Onan BGD, NHD Generator Sets Service Repair Workshop Manual

Caution: This document contains mixed page sizes (8.5 x 11 or 11 x 17), which may affect printing. Please adjust your printer settings according to the size of each page you wish to print.

BGD, NHD Printed in USA. 965-0529 5-92 (Spec A-G)

Safety Precautions Before operating the generator set, read the Operalor's Manual and becMne familiar with it and the e uipment. Safe and efficient operation can be achieved e& If the unit is properly operated and maintained. Many accidents aie caused by failure to fdlow fundamental rules and pr.ecaUtons. Thefollowing sym&ls, found throughout this manual, alert you to potential dangerouscdionstotheoperator, senrice pr- mis symbol warns of immediaie haz- ards which will reswlt in severe personal injuty or death. This symbol refers fo a hazard ur unsafe practice which can result in severe personal 1nju)y or death. 1 - 1 Jhls symboirel'ers tu a hazard or unsafe practice which can iesult in personal injury or prod- uct or property damage. FUEL AND FUMES ARE FLAMMABLE. Fire, explosion, and personal injury can result from improper practices. sonnel, or 2 e equipment. DO NO7 5ll,fuel tanks while engine is running. Fuel contact with hot engine or exhaust is a potential fire hazard. DO NOT SMOKE OR US€ AN OPW F!E near the generator sei or fuel tank Fuel lines must be adequately secured and free of leaks. Fuel connection at the engine should be made with an ap ' proved flexjbie, non-corxiuctive iine. Do not use cogper pip ng on flexible lines as copper will work harden zm beme brittle. Be sure all fuei suppiieshave a positive shutoff valve. GASOLINE AND k?G FUEL MAY BE ACClDENTALLY 1G- NlTED BY ELECTRICAL SPARKS, resenting We hazard of fire or ex+ion, which can resui in severe personal injury or death. When Installing the generator set: ,. e e i o e Do not lie electrical wiring to fuel lines. Do not run electrical lines and fuel lines through the same compattment openings. Keep elecirical and fuel lines as far apart as possible. Place a physical barrier 'miween fuel lines and electrical . lines wherever possible. If electrical and iuel lines must passthrough the same corn- partment opening, make certain that they are physically separated by running 'hm through indiiidual channels, or by passing each line iihrcugh a separate piice d tubing. DO NOT SMOKE while servicing batteries. 'Lead acid batteries emit a highiy explosive hydrogen gas that can be ig- nited by electrical arcing or by smoking. EXHAUSTGASESAREDEADLY Neversleep in the vehicle with the generatorset running un- - lessvehicle is equipped with an operating carbon monoxide detector. Provide an adequate e$aust system to properly expel dis- charged gases. inspect exhaustsystem daily for. leaks per the maintenance schedule. Be sure that exhaust manifolds are secure and not warped. Do not use exhaust gases to heat i! compartment. e Be sure the unit is well ventilated. MOWNG PARTS CAN CAUSE SEVERE PERSONAL IN- JURY OR DEATH %fore starting work on the generatorset,disconnect batteries. This will prevent accidentalarcing. Keep your hailds away .frommoving prts. Make sure that fasteners on the generator set are secure. Tighten supports and clamps, keep guards in position over bns, drive belts, etc. Do not wear loose clothing or jewelry while working on generator sets. Loose clothing and jewelry can become caught in moving parts. Jewelry can short oui electrical contacts and cause shock or burning. ifadjustmentmustbemadewhiletheunitis running, useex- ireme caution around hot manifolds, moving parts, etc. s # ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Disconnect starting battery before removing protective shieldsortouching eiectrical equipment. Use rubber insula- 3ve mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment. Do not wear dam polothing (particulariyweLshoes)orallow skin sur- faces io be damp when handiing electrical equipmefit. Use exireme caution when wor!dng on electrical compo- nents. High voltages can cause injury or bath. Follow all ate and local elecbkai codes. Have all electrical installations priormed by a qualified licensed electrician. Tag open switches io avoid accidental closure. DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY SUlLDiNG PCTRICAL SYSTEM. Hazardous voltages can low from ihe generatorset into the utility he. This creates a potential for electrocution w property damage. Connect onlythroughan approved device and after building main switch is open. Consult an electrician in regard 20 emergency power *e. GE~JE~AL SAFETY PRECAUTIONS Have afireextinguisher nearby. Maintain exiinguisher properly and become familiar with its use. Extinguishers rated ABC by the NFPA are appropriate for at1 appiications. Con- sult ihe local fire deparhent for the ecrreci tyj~ of extin- guisher for various applications. Hot ccoiantsunder pressure can cause severe personal injury. DO NOTopen a radiator presswe cap while the engine is running. Stopthe engine and carefully bleed the system pressure. 3enzeneand lead,found insome gasoline, hsve been iden- titled by somestate and federalagencies as causing cancer or reproductive toxicity. When checking,draining or adding gasoline, take care not to ingest, breathe the fumes, or con- tactgasoline. . Used engineoils have &en identified by some siate or fed- eral agencies as causing cancer or reproductive toxicity. When checking or changing engine oil, take care not to ingest, breathe the fumes, or contact used oil. \Remove all unnecessary grease and oil from the unit. Accu- mulated grease and oii'can cause overheating and engine damage, which presents a potential fire hazard. DO NOT store anything in the generatorcompartment such asoil or gas cans, oily rags, chains,wooden blocks, portable propane cylinders, etc. A fire could result cr the generator set operation (cooling, noise and vibration) may be ad- versely affected. Keep the ccmpartment floor clean and dry. Do not work on this equipment when mentally or physically fatigued, or after consuming any alcohol or drug that makes ihe operation oi equipment unsafe. RV-9 " I

