Onan MicroLite 2800 Series Service Manual Download Page 82

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Summary of Contents for MicroLite 2800 Series

Page 1: ...w MicroLite 2800 Series Printed in U S A 981 0506 3 91 SpecA B...

Page 2: ...epyour handsaway from moving parts 0 Make sure that fasteners on the generator set are secure Tightensupportsand clamps keep guards in positionover fans drive belts etc 0 Donotwear loose clothing or j...

Page 3: ...1 LPG Fuel System 6 18 Electric Starter 6 21 CONTROL 7 1 Introduction 7 1 Control Description 7 1 Control Operation Gasoline Fueled 7 1 Control Operation LPG Fueled 7 3 ControlTroubleshooting 7 6 GENE...

Page 4: ...SECTION TITLE PAGE 10 SERVICECHECKLIST 10 1 General 10 1 Mounting 10 1 Lubrication 10 1 Wiring 10 1 Initial Start Adjustments 10 1 OutputChecks 10 1 ExhaustSystem 10 1 FuelSystem 10 2 Control 10 2 Me...

Page 5: ...re 1 Always use genuine Onan replacement partsobtained fromanauthorizedOnandealeror distributor Universal replacementtypeparts usuallyintendedforautomotive use oftenlooksimilarbutdo notDerformtoOnansp...

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Page 7: ...qt 0 95 L Ventilation FreeArea 24 in2 154 8 cm2 Fuel Gasoline Gasohol LPG TUNE UP SPECS Spark Plug Gap 0 025 in 0 64 mm Timing 25 BTC Valve Lash Intakeand Exhaust 0 002 in 0 05 mm GENERATOR DETAILS G...

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Page 9: ...12 Valve and Guide Stem Clearance Between ReferenceValve Intake 0 00079 0 001 73 0 020 0 044 0 00157 0 00283 0 040 0 072 Intake Opening Valve Opening Closing Closing Timing when cool Exhaust Opening C...

Page 10: ...Value Allowable Limit Cylinder Inner Diameter Minimum Clearance Between Cylinder and Piston Piston Outer Diameter Skirt Diameter Piston Ring ReferenceValue Allowable Limit Gap Clearance ReferenceLimit...

Page 11: ...Crank pin oil Clearance Allowable Limit Piston Pin Outer Diameter I 0 5906 0 5907 15 000 1 5 005 1 1798 1 1804 29 967 29 982 1 1780 29 92 0 0007 0 0021 0 018 0 054 0 0039 0 10 Connecting Rod Small En...

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Page 13: ...ntakeManifold 8 15 11 20 I Carburetor Mounting Nut 6 8 7 11 Muffler Bkt to Engine 5 9 7 12 I Muffler Flangeto Engine 10 1 4 14 20 ____ Oil Base and Generator Housingto Mounting Stud Oil Base to Engine...

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Page 15: ...groove cleaner Outside micrometer set 0to 4 in Telescoping gauge set 1 2in to 6 in Holegauge 0 300 in to 0 400 in Valve Seal ReplacementTool 4 Valve seat cutter Generator and Control Tools Leador dead...

Page 16: ...tal lation a special compartment see Figure 5 1 is built into the coach to house the generator set The com partment is constructed with a vapor tight barrier that seals off the generatorset from the c...

Page 17: ...FLOOR FIGURE 5 1 TYPICAL COMPARTMENTMOUNT INSTALLATION M 1723 5 3...

Page 18: ...ply system and the appliance stove heater etc fuel supply system Inaddition close the fuel shutoff valves at each appliance LP Gas Propane is extremelyilam I mableandpoisonous and canresult in severe...

Page 19: ...procedure and that the procedure is performed very carefully and only as instructed 2 3 4 5 6 Useaforklifttruckto supporttheweightofthegener ator set at the pointsshown in Figure5 3 Raise the forklift...

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Page 21: ...fuel mixturescrews b incorrectfloat level c dirt in carburetor d vacuum leak 3 Contaminatedfuel 4 Carburetor icing 5 Incorrecttiming due to a defective magneto b incorrect flywheelor generator mounti...

Page 22: ...r oil covering engine 3 Incorrect ignitiontiming 4 Cooling fan pluggedor broken cooling fins 5 Leanfuel mixturedue to a incorrectlyadjusted fuel mixture screws b incorrectfloat level c dirt in carbure...

