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Reliable service can be obtained only or any other source of electrical power. Connection with close adherance to the procedures in this manu- could lead to electrocution of utility workers, damage to equipment and fire. When contacting Onan for parts, service or product information, be ready to provide the model number and the serial number, both of which appear on the genset nameplate (Figure 1-1). Each character of FIGURE 1-1. SERIAL MODEL 1. Power capacity in kilowatts - (4000 watts) 1. All measurements are listed in inches with millimeter measurements in parentheses. Measurements are for standard size parts.All measurements are listed in inches with millimeter measurements in parentheses. Measurements are for standard size parts. FACTORY SPECIFICATION ALLOWABLE DESCRIPTION MIN. MAX. LIMIT Piston Pin Piston Pin O.D. 0.7087 0.7089 0.7067 (Between Pin Bosses) All measurements are listed in inches with millimeter measurements in parentheses. Measurements are for standard size parts. FACTORY SPECIFICATION ALLOWABLE DESCRIPTION MIN. MAX. LIMIT Intake Valve Seat Seat Width 0.0433 (1.1) Seat Angle Exhaust Valve. All threads must be clean and lubricated with new engine oil before tightening. The cylinder head mounting bolts must be tightened in the proper sequence, refer to Section 10. Engine Block Assembl y. When tightening torques are not specified, tighten the screws and nuts according to Tables 4-3 and 4-4 on Page 4-2. Bolt (Spec A) 38-43 52-58 Mount Assy. Bolt (Begin Spec B) 35-40 47-53 Stator Housing to Engine Block 15-18 21-24. Safeguards to Avoid Hazards Engine Tools Use personal protection: Protect your body by. Re- line vapor. fer to Figures 5-1 and 5-2 on Page 5-3 for compo- B. Move the transmission to PARK, After the genset is disconnected from electrical, ex- lock the brakes and remove the ignition key. Do not haust and fuel systems, examine the set mounting move the vehicle during this procedure. Retighten 1.
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Use a forklift to support the genset at the points side panels to back panel bolts.Use the following troubleshooting guide to help Refer to Figures 6-1 and 6-2 on Pages 6-2 and diagnose genset problems. The troubleshooting 6-3 to identify the component locations for the section is divided into four parts: Spec A and Spec B models. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz- ards should perform service procedures.With the engine cranking, a permanent magnet in the flywheel rotates, at the proper time, past the magneto to induce a voltage at the ignition coil (T1) that fires the spark plug (E1) for ignition. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz- ards should perform service procedures.Only qualified service personnel with knowledge of fuels, electricity, and machinery haz- ards should perform service procedures.The following events occur: Control assembly (A1) opens the circuit to the start solenoid (K1), which opens the circuit to the starter motor (M1) to stop cranking. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz- ards should perform service procedures.The AC output voltage from the B1-B2 winding is converted to DC voltage when it passes through the full-wave rectifier bridge (CR1). Only qualified service personnel with knowledge of fuels, electricity, and machinery haz- ards should perform service procedures.Control assembly (A1) also opens the circuit to the fuel pump (E2) and to the remote control. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz- ards should perform service procedures.Only qualified service personnel with knowledge of fuels, electricity, and machinery haz- ards should perform service procedures.
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With the engine cranking, a permanent magnet in the flywheel rotates, at the proper time, past the magneto to induce a voltage at the ignition coil (T1) that fires the spark plug (E1) for ignition. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz- ards should perform service procedures.Only qualified service personnel with knowledge of fuels, electricity, and machinery haz- ards should perform service procedures.The following events occur: Control assembly (A1) opens the circuit to the start solenoid (K1), which opens the circuit to the starter motor (M1) to stop cranking. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz- ards should perform service procedures.The 60 Hz Spec B models do not have battery charging. The AC output voltage from the B1-B2 winding is converted to DC voltage when it passes through the battery charger assembly (VR2). Only qualified service personnel with knowledge of fuels, electricity, and machinery haz- ards should perform service procedures.Control assembly (A1) also opens the circuit to the fuel pump (E2), the fuel shutoff solenoid (E3), and to the remote control. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz- ards should perform service procedures.Refer to the wiring diagrams in Section 12. Figures 6-1 for wiring connections. These outputs perform the following functions: The battery charge winding B1-B2 is used to power the control assembly (A1), fuel pump (E2), the remote con- trol, and to prevent discharge of the genset starting battery during genset operation. These outputs perform as follows: The battery charge winding B1-B2 is provided on the 50 Hz models only to power battery charger (VR2). Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on page iii. TABLE 6-14.
