Onan KY 4000 Series MicroLite Generator Sets Full Service & Repair Manual

Printed U.S.A. 981-0503 2Ć97 MicroLite 4000 Series KY

Table of Contents i SECTION TITLE PAGE SAFETY PRECAUTIONS iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INTRODUCTION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DIMENSIONS AND CLEARANCES 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TORQUE SPECIFICATIONS 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 PREPARING FOR SERVICE 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Considerations 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set Removal Guidelines 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 TROUBLESHOOTING 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Troubleshooting 6-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Primary Systems Troubleshooting 6-32 . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CONTROL 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Description 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Operation 7-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Component Tests 7-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 PRIMARY ENGINE SYSTEMS 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System 8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition System 8-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Ventilation System 8-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor 8-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline Fuel System 8-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LPG Fuel System 8-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric Starter 8-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. ! !

ii 9 GENERATOR 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Description 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Operation 9-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Service 9-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Testing 9-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Regulator (VR1) Test 9-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brushes and Slip Rings 9-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotor Bearing Replacement 9-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ENGINE BLOCK ASSEMBLY 10-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 10-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leak Down Test 10-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan and Oil Level Switch 10-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Head Cover 10-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arms, Push Rods and Cylinder Head 10-3 . . . . . . . . . . . . . . . . . . . . . . . Valve System 10-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Cover 10-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor 10-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft, Tappet and Balancer Removal 10-9 . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and Crankshaft 10-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection of Engine Parts 10-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and Crankshaft Installation 10-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearings 10-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Seal 10-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression Release System 10-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SERVICE CHECKLIST 11-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General 11-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting 11-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication 11-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring 11-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Start Adjustments 11-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System 11-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System 11-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Check 11-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control 11-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical 11-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 WIRING SCHEMATIC/DIAGRAM 12-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Precautions iii Thoroughly read the SERVICE MANUAL before servic- ing the genset. Reliable service can be obtained only with close adherance to the procedures in this manual. The following symbols in this Manual alert you to potential hazards to the operator, service person and equipment. Alerts you to an immediate hazard which will result in severe personal injury or death. WARNING Alerts you to a hazard or unsafe practice which can result in severe personal injury or death. CAUTION Alerts you to a hazard or unsafe practice which can result in personal injury or equipment damage. Electricity, fuel, exhaust, moving parts and batteries present hazards which can result in severe personal injury or death. GENERAL PRECAUTIONS • Keep ABC fire extinguishers handy. • Make sure all fasteners are secure and torqued prop- erly. • Keep the genset and its compartment clean. Excess oil and oily rags can catch fire. Dirt and gear stowed in the compartment can restrict cooling air. • Before working on the genset, disconnect the negative ( –) battery cable at the battery to prevent starting. • Use caution when making adjustments while the genset is running—hot, moving or electrically live parts can cause severe personal injury or death. • Used engine oil has been identified by some state and federal agencies as causing cancer or reproductive toxicity. Do not ingest, inhale, or contact used oil or its vapors. • Benzene and lead in some gasolines have been identified by some state and federal agencies as causing cancer or reproductive toxicity. Do not ingest, inhale or contact gasoline or its vapors. • Do not work on the genset when mentally or physical- ly fatigued or after consuming alcohol or drugs. • Carefully follow all applicable local, state and federal codes. GENERATOR VOLTAGE IS DEADLY! • Generator output connections must be made by a qualified electrician in accordance with applicable codes. • The genset must not be connected to the public utility or any other source of electrical power. Connection could lead to electrocution of utility workers, damage to equipment and fire. An approved switching device must be used to prevent interconnections. • Use caution when working on live electrical equipment. Remove jewelry, make sure clothing and shoes are dry and stand on a dry wooden platform on the ground or floor. FUEL IS FLAMMABLE AND EXPLOSIVE • Keep flames, cigarettes, sparks, pilot lights, electrical arc-producing equipment and switches and all other sources of ignition well away from areas where fuel fumes are present and areas sharing ventilation. • Fuel lines must be secured, free of leaks and sepa- rated or shielded from electrical wiring. • Use approved non-conductive flexible fuel hose for fuel connections at the genset. ENGINE EXHAUST IS DEADLY! • Learn the symptoms of carbon monoxide poisoning in this Manual. • Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector. • The exhaust system must be installed in accordance with the genset Installation Manual. • Do not use engine cooling air to heat the vehicle interi- or. • Make sure there is ample fresh air when operating the genset in a confined area. MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH • Do not wear loose clothing or jewelry near moving parts such as PTO shafts, fans, belts and pulleys. • Keep hands away from moving parts. • Keep guards in place over fans, belts, pulleys, etc. BATTERY GAS IS EXPLOSIVE • Wear safety glasses and do not smoke while servic- ing batteries. • When disconnecting or reconnecting battery cables, always disconnect the negative (–) battery cable first and reconnect it last to reduce arcing. MBL-2