Page 23: ...buretor 5 Governormechanismworn excessively or motion spring faulty 6 Fuel supply problem caused by a Faulty fuel pump b Contaminated fuel supply c Vapor locking d Pluggedfuel filter 7 Carburetoricing...

Page 24: ...ther valve is or oil is diluted dirty or defective 3 Oil leaks 4 Excessiveengine wear 5 Intakevalve seal worn or defective 6 Light loading 1 Low oil level 2 Low oil level switch defective 3 Worn spark...

Page 25: ...ement parts when servicing fhe exhaust system Unauthorized modifications will also void the warrantyand cancel the ULListingKSA Certification Liability for injury or damages due to unauthorized modifi...

Page 26: ...2 inch O D 18 gauge aluminizedor stainless steeltubingfortailpipe Do notuseflexibletailpipesince it might break due to road shock and vibration Installexhaust tailpipe at least 3 inches 76 mm away fr...

Page 27: ...t thehazardof ofseverepersonalinjury or death Do not terminatetailpipe underthevehicle Directexhaust gases away from any vent window door orany open ing which can be opened and is not permanently seal...

Page 28: ...cooling fins 1nspection Removethesparkplugbootandinspectthe engine cooling fins by viewing the area around the spark plug Ifthe engine is clean in this areaand the air inlet area is clean disasemblyfo...

Page 29: ...eter leadto the spark plug connec tor insidetheboot and the other leadtotheground leadringterminal Theresistanceshouldbeapprox imately1 1000hmsat75 F 240C Replacethecoil if a high or low reading is me...

Page 30: ...gov ernor maintainsa constantenginespeed under chang ing load conditions so that generator voltage and fre quency do not vary GovernorAdjustments Contactwithmovingparts cancause severepersonalinjuryKe...

Page 31: ...terAssembly The air filter and preheaterassemblyconsists of the air filter cover air filter scroll assembly preheatdoor pre heat linkage preheat hose and intake air stove portion of the muffler assemb...

Page 32: ...ts and disconnect the choke linkagefrom the carburetor Removethe vacuum hosefrom the intakemanifold Remove the governor control linkage and spring attached to the carburetor CARBURETOR ASSEMBLY 4 Disc...

Page 33: ...entsor remov ing any parts Starttheengineandallow itto runfor about 10minutes The location of the adjustmentscrews isshown in Fig ure 6 9 Usethe following procedure to adjust 1 2 3 4 5 6 7 Stop the se...

Page 34: ...om the bottomo f the carburetor V CHOKE PLATE PILOT JET SCREW 3 Carefully note position of the float assembly parts thenslideout retainingpinandremovethefloat and needlevalve 4 Unscrew and removethe m...

Page 35: ...pringsare properly placed and the float movesfreely without binding See Figure6 12 POSITION HOOK UNDERTAB ON FLOAT 4 Invert the float and needle valve assembly and check float level by measuring betwe...

Page 36: ...wn an ambient temperature of approxi mately 75 F 24OC is required beforemaking initial setting Move the choke lever back and forth to check for free movement Verify that choke does not bind or stick S...

Page 37: ...back and forth to check for free movement Verify that choke does not bind or stick Remove vacuum supply and reconnect the diaph ragm hose to rear side of intakemanifold DIAPHRAGCHOSE h CHOKE LINKAGE...

Page 38: ...rect as necessary to comply with applicablecodes beforecontinuingservice work Demand Regulator with Automatic Priming Solenoid The demand regulator is designed for low pressure vaporized fuel An autom...

Page 39: ...l flow in the 0 25 to 0 35 water column pressure range If air flows through the regulator without any pressure being appliedto the balance line the lock off adjustmentscrew mustbeturned in to increase...

Page 40: ...cy 3 Turn the main adjustment screw inward until vol tage or frequency drops and then outward until voltage or frequency drops again Set the main adjustmentscrewatthepointwherethevoltageand frequency...

Page 41: ...nerator set starting battery has been disconnected negative cable first before proceeding Removethe generatorset outer hous ing and disconnect the positive cable from the starter lug Removethestarterm...

Page 42: ...brush wires are fac ing up Place washer on commutator end of shaft and put armatureinto brushendcap Pushthe four brushes toward commutator makingsure springsare prop erly positioned on brushes Replac...

Page 43: ...just above the armature while slowly rotating armature in growler A shorted armature will cause the bladeto vibrate and beattractedto the core Replacea shorted armature with a new part ES 1615 FIGURE...