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GENERATOR TROUBLESHOOTING Trouble Possible Cause Corrective Action. Make certain that the carburetor is TROUBLESHOOTING clean before troubleshooting for performance prob- Use the following troubleshooting guide to locate lems. problems with the engine primary systems. Many of the primary systems can be serviced without re- moving the genset from the vehicle. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz- ards should perform service procedures. Review safety precautions on page iii. TABLE 6-16. TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Trouble Possible Cause Corrective Action. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz- ards should perform service procedures. Review safety precautions on page iii. TABLE 6-17. TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Trouble Possible Cause Corrective Action. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz- ards should perform service procedures. Review safety precautions on page iii. TABLE 6-18. TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Trouble Possible Cause Corrective Action. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz- ards should perform service procedures. Review safety precautions on page iii. TABLE 6-19. TROUBLESHOOTING ENGINE PRIMARY SYSTEMS Trouble Possible Cause Corrective Action. The control consists of the circuitry used for Rectifier Bridge (CR1) starting, monitoring fault conditions, instrumenta- Battery Charger Assembly (VR2) tion, battery charging, and stopping. If an overload occurs, the breaker can be re- set after all loads are removed from the genset. The start solenoid (K1) is used for closing and open- Control Assembly (A1) ing the circuit between the battery and the starter motor. Always refer to the specific wir- stopped from a remote location. See Figure 7-3.
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Continuity should be measured between pin 1 and pin 3 (pin 13 made to verify if components are defective. Do not touch the volt- meter or any wiring when the genset is operat- A check can be made by measuring the resistance ing. Attach and remove meter leads only when of the coil terminals I and S (Figure 7-4). Disconnect the leads from the resistor and measure the resistance between terminals on one end to the resistor and the terminals on the oth- er end. The battery charger can be checked with a voltmeter.The transformer can be checked with an ohm- meter. Isolate the transformer leads from the circuit and measure the resistance between H1 - H2 pri- mary winding. Remove service procedures. Many of the primary systems the access panel and inspect the engine and control can be serviced without removing the genset from area. Un- authorized modifications will void the Onan EXHAUST SYSTEM warranty. Exhaust gas can cause severe per- WARNING Obtain the required replacement parts including a sonal injury or death. To prevent exhaust leaks, new exhaust gasket. Install the muffler in reverse always install a new exhaust gasket, and re- order of removal. Use only Onan-specified exhaust for tailpipe.Use a sufficient. If tailpipe deflector is nited by a hot tailpipe.The ignition system consists of the magneto as- Ignition Coil (T1) sembly, ignition coil, spark plug and ignition wiring. If a problem with the ignition system is suspected, The ignition coil is a transformer that steps up the the spark plug can be inspected and an ignition magneto output voltage to about 20,000 volts for. A stuck or dam- aged breather valve can cause oil leaks, high oil The magneto assembly is a noncontact capacitive consumption, rough idle, reduced engine power, discharge (breakerless) type that is mounted to the and a rapid formation of sludge and varnish within generator endbell.
The governor controls engine speed, which directly A binding governor shaft, governor linkage, or car- affects the frequency and voltage output of the gen- buretor throttle will cause hunting. Also a fouled erator. To increase the sensitivity, turn the adjustment screw counter- clockwise. To decrease the sensitivity, turn the adjustment screw clockwise. 60 Hz 50 Hz 50 Hz 6. The main components of the fuel system include: Air filter Air preheater Choke Carburetor Intake manifold Fuel filter Fuel pump Air Filter and Preheater Assembly FS1866s This assembly consists of the air filter housing, air filter, and preheat door assembly. This assembly consists of the carburetor and the in- 4. Close the choke and throttle plates by rotating take manifold assembly. See Figure 8-9. It is easier their shafts in a counterclockwise direction. Nor should the carburetor be overhauled. Instead, a malfunctioning carbure- tor should be replaced. Locate The most common causes of poor carburetion are the point where voltage and frequency are the the idle and main mixture screws being out of ad- highest. CARBURETOR OVERHAUL moving the chamber set plug. (PRIOR TO SPEC D) Redistribution or publication of this document, OnaFresh is a trademark of Onan Corporation.Turn them in until only light tension buretor cleaner. Do not soak rubber or plastic can be felt. Allow the genset to cool down consists of a bimetal choke coil, coil housing, heater before handling the choke assembly. CHOKE ASSEMBLY Bimetal Coil Replacement: After making the the adjustment plate to release the bimetal coil.If the choke does not open properly, and install linkage on the new coil. The output pressure from an automotive FS1868-1s pump is much higher and can cause carburetor flooding or fuel leakage, creating a fire hazard. FUEL PUMP TEST Redistribution or publication of this document, by any means, is strictly prohibited. 8-21. NFPA 58, Section and Intake Manifold Assembly on Page 8-12.