1. Introduction 1-1 This is the service manual for the KY 4000 Series MicroLite generator sets (gensets). Read and carefully observe all of the instructions and precautions in this manual. WARNING Improper service or parts replacement can lead to severe personal injury or death and to damage to equipment and property. Ser- vice personnel must be qualified to perform electrical and mechanical service. WARNING Unauthorized modifications or replacement of fuel, exhaust, air intake or speed control system components that affect engine emissions are prohibited by law in the State of California. WARNING LPG (liquified petroleum gas) is flammable and explosive and can cause as- phyxiation. NFPA 58, Section 1.6 requires all persons handling LPG to be trained in proper handling and operating procedures. See the Operator’s Manual for instructions concerning operation, maintenance and storage and for recommendations concerning engine lubricat- ing oil and fuel. See the Installation Manual for important recommendations concerning the installation and for a list of the installation codes and standards for safety which may be applicable. See the Parts Manual for parts identification numbers and required quantities and for exploded views of the genset subassemblies. Genuine Onan replacement parts are recommended for best results. 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 these numbers is significant (Figures 1-2 and 1-3 on Page 1-2). SN5304U1G2RA 304 cc A953123456 NAMEPLATE WITH TYPICAL MODEL AND SERIAL NUMBER DATA 4KYFA26100E FIGURE 1-1. TYPICAL NAMEPLATE MicroLite is a trademark of the Onan Corporation.

1-2 Model Number Identification Figure 1-2 shows a breakdown of the model number for a typical genset. MODEL NO. 4 KY FA 26100 E 1 2 3 4 5 6 1. Power capacity in kilowatts - (4000 watts) 2. Product family designation. 3. Starting method - (Remote startable) 4. Voltage and frequency code - (120 volt, 60-Hz ) 5. Specification number - (Code for options and special features) 6. Specification letter - (Used to identify major design or manufacturing changes) FIGURE 1-2. MODEL NUMBER IDENTIFICATION Serial Number Identification Figure 1-3 shows a breakdown of the serial number for a typical genset. SERIAL NO. D 95 3 123456 1 2 3 4 1. Month genset was built: A = January B = February etc. 2. Year genset was built: 94 = 1994 95 = 1995 etc. 3. Location where genset was built: 0 = Fridley, Minnesota 3 = Huntsville, Alabama 4. Active serial number FIGURE 1-3. SERIAL NUMBER IDENTIFICATION

