORE OR REAM until it is 0.97 k 0.02 inch (24.6 k 0.5 mm) from the
mounting face of the cover.
FIGURE 9-31. REAR BEARING Redistribution or publication of this document,
by any means, is strictly prohibited.
* 9-16
Lubricatethe lips of the replacementseal with a light shaft section for the rear bearing plate installation
coating of grease before installing the rear bearing procedures. Refer to the Gear Cover section for the
plate or gear cover. This provides initial lubrication gear cover installation procedures.
until engine oil reaches the seal. Refer to the Crank-
9-17
. .
Y
. . .
After servicing, inspect and test thecomplete installa- INITIAL START ADJUSTMENTS
tion to confirm that the generator set will operate
Adjust the carburetor idle and adjustment screw and
properly and will pull full rated load. Check each of
main adjustment screw as specified in the Fuel Sys-
the following areas before putting theset into service.
tem section to allow starting.
MOUNTING Start the set and immediately adjust the governor
Examineall mounting boltsand supporting members speed adjustment nut to obtain a safe no-load operat-
to verify that the generator set is properly mounted. ing speed. With no load applied, listen for any un-
All fasteners should be tightened securely to prevent usual sounds or vibrations. When the choke is com-
them from working loose when subjected to vib- pletely open, adjust the carburetor and governor as
ration. specified in the Fuel System section.
~AWARNING I
EXHAUST GAS IS DEADLY!
Exhaust gases contain carbon monoxide, an odorless and colorless gas formed
during the combustion of hydrocarbon fuels. Carbon monoxideis poisonous and
can cause unconsciousnessanddeath Symptoms of carimnmonoxidepoisoning
are the following:
If you or anyone else experience any of fhese sympfoms, shut down the unit and
get out into the fresh airimmediafely. If sympfoms persist, seekmedicalaftention.
DO NOT OPERATE THE UNIT UNTIL IT HAS BEEN INSPECTED AND REPAIRED.
10-1
FUEL SYSTEM CONTROL
With the generator set operating, inspect the fuel Stop and start the generator set several times at the
supply lines, return lines, filters, and fittingsfor leaks. set control and remote control to verify the control
Check anyflexiblesectionsforcuts, cracksand abra- functions properly.
sions and make sure they are not rubbing against
anything that could cause breakage. MECHANICAL \I
10-2
.