Onan KV Microlite 2800 Series Generator Complete Workshop Service Repair Manual

w MicroLite'" 2800 Series Printed in U.S.A. 981 -0506 3-91 (Spec A & B)

Safety Precautions Before operating tho generator set, read the Operator's Manual and become familiar with it and the ui ment. Safe proper1 operatad and malntalned. Many accidents are The following symbols. found throughout this manual, alert you to potentiall dangerousconditionsto the operator, service per- and etnclent opontlon can be achieved on 77 y f the unlt Is caused ?I y failure to follow fundamentalrules and precautions. sonnel. or t x e equipment. Thls symbol warns of lmmedlate haz- anis whlch wlll result In seven? personal lnjuty or death. A+W-AFINING~ Thls symbol refers to a hazard or unsafe practlce whlch can result In severe personal lnjqf or death. &CAUTION? - _.__ Thls symbol refers to a hazard or unsafe - - . practice which can result In personal InjuIy or prod- uct or property damage. FUEL AND FUMES ARE FLAMMABLE. Fire, explosion, and personal injury can resutt from improper practices. DO NOT fill fuel tanks while engine is running. Fuel contact with hot engine of exhaust is a potential fire hazard. DO NOT SMOKE OR USE AN OPEN FLAME nearthe gen- orator set or fuel thank Fuel lines must be adequately secured and free of leaks. Fuel connection at the engine should be made with an ap- provedflexible, nor~~nductive line. Do not use copper pip- ing on flexible lines as copper will work harden and become bnttle. Be sure all fuel supplies have a positive shutoff valve. GASOLINE AND LPG FUEL MAY BE ACCIDENTAUY IG NmED BY ELECTRICALSPARKS, rumntlngthr huardof Jury or death. Whon lnrtalllng tho generator set: fln or explosion, whkh an rosu P t In savere p ond In- Do not tie electrical wiring to fuel lines. Do not run electrical lines and fuel lines through the same compartment openings. Keep electrical and fuel lines as far apart as possible. Place a physical barrier between fuel lines and electrical lines wherever possible. If electrical and fuel lines must pass throughthe same com- partment opening, make certain that they are physically ssparated by ruming them thrwgh individual channels, or by passing each line through a separate piece of tubing. DO NOT SMOKE while servicing batteries. Lead acid bat- teries emit a highly explosive hydrogen gas that can be ig- nited by eiectricai arcing or by smoking. EXHAUST GASES ARE DEADLY 0 Never sleep in the vehicle with the generator set running un- less vehicle is equipped with an operating carbon monoxide detector. Provide an adequate exhaust system to properly expel dis- charged gases. Inspect exhaust system daily for leaks per the maintenanceschedule. Ensure that exhaust manifokls are secure and not warped. Do not use exhaust gases to heat a compartment. Be sure the unit is well ventilated. MOVING PARTS CAN CAUSE SEVERE PERSONAL IN- JURY OR DEATH Beforestarting work on the generator set. disconnect batter- ies. This will prevent accidental arcing. Keep your hands away from moving parts. 0 Make sure that fasteners on the generator set are secure. Tighten supports and clamps. keep guards in position over fans, drive belts, etc. 0 Do not wear loose clothing or jewelry while working on gen- erator sets. Loose clothingand jewelry can become caught in moving parts. Jewelry can short out electrical contacts and cause shock or burning. 0 If adjustment must be made while the unit is running, use ex- treme caution around hot manifolds, moving parts, etc. ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH I I Disconnect starting battery before removing protective shields or touching electricalequipment. Use rubber insula- tive mats placed on dry wood platforms over floors that are metalor concretewhen around electrical equipment. Do not wear darnpclothing (particularlywet shoes) orallawskin sur- faces to be damp when handling electrical equipment. Use extreme caution when working on electrical compo- nents. High voltages can cause injury or death. FoUowall state and local electrical codes. Have all electrical installations performed by a qualified licensed electrician. Tag open switches to avoid accidental closure. DO NOT CONNECT GENERATOR SE3 DIRECTLY TO ages can flow from the generator set intothe utility line. This croates a potential for electrocution or property damage. Connect onlythrough an approved device and after building main switch is open. Consult an electriaan in regard to emergency power use. ANY BUILDING ELECTRICAL SYSTEM. Hazardous volt- GENERAL SAFETY PRECALmONS Haveafire extinguishernearby. Maintainextinguisher prop- erly and become familiar with its use. Extinguishers rated ABC by the NFPA are appropriate for all applications. Con- dt the local fire department for the meet type of extin- guisher for various applications. Hot codants under pressure can cause severe personal in- jury. DO NOTopen a radiator pressurecap w hii th4 engine b running. Stop the engine and carefully Meed the system -e- Benzene and lead. f w n d in some gasdine, have been iden- tified by some state and federal agencies as causing cancer orreproductive toxicity. When checking, draining or adding gasoline. take care not to ingest, breathe the fumes, or con- tact gasdine. Used engine oils have been identified by some state or fed- eral agencies as causing cancer or reproductive toxicity. When chec#ng or changing engine oil. take care not to in- gest, breathe the fumes. or contact used oil. Removeall unnecessary grease and oil from the unit. Accu- mulated grease and oil can cause overheating and engine damage, which presents a potential fire hazard. DO NOTstore anything in the generator compartment such as oil or gas cans, oily rags, chains, wooden blocks, portable propane cylinders, etc. A fire could resuH or the generatoi set operation (cooling, noise and vibration) may be ad. versely affected. Keep the compartment floor clean and dry. Do not work on this equipment when mentally or physically fatigued, or after consuming any alcohol or drugthat makes the operation of equipment unsafe. RV-8