Repeat the procedure lows by pressurizing the back (vent) side of the reg- if necessary.If there is a smell of gas when the genset is not running, or any other reason to suspect that the valve is leaking, connect the inlet of the valve to a source of air pressure regu- lated to not more than 14 inches WC (356 mm WC) and disconnect the outlet hose. If low or no voltage is measured check the starting battery, start solenoid, and control A 12-volt electric starter with a negative ground is wiring.When the starter is energized, an inertial engagement system causes the starter pinion gear to engage the ring gear on the fan hub assembly. The genset must be removed from the vehicle be- 4. Remove the starter mounting nuts (bolts on fore the starter can be serviced. See Section 5. Pre- Spec A). A low resistance reading indi- cates a grounded armature. Replace a grounded armature with a new one. See Figure 8-25. Testing Armature for Shorts Use a growler (Figure 8-26) to locate shorts in the armature. In- sert the brush tabs into the spring ends and Use this procedure to return the electric starter as- slide brushes into brush holders in endcap.Output voltage is controlled by an elec- ing. Carefully disconnect the wire harness leads Carefully pull the stator straight out from the from the brush block and pull each brush out- housing. If the stator will not slide out, tap on ward from the holder and at the same time in- generator housing while pulling on the stator to sert a piece of wire into the small hole in the. Install the key into the erator: key slot. Begin with the Field Voltage personal injury or death. Use extreme caution Test, following, to help locate possible problems. when working on electrical circuitry. Place the test prods on the slip rings as shown in Figure 9-8. The ohmmeter should indicate continu- ity between the slip rings of approximately 19 to 27 ohms. If stator tests indicate a shorted winding, replace the stator.
Always re- Confirm that the voltage regulator is faulty before place the brush springs when installing new replacing it. Use a meter with a diode checking func- brushes to maintain proper tension on the brushes. Turn the rotor until all grooves or roughness are smoothed out. Cover the end of the rotor shaft with a steel plate to prevent deformation of the shaft during removal. This section covers service procedures for the en- C. Using a tester with a T.D.C. indicator fea- gine block assembly. A leak down test can be per- ture. FIGURE 10-2. OIL PAN REMOVAL (SPEC A Remove the oil pan mounting bolts and pan (Figure SHOWN) 10-2). Re- move the rocker arms and push rods (Figure 10-4). It may also be due to weak valve springs, insufficient tappet clearance, This engine uses an overhead valve design, as warping, and misalignment.Clean metal is a good heat conductor but carbon insulates and retains the heat. This increases combustion chamber temper- ature which causes warping and burning. Valve stem guides or valve seats that are worn, 2. Use a vernier caliper to measure the valve seat loose, cracked, or severely pitted should be re- width (Figure 10-10). Adjust the valve clearance only when the engine is at ambient temperature. 1. Follow head cover removal instructions in the Head Cover section on Page 10-2. Inspect the valve stems for proper alignment with the rocker arms. Do not attempt to pry the crankcase cover off or damage can result. Remove the crankcase cover mounting bolts. Hold the crankcase cover and lightly tap the end of the crankshaft with a plastic ham- mer. Mark the tappets because tappet clearances differ and the tap- pets must be reassembled in their original posi- tions. Mark direction of assembly for connecting the rod, cap, and splasher. 2. Remove the rod cap from the rod and push the piston assembly out the top of the cylinder (Fig- ure 10-18).
This inspection must be made after all parts have been removed and the block has been thoroughly cleaned and dried. 1. Make sure that there are no scuff marks and no wear or out-of-round beyond the specifications. Deglazing gives a fine finish but does not enlarge the cylinder diameter, so the original pistons with new rings can be used. Remove dirt and deposits from the piston sur- faces with parts cleaning solvent. Clean the piston ring grooves with a groove cleaner (Figure 10-23) or the end of a piston ring filed to a sharp point. Piston Boss I.D.: 1. Measure the piston boss I.D. in both the vertical and horizontal direction with a cylinder gauge (Figure 10-26). Piston Assembly Install the rings on the piston beginning with the oil control ring. Slide the crankshaft into the bearing and add shim(s). Install the crankcase cover and check to see that the crankshaft turns freely. Measure the side clearance of the crankshaft as follows: Side Clearance of Crankshaft 1. The bearing in the engine block can be pressed out after the oil seal is removed (fol- lowing section). The bearings in the crankcase cov- er can be pulled out using a puller. The system works as follows: 1. Exhaust gases contain carbon monoxide, an odorless and colorless gas. Carbon monoxide is poisonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning can include: Dizziness Throbbing in Temples Nausea Muscular Twitching Headache Vomiting. DESCRIPTION FIG NO. 611-1194 Wiring Schematic - MicroLite, Spec A (60 Hertz).12-1 611-1194 Wiring Diagram - MicroLite, Spec A (60 Hertz). Cummins and Onan are registered trademarks of Cummins Inc. And by having access to our ebooks online or by storing it on your computer, you have convenient answers with Onan Microquiet 4000 Service Manual. To get started finding Onan Microquiet 4000 Service Manual, you are right to find our website which has a comprehensive collection of manuals listed.
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