Page 44: ...th of an inch 2 5 mm from the edge of the plastic retainer or so it is evenly spacedfrom each side D Place spring cover over top o f plastic retainer then the return spring on top of the retainer E Wi...

Page 45: ...onnectrelayalsoclosesthecircuitbetween the batteryand the fuel pump E2 andthe K3 relay during generator set operation The start disconnect relay is locatedon the control panel and is removable for ser...

Page 46: ...start motor Bl 0 Opening the K2 2 K2 6 contacts disconnects B from the voltage regulator 0 Closing the K2 3 K2 5 contacts applies B to the fuel pump E2 and to the K3relay throughfuse F1 providing fue...

Page 47: ...ening the K2 2 K2 6 contacts disconnects B from the voltage regulator 0 Closing the K2 3 K2 5 contacts applies B to the fuel solenoid E2 through fuse F1 providing fuel flow to the carburetor As the en...

Page 48: ...w Oil Level Switch Start Stop Resistor Charging Plug Remote Plug VoltageRegulator Meter Total Run Time Meter Battery Condition Start DisconnectRelay StartSolenoid Choke Magneto Ignition Generator Fuse...

Page 49: ...el Switch StarVStop Resistor Charging Plug Remote Plug VoltageRegulator Meter Total Run Time MeterBatteryCondition Start DisconnectRelay Start Solenoid Magneto Ignition Generator Fuse FUELSOLENOID Spa...

Page 50: ...control b faulty set control start stop control wiring panel wiring switch Sl 3 Insufficientvoltagefor cranking due to a battery not charged or b terminal connections looseor c insufficientbatterycabl...

Page 51: ...utput voltage from generator generator and control 2 Start disconnect relay K2 not energizingdue to a open circuit to K2 relay coil b faulty K2 relay 3 Fuel pump not energized due to faulty ballast re...

Page 52: ...stateof charge 2 Load connected to battery while set is turned off 3 Disconnectthe negative battery cableat the battery and remove lead markedF1 1 to CR2 C from control fuse F1 terminal 1 Connect a DC...

Page 53: ...if reading does not equal battery voltage minus 10 volts zener diode in remote control is defective 1 Faulty set control start stop switch SI 2 K5 relay not energizing due to a open circuit to K5 rela...

Page 54: ...CONTROL STARTISTOP FUSES SWITCH 5 A M P STOP START FIGURE 7 3 CONTROLCOMPONENT LOCATIONS 7 10...

Page 55: ...eld winding t magnetic field is established by a DC current flowing Generator Cooling Cooling airflow for the generator is provided by a cen trifugal fan mountedon the shaft behindthe bearing A portio...

Page 56: ...tage is obtained Duringoperation theregulatorisconstantlymonitoring the output voltage When additional load is applied to thegenerator theoutputvoltagestartstodecrease The regulatorsensesthis decrease...

Page 57: ...top Resistor Charging Plug Remote Plug VoltageRegulator Meter TotalRunTime Meter Battery Condition Start DisconnectRelay Start Solenoid Choke Magneto Ignition Generator Fuse 5A Fuel Pump Spark Plug La...

Page 58: ...Level Switch StartlStop Resistor Charging Plug Remote Plug Voltage Regulator MeterTotal Run Time Meter BatteryCondition Start DisconnectRelay Start Solenoid Magneto Ignition Generator Fuse FUELSOLENOI...

Page 59: ...ounded or shorted rotor or stator 7 Faulty electronic voltage regulator 1 Enginegovernor incorrectly 2 Brushesworn or not making adjusted good contact with slip rings 3 Jumper lead not making contact...

Page 60: ...ircuit breaker 2 Airflow restricteddue to dirt or debris covering vent openings in stator housing 3 Stator windings covered with oil or dirt 4 Open grounded or shorted circuit in rotor or stator CORRE...

Page 61: ...G 1111 SCROLL HOUSING FIGURE 8 3 GENERATOR 8 7...

Page 62: ...sonal injury or death Do not permit any flame spark pilot light cigarette or other ignition sourcenear thegenerator set KeepatypeABC fire extinguisher nearby Removethe K3 relayfrom the inlet baffleass...

Page 63: ...lide out tap on generator housing while pulling on stator to remove Do not bend or flex stator wire terminals or damage can occur Bending or flexing the stator terminalscancausebreakageof the terminal...

Page 64: ...leadto the start solenoid Attach K3 relayto the inlet baffleassembly Figure 7 3 16 Installthecontrolpanel Inspectassembly checkall electrical and mechanicalconnections for correct fit and location Pl...