Table of Contents SECTION TITLE PAGE SAFETY PRECAUTIONS .............................. Inside Front Cover About this Manual ............................................... 1-1 Model Identification .............................................. 1-1 1 INTRODUCTION ................................................. 1-1 2 GENERAL SPECIFICATIONS ....................................... 2-1 3 DIMENSIONSAND CLEARANCES .................................. 3-1 4 TORQUE SPECIFICATIONS ........................................ 4-1 Troubleshooting .................................................. 5-1 Special Tools ................................................... 5-1 Safety Considerations ............................................ 5-1 Set Removal Guidelines .......................................... 5-2 ENGINE . PRIMARY SYSTEMS ..................................... 6-1 Introduction .................................................... 6-1 Troubleshooting Engine Primary Systems .......... : ................. 6-1 Exhaust System ................................................ 6-4 Cooling System ................................................. 6-7 Electronic Ignition System ......................................... 6-9 Breaker Point Ignition System ..................................... 6-11 Crankcase Ventilation System .................................... 6-13 Cylinder Compression Test ....................................... 6-14 Governor ..................................................... 6-14 Fuel System . LPG Liquid Withdrawal ............................... 6-25 Fuel System . LPG Vapor Withdrawal ............................... 6-31 Electric Starter ................................................. 6-32 Introduction .................................................... 7-1 Control Description ............................................... 7-1 Testing Control Board AI .......................................... 7-3 Control Troubleshooting ........................................... 7-4 Generator/Control Component Descriptions ............ : .............. 8-1 Generator Operation ............................................. 8-3 GeneratorTroubleshooting ........................................ 8-4 Generator Service ............................................... 8-6 Brushes and Slip Rings ........................................... 8-9 GeneratorTesting .............................................. 8-11 Testing Voltage Regulator VR1 .................................... 8-13 General ....................................................... 9-1 Oil Filter and Adapter Service ...................................... 9-1 CylinderHeads ................................................. 9-1 Valve System .................................................. 9-2 5 PREPARING FOR SERVICE ........................................ 5-1 6 Fuel System . Gasoline .......................................... 6-16 7 CONTROL ...................................................... 7-1 Control Operation ................................. ............. 7-3 8 GENERATOR .................................................... 8-1 9 ENGINE BLOCK ASSEMBLY ....................................... 9-1 i

SECTION TITLE Gear Cover .................................................... 9-7 Governor Cup .................................................. 9-8 Timing Gears and Camshalt ....................................... 9-8 LubricationSystem .............................................. 9-9 Crankshaft .................................................... 9-14 Piston Assembly ............................................... 9-10 Cylinder Block ................................................. 9-14 Bearings ..................................................... 9-17 Oil seals ..................................................... 9-18 10 SERVICE CHECKLIST ............................................ 10-1 Mounting ..................................................... 10-1 Lubrication .................................................... 10-1 Wl&g ....................................................... 10-1 Initial Siart Adjustments .......................................... 10-1 output check .................................................. 10-1 Exhaust system . - ..... : ....................................... 10-1 Fuel System ... : ............................................... 10-1 Corltrol ....................................................... 10-1 Mechanical ................................................... 10-1 11 WIRING WAGRAMS .............................................. 11-1 . ii I