Table of Contents SECTION 1 . 2 . 3 . 4 . 5 . 6 . 7 . 8 . 9 . TITLE PAGE SAFETY PRECAUTIONS .......................... Inside Front Cover INTRODUCTION ............................................ 1-1 About this Manual ......................................... 1-1 Model Identification ........................................ 1-1 SPECIFICATIONS ........................................... 2-1 DIMENSIONS AND CLEARANCES ............................... 3-1 TORQUE SPECIFICATIONS ................................... 4-1 PREPARING TO SERVICE ..................................... 5-1 Troubleshooting ........................................... 5-1 SpecialTools ............................................. 5-1 Safety Considerations ....................................... 5-1 Set Removal .............................................. 5-2 ENGINE-PRIMARY SYSTEMS .................................. 6-1 Introduction .............................................. 6-1 Troubleshooting Engine Primary Systems ........................ 6-1 Exhaust System ........................................... 6-5 Cooling System ........................................... 6-8 ignition System ............................................ 6-8 Crankcase Ventilation System ................................ 6-10 Governor ............................................... 6-10 Gasoline Fuel System ...................................... 6-11 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 Control Troubleshooting ..................................... 7-6 GENERATOR ............................................... 8-1 Introduction .............................................. 8-1 Generator Description ...................................... 8-1 Generator Operation ........................................ 8-2 Generator Troubleshooting ................................... 8-2 Generator Service ......................................... 8-8 Brushes and Slip Rings ..................................... 8-10 Voltage Regulator (VR1) Test ................................ 8-11 Generator Testing ......................................... 8-11 Rotor Bearing Replacement ................................. 8-15 ENGINE-BLOCK ASSEMBLY .................................. -9-1 introduction .............................................. 9-1 Oil Pan and Oil Level Switch .................................. 9-1 Head Cover .............................................. 9-2 Cylinder Head ............................................ 9-2 Valve System ............................................. 9-2 Crankcase Cover .......................................... 9-5 Camshaft and Tappet Removal ................................ 9-5 Governor ................................................ 9-6 Piston Assembly Removal and Service .......................... 9-6 Crankshaft .............................................. 9-10 Cylinder Block ........................................... 9-10 Timing Gears ............................................ 9-12 Bearings ............................................... 9-12 OilSeal ................................................ 9-12

Table of Contents SECTION TITLE PAGE 10 . SERVICE CHECKLIST ........................................................... 10-1 General ......................................................................... 10-1 Mounting ....................................................................... 10-1 Lubrication ..................................................................... 10-1 Wiring .......................................................................... 10-1 Initial Start Adjustments ........................................................ 10-1 Output Checks ................................................................. 10-1 Exhaust System ................................................................ 10-1 Fuel System .................................................................... 10-2 Control ......................................................................... 10-2 Mechanical ..................................................................... 10-2 ii

Section 1 Introduction I ABOUT THIS MANUAL This manual provides service information for the Onan KV generator set. It is intended for the experienced serviceperson. This manual covers troubleshooting, disassembly, repair, reassembly, and adjustments for the engine, generator, and control. The serviceperson should be thoroughly familiar with the principles of gas- oline engine operation and have a basic knowledge of electrical fundamentals. Other Onan publications such as Electrical/Mechanical Fundamentals (932-0408), Onan Generator Training Manual (932-0404), and KV Operator’s Manual (981 -01 29) and Installation Manual (981 -0626) are recommendedas additional sources of information. I MODEL IDENTIFICATION When contacting an Onan dealer or distributor, always supply the complete Model number and Serial number as shown on the Onan nameplate. This information is necessaryto identifythe set when ordering replacement parts. See Figure 1. Always use genuine Onan replacement parts obtained from an authorized Onan dealer or distributor. Universal replacementtype parts (usually intendedfor automotive use)often look similar but do not Derformto Onan speci- fications. Only genuine Onan ieptacement designed and tested for the application. parts are Read all service procedures completely before begin- ning any repair work and observe all cautions and warn- ings. It is extremely important that the generator set installation maintain compliance with the applicable codes and standards for RV installations (see Installa- tion Manual).The most critical areas of concern include the exhaust system, fuel system, electrical wiring, com- partment construction, and ventilation system. Improper service can create an unsafe installation that can result in damage to the vehicle and equipment and can cause severe personal injury or death to the user. l AWARNING I H Serial NO. I PF Amps Hz FIGURE 1. ONAN NAMEPLATE INCORRECTSERVICE OR REPLACEMENT OF PARTS CAN RESULTIN SEVERE PERSONAL INJURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PER- SONNEL MUSTBE QUALIFIED TO PERFORM ELECTRICALAND/OR MECHAN- ICAL SERVICE. 1-1