Page 65: ...rocedures this sec tion to reinstall fan hub and remaining generator components Slip Ring Service Follow Generator Disassembly procedures this sec tion throughfan hubassemblyremoval Inspectthe slip ri...

Page 66: ...no outputvoltage was measured replacethe volt age regulatorand retest If batteryvoltage is not supp lied to the voltage regulator during starting refer to Control section 7 for troubleshooting procedu...

Page 67: ...nd holditthere Touchthe othertest prodto one of the slip ringsasshown inFigure8 10 Areadingof lessthan onemegohmindicatestherotorisgrounded Replacea grounded rotor with a new rotor ES1764 FIGURE 8 10...

Page 68: ...ity Infinity B2 to Ground Q1 toGround Infinity Q2to Ground Infinity OpenorShortedStator WindingsTest Totestfor open windings set the ohmmeter for the highest resistance scaleand then connectthe test p...

Page 69: ...cuttingthecollec tor ring assembly Removethe bearingsand make two cuts approximately halfway through the inner race 180 apart See Figure8 14 Place rotor with one cut face down on a hard surfaceand cen...

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Page 71: ...d A suggested order of disassemblyfor the engine block assembly follows 1 oil pan and oil levelswitch 2 head cover breather and cowling 3 rocker arms and push rods 4 cylinder head valve springs and v...

Page 72: ...rms and push rods 3 Removecowling mountingboltsandliftoff cowling 4 Usea 12mm socketwrench to removethe cylinder head mountingbolts and lift off the head 5 Clean out all carbon deposits Be careful not...

Page 73: ...creasingoil consumption and makingheavy carbon deposits Clean metal is a good heat conductor but carbon insulates and retains the heat This increases combustionchambertemperaturewhich causeswarp ing a...

Page 74: ...to make it seat correctly removesthe margin Tomakeavalvegas tight everytrace of pitting mustbe removedfrom the valve face and seat Deeplypitted or cut valves must be replaced 6 INCH 1 6 rnm MINIMUM RE...

Page 75: ...the outer locking nut Loosenthe outer locking nut and turn the adjusting nut as neededto obtainthe correct clearance Tighten locking nutafter adjust ment is made Recheckthe valve clearance after adjus...

Page 76: ...rod Markdirec tion of assembly for connecting rod cap and splasher 2 Lift the rod cap from the rod and push the piston assembly out of the top of the cylinder with the handle of a hammer Be careful no...

Page 77: ...ECKING RING LAND CT 1060 FIGURE 9 17 CLEANING RING GROOVES c Inspection The following covers inspection proceduresfor piston and connecting rod PistonInspectionAnspectthe pistonforfracturesatthe ring...

Page 78: ...Dimensionsand Clearancessection The practiceoffiling ringendstoincreasetheendgap is not recommended If the ring end gap does not meet specifications check for the correctness of ring and bore sizes R...

Page 79: ...ral times to properlyalign it withthe connectingrod Clearance varies on the crankpin if this is not done Crankthe engine by hand to see that the crankshaft turns freely without binding CrankpinClearan...

Page 80: ...thoroughly cleaned and dried Makeathoroughcheck for cracks usinganystand ardmethodof crack detection Onemethodof crack detection follows Minute cracks may be detected by coating the suspected area wit...

Page 81: ...cavities to hold oil during piston ring break in 1 Wipe cylinder bores with a clean cloth which has been dipped in clean light engine oil 2 Usea brushtype deglazingtool with coated bristle tips to pro...

Page 82: ...LIGNMENT BEARINGS One bearing is pressed into the engine block and the other bearingis pressed into the crankcasecover The bearing intheengine blockcan bepressedoutafterthe oil seal is removed followi...

Page 83: ...adjustthegovernorspeed adjustment screw to obtain a safe no load operating speed With no load applied listen for any unusual sounds or vibrations When the choke is completely open adjustthe carburetor...

Page 84: ...f leaks are detected shut generator set down and correct leak immediately CONTROL Stopandstartthe generatorset severaltimesat the set control and remote control if equipped to verify the control funct...

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Page 86: ...I Onan Corporation 140073rdAvenue N E Minneapolis MN 55432 612 574 5000InternationalUse Telex 275477 Fax 612 574 8087 Onan is a registeredtrademarko f Onan Corporation 1 800 888 ONAN...

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