Section 1 Introduction ABOUT THIS MANUAL This manual provides service information for the Onan BGD and NHD series commercial vehicle generator sets. This manual describes troubleshooting, disas- sembly, repair, reassembly, and adjustments to the engine, generator, and control system. The technician must understand basic principles of electrical genera- tion and gasoline engine operation. Basic information can be found in the following Onan publications: ElectricaVMechanical Fundamentals (publication 932-0408) Onan Generator Training Manual (publication 932-0404) BGD and NHD Operator's Manual (publication 985-0130) BGD and NHD InstallationManual (publication 965-0629) CARBURETOR AND GOVERNOR ADJUSTMENTS . $PARK PLUG Installation must comply with the applicable codes and standards (see the Installation Manual). Improper servicing may create an unsafe installation,resulting in damage to the vehicle and equipment or severe personal injury or death to the user. Read all service procedures completely before beginning any repair work, and observe all cautions and warnings. MODEL IDENTIFICATION When contacting an Onan dealer or distributor, supply the completemodel number: and serial number from the set nameplate. This informationidentifiesthe set when ordering replacement parts. Always use genuine Onan replacement parts, obtained from an authorized Onan dealer or distributor. Other replacement parts might not perform to Onan specifications. Incorrect service or repjacement of IaWARNlNGI parts can result in severe personal injuty and/or equipment damage. Service personnel must be qualified toperform electricaland/ormechan- id service. SPARK PLUG AIR BRACKET WITH RELAYS AND BAllERY CHARGING VOLTAGE REGULATOR CLEANER TERMINAL FOR THE EGATlVE (-) BAllERY SHAFT MODELS) COOLING AIR ER OUTPUT LEADS FUEL PUMP AND THE EXHAUST FLANGE IS THROUGH THE DISCHARGE OPENING ACCESSIBLE MOUNllNG TRAY FAN HOUSING FOR NEGATIVE I-] REMOTE CONTROL WIRE HARNESS M-1600-15 ',!!!!$&$E FIGURE 1-1. TYPICAL GENERATOR SET RECEPTACLE 1-1

Section 2. Specifications General Weight . Overall Dimensions (H x L x W) Minimum Free Area for Ventilating Air MinimumVertical Clearance At Air Discharge Outlet Exhaust Tailpi Diameter anc~ kterid Contrd Panel Fuse (Fl) I nition / Choke Fuse (F2) (kg inning Spec Fj EnSl- compressionRatio Displacement Bore stroke Cylinder Compression (Hot) Spark Plug Gap Valve Lash Intake Exhaust Engine Oil Capacity (Dry Filter) Swc F Phor to Spec F Electronic (Non-adjustable) Breaker-Point(Typical)’ Breaker-PointGap’ Ignition Timing Fuel Connections Maximum Gasdine Supply Pressure(at Cqrburetor) Maximum Gasdine Fuel Pump Lift Min. - Max. Propane Supply Pressure (Vapor Withdrawal) Connection(VaporWithdrawal) Propane Supply Connection (Liquid withdrawal) t GasolineSupply F ~ng 3 Propane Supply WDEL BGD 204 pounds (92 kg) 14 x 25114 x 19 in. (356 x 641 x 478 mm) 85 sq. in. (548 sq. cm) 2 in. (51 mm) 1-3/8 in. ID, 18 Gauge RigidSteelTubing 5 ampsSIOW-BIOW 10 amps 47.7 in3 (782 cm3) 6.93 325 in. (82.6 mm) 287 in. (729 mm) 75-1 15 psi (51 7-793 kPa) 0.025 in. (0.64 mm) 0.005 in. 0.127 mm 0.013 in. 10.330 mmi 3.5 quarts (3.3 L) 4.0 quarts (3.8 L) 140-1 80 BTC 200 BTC 0.01 6 in. (0.41 mm) 6psi (41 kPa) 3 Ft. (0.9 m) 114 in. ID Hose Barb 7-14in. (178-356mm) WC 3/4 in. NPTFTapping 1/4 in. NPTFTapping MODEL NHD 230 pounds (1 04 kg) (371 x 649 x 535 mm) 85 sq. in. (548 sq. cm) 1448 x 2!5-9/16 x 21-1/16 in. 2 in. (51 mm) 1-318 in. ID, 18 Gauge Rigid Steel Tubing 5 amps SIM-BIOW 10 amps 60 in3 (983 cm3) 7-03 3.56 in (90.4 mm) 3.00 in. (762 mm) 1 O(1.120 psi (690-827 kPa) 0.025 in. (0.64 mm) 0.005 in. 0.1 27 mm 0.013 in. 10.330 mmj 3.5 quarts (3.3 L) 4.0 quarts (3.8 L) 14’-180 BTC 200 BTC 0.01 6 in. (0.41 mmy 6 psi (41 kPa) 3 Ft. (0.9 m) 114 in. ID Hose Barb 7- 14 in. (1 78 - 356 mm! WC 3/4 in. NPTFTapping 1/4 in. NPTFTapping ’ - Spec A for Model BGDand Specs A and B for Model NHD. *’ - 0.021 in. (0.53 mm) for LPG. 2-1