2. Specifications 2-1 GASOLINE MODELS LPG MODELS 4.0 KY 3.6 KY 3.6 KY 3.3 KY GENERATOR: 2-Pole Revolving Field, Self-Excited, Electronically Regulated, 1-Phase Power 4000 watts 3600 watts 3600 watts 3300 watts Frequency 60 Hertz 50 Hertz 60 Hertz 50 Hertz Voltage 100/120 volts 100/220/230 volts 100/120 volts 100/220/230 volts Current 40/33.3 amperes 36/16.4/15.7 amperes 36/30 amperes 33/15.0/14.3 amperes Speed 3600 rpm 3000 rpm 3600 rpm 3000 rpm FUEL CONSUMPTION: Gasoline LPG No load Half load Full load 0.29 gph (1.1 l/h) 0.48 gph (1.8 l/h) 0.71 gph (2.7 l/h) 0.21 gph (0.8 l/h) 0.37 gph (1.4 l/h) 0.58 gph (2.2 l/h) 1.5 lbs/h (0.7 kg/h) 2.4 lbs/h (1.1 kg/h) 3.1 lbs/h (1.4 kg/h) 1.1 lbs/h (0.5 kg/h) 2.2 lbs/h (1.0 kg/h) 2.9 lbs/h (1.3 kg/h) ENGINE: 1-Cylinder, 4-Cycle, Spark-Ignited, OHV, Air Cooled Bore 3.11 inch (79 mm) 3.11 inch (79 mm) Stroke 2.44 inch (62 mm) 2.44 inch (62 mm) Displacement 18.5 inch 3 (304 cc) 18.5 inch 3 (304 cc) Compression Ratio 8.5 : 1 8.5 : 1 Oil Capacity (Beginning Spec B)* 1.6 quart (1.5 l) 1.6 quart (1.5 l) Oil Capacity (Spec A)* 1.7 quart (1.6 l) 1.7 quart (1.6 l) Intake Valve Clearance (Cold) 0.002 inch (0.05 mm) 0.002 inch (0.05 mm) Exhaust Valve Clearance (Cold) 0.002 inch (0.05 mm) 0.002 inch (0.05 mm) Spark Plug Gap 0.025 inch (0.64 mm) 0.020 inch (0.51 mm) Spark Plug Tightening Torque 13 lbs-ft (17 N-m) 13 lbs-ft (17 N-m) Ignition Timing (magneto type ignition) 25° BTDC, non-adjustable 25° BTDC, non-adjustable LPG Vapor Supply Pressure (Range) – 9 to 13 inch (229 to 330 mm) W.C. (water column) DC SYSTEM: Nominal Battery Voltage 12 volts 12 volts Minimum Battery Cold Cranking Capacity: Above/Below Freezing 360/450 amperes 360/450 amperes Control Fuse 5 amperes 5 amperes Maximum Regulated-Voltage Bat- tery Charging Current – 10 amperes – 10 amperes * –See Periodic Maintenance in the Operator’s Manual for oil filling instructions.

3. Dimensions and Clearances 3-1 All clearances are at 70° F (21° C) room temperature. All measurements are listed in inches with millimeter measurements in parentheses. Measurements are for standard size parts. FACTORY SPECIFICATION ALLOWABLE DESCRIPTION MIN. MAX. LIMIT Cylinder Head Cylinder Head Distortion – – 0.0157 – – (0.4) Cylinder Block Cylinder Bore I.D. 3.1102 3.1110 3.1138 (79.00) (79.02) (79.09) Crankshaft Connecting Rod Journal O.D. 1.3177 1.3181 1.3157 (33.47) (33.48) (33.42) Side Clearance – – 0.0098 – – (0.25) Connecting Rod Piston Pin Bore I.D. 0.7093 0.7096 0.7106 (18.015) (18.025) (18.050) Large Bore I.D. 1.3189 1.3199 1.3204 (33.500) (33.525) (33.540) Large Bore Clearance 0.0008 0.0022 0.0047 (0.020) (0.055) (0.120) Side Clearance on Crankshaft 0.0157 0.0433 0.0590 (0.40) (1.10) (1.5) Camshaft Lobe Height (Intake and Exhaust) 1.4035 1.4059 1.3997 (35.65) (35.71) (35.55) Piston Piston Skirt O.D. 3.1089 3.1094 3.1063 (78.965) (78.98) (78.90) Pin Bore I.D. 0.7084 0.7087 0.7084/0.7087 (17.994) (18.002) (17.994/18.002)

Onan KY 4000 Series MicroLite Generator Sets Full Service & Repair Manual

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