Section 2. Specifications GENERAL . Engine Design. ............................................... 4-Cycle, Single Cylinder, Overhead Valve Generator Design .......................................... Onan, Revolving Field, 2-Pole, Brushless AC Starting System ............................................................... .12-V0lt Electric Starter Engine Speed ............................................ .60 Hertz . 3600 r/min, 50 Hertz - 3000 r/min Weight.. .............................................................................. 110 Ib (50 kg) \ ENGINE DETAILS Displacement.. ...................................................................... 12 ins (197 cm3) Compression Ratio.. ........................................................................... 8.51 Bore.. .............................................................................. .2.64 in (67 mm) Stroke ............................................................................... .2.2 in (56 mm) Oil Capacity.. ......................................................................... 1.0 qt (0.95 L) Ventilation (Free Area). ............................................................. .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 (Intake and Exhaust) ..................................................... 0.002 in (0.05 mm) GENERATOR DETAILS Gasoline Models .... 1.7 KV 2.0 KV 2.2 KV 2.8 KV Power (Watts) ....... 1700 2000 2200 2800 Voltage ............. 240 220 120 120 Amps.. ............. 7.1 9.1 18.3 23.3 Frequency (Hertz) ... 50 50 60 60 Phase .............. 10 10 10 10 Wires .............. 2 2 2 2 Battery Charge.. .... 1 Amp 1 Amp 1 Amp 1 Amp LPG Models ........ Power (Watts) ....... Voltage ............. Amps. .............. Frequency (Hertz) . . , Phase .............. Wires .............. Battery Charge ...... 2.0 KV 2000 220 9.1 50 10 2 1 Amp 2.5 KV 2500 120 20.8 60 10 2 1 Amp 2-1

ITEM CYLINDER HEAD Cylinder Head Deformation Limit Section 3. Dimensions and Clearances INCHES MILLIMETERS 0.00394/3.39370 0.1001100.0 Allowable Limit Intake Exhaust Valve Clearance Torque I (18-24 ftolb) (25-33 Nom) 0.0039 0.1 0 0.00079-0.0031 0.02-0.080 0.00079-0.0031 0.02-0.080 Intake 44.5"-45' 44.5" -45" VALVE Valve Face Angle 0.0591 1.5 0.2153-0.21 57 5.468-5.480 Exhaust 0.2142-0.2150 5.440-5.460 Valve Stem Diameter Valve Guide Inside Diameter I 0.2165-0.21 70 5.500-5.512 Valve and Guide Stem Clearance Between Reference Valve Intake 0.00079-0.001 73 0.020-0.044 0.001 57-0.00283 0.040-0.072 Intake Opening Valve Opening Closing Closing Timing (when cool) Exhaust Opening Closing 78' (58'-70' before top dead center) 118' (98"-110° after bottom dead center) 118' (98'-110°after bottom dead center) 78" (58"-70' before top dead center) Reference Value 1.299-1.319 33.0-33.5 i Allowable Limit 1.287 32.7 Valve Spring Free Height Reference Value 12.94 Ibf 0.8858 in 5.87 kgff 22.5 m 11.64 lb/0.8858 in 5.28 kgfl22.5 m Load and Height 0.0591 1.5 I Allowable Squareness Limit Valve Seat Intake Exhaust Valve Seat Angle 45" 45" Reference Valve I 0.0394-0.051 2 1.0-1.3 3-1

Section 3. Dimensions and Clearances - Continued ITEM Valve Lifter Outer Diameter ReferenceValue Clearance Between Valve Lifter Allowable Limit And Guide Camshaft Standard Journal Diameter Clearance Between Camshaft Journal Bearing (Flywheel Side) Intake Value Exhaust Intake Limit Exhaust Reference Cam Height Allowable Allowable Side Clearance Limit Bending Limit Timing Gear Backlash ReferenceValue Allowable Limit ReferenceValue Allowable Limit Cylinder Inner Diameter Minimum Clearance Between Cylinder and Piston Piston Outer Diameter (Skirt Diameter) Piston Ring ReferenceValue Allowable Limit Gap Clearance Reference Limit Between Ring And Ring Allowable Limit Groove INCHES MILLIMETERS - : 0.001 4-0.0030 0.035-0.075 I 0.0039 0.1 0.5892-0.5899 14.966-1 4.984 0.0006-0.0020 0.01 6-0.052 0.9705 24.65 0.9705 24.65 1 0.9665 24.55 0.9665 24.55 0.0079 0.0020 0.0036-0.0056 0.092-0.1 41 0.0079 2.6378-2.6386 67.00-67.02 0.0039 0.1 0 I 0.001 6 0.04 2.6354-2.6362 66.94-66.96 0.0079-0.01 57 0.20-0.40 0.0354 0.90 I 0.0008-0.0024 0.02-0.06 I 0.0039 0.1 0 . 3-2