Specifications (Cont .) 5.0 kw MODEL BGD- MODELNHD 6.5 kw 12 4551227alnps - $0 - 54a27.1 amps 4.0 kW 26.3/132 amps - ' 0.8 gph (3.0 uh) 057gph(22L/h) 0.35 gph (1 -3 Uh) 2t.Wl0.5 amps - - 51 31 5.7 amps 1 3 gph (4.9 lfh) ' 0.7 gph (25 lfh) 0.4 gph (1.5 lfh) 0.73 gph (2.8 uh) 0.53 gph (20 Vh) 0.35 gph (1 3 Vh) 45.w22.7 amps - 1.18 gph (4.5 Uh) 0.78 gph (3.0 Uh) 0.5 gph (1.9 Uh) Propane Fueledsets Rated PawerOutput 3.5 kW FuU-Load~Cwrenl ' (1 -Phase Generators) At 7lOmO Vok 31 M 5 . 9 amps At 120l240 volts - Propane Consumption Under FulCLoad Under Half-Load 0.98 gph (3.7 Uh) 0.65 gph (2.5 Uh) ' UnderNdoad 0.4 gph (1.5 Uh) - 522326.3 amps 1 J gph (6.4 Uh) 1.05 gph (4.0 Vh) 0.65 gph (2.5 uh) r 4.5 kW - 21 . ?I 1 0.8 amps 0.8 gph (3.0 Uh) 0.6 gph (2.3 Uh) 0.4 gph (1.5 Uh) 4.0 kW - 3331 6.7 amps 1.3 gph (4.9 Uh) 0.8 gph (3.0 uh) 0.5 gph (1.9 vh) $2 8 . t4.4 f4.6 50 0.5 -These values are for generatorshavinga Series-Delta connection. 2-2

Section 3. Dimensions and Clearances I CYLINDERS AND PISTON ASSEMBLY (Std size honed) Cylinder Taper (Max) Cylinder Bore* NHD I BGD I I MODELS I Values are in inches (millimeters) unless specified otherwise (82.52-82.55 mm) (90.49-90.51 mm) 0.005 0.003 . (0.1 3 mm) (0.08 mm) 3.2490-3.2500 3.5625-3.5635 Cylinder Out Of Round (Max) Cylinder Clearance In 0.003 . 0.003 . (0.08 rnrn) (0.08 mm) 0.0033-0.0053 0.0070-0.0090 (0.084-0.1 35 mm) (0.1 78-0.229 mm) Ring Gap Piston Ring #1 (top) Groove Width Piston Ring #2 Groove Width 0.01 0-0.020 0.01 0-0.020 (0.25-0.50 mm) (0.25-0.50 mm) 0.0602-0.061 2 0.0602-0.061 2 (1.53-1.55 mm) (1.53-1.55 mm) I 0.0602-0.061 2 (1.53-1.55 mm) ~~ ~~__ 0.0602-0.061 2 (1.53-1.55 mm) Piston Ring #3 Groove Width 0.1 193-0.1 203 (3.03-3.06 mm) 0.1 193-0.1203 (3.03-3.06 mm) Piston Ring #1 (top) Groove Width - Prior to Spec F Groove Width - Pdor to Spec F Piston Ring #2 0.080-0.081 0.080-0.081 (2.03-2.06 mm) (2.03-2.06 mm) (2.03-2.06 mm) (2.03-2.06 mm) 0.080-0.081 0.080-0.081 Piston Ring#3 Groove Width - Prior to Spec F Side Clearance Piston Ring #1 (Top) Connecting Rod Side Clearance 0.1 88-0.1 89 0.1 88-0.1 89 (4.78-4.80 mm) (4.78-4.80 mm) (0.076-0.203 mm) (0.051-0.203 rnm) 0.003-0.008 0.002-0.008. Piston Pin Diameter In Rod Piston Pin Fit 0.6875-0.6877 0.7500-0.7502 (1 7.46-1 7.47 mm) (0.005-0.01 8 mm) (1 9.05-19.06 mm) (0.005-0.020 rnm) 0.0002-0.0008 0.0002-0.0007 *The bore is 0.005 inches oversize if the engine serial number has suffix "€. . 0.002-0.01 6 (0.051 -0.406 mm) 3- 1 , 0.002-0.01 6 (0.051-0.406 mm) Connecting Rod Bearing Clearance 0.0020-0.0033 0.002-0.0033 (0.051 -0.084 rnm) (0.051-0.084 mm)

You're Reading a Preview

Onan BGD, NHD Generator Sets Service Repair Workshop Manual

Recently Viewed