Onan RV GenSet KY/KYD Gensets OEM Service & Repair Manual

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KY 981-0530C Printed in U.S.A. 01-06 Service Manual Beginning KY Spec J, KYD Spec A KYD

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. ! ! gasoline warnings

i Table of Contents SECTION PAGE SAFETY PRECAUTIONS iv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Genset 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinstalling Genset 5-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. CONTROL 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller A1 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Component Tests 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. GENERATOR 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Description 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Service 7-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brushes and Slip Rings 7-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Testing 7-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotor Bearing Replacement 7-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. PRIMARY ENGINE SYSTEMS 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System 8-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition System 8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Ventilation System 8-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor 8-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline Fuel System 8-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LPG Fuel System 8-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric Starter 8-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii SECTION PAGE 9. ENGINE BLOCK ASSEMBLY 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leak Down Test 9-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan 9-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Head Cover 9-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arms, Push Rods and Cylinder Head 9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve System 9-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Cover 9-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor 9-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft, Tappet and Balancer Removal 9-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and Crankshaft 9-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting Engine Parts 9-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and Crankshaft Installation 9-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearings 9-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Seal 9-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. TROUBLESHOOTING 10-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Starts or Stops Without Command – No Fault Code 10-2 . . . . . . . . . . . . . . . . No Response – Status Indicator Light Dead 10-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting Batteries Run Down 10-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Engages – Disengages 10-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No AC Power – Genset Running, Status LED On Steady 10-4 . . . . . . . . . . . . . . . . . . Genset Cranks But Does Not Start – No Fault Code 10-5 . . . . . . . . . . . . . . . . . . . . . . . Genset Runs But Stops When Switch Is Released – No Fault Code 10-5 . . . . . . . . . Service Check Fault – Fault Code 3 10-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overcrank – Fault Code 4 10-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overvoltage – Fault Code 12 10-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undervoltage – Fault Code 13 10-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overfrequency – Fault Code 14 10-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Underfrequency – Fault Code 15 10-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Sense Lost – Fault Code 27 10-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Battery Voltage – Fault Code 29 10-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Cranking Speed Sense – Fault Code 32 10-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Code 33 – Fault Code 33 10-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Card Failure – Fault Code 35 10-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii SECTION PAGE 10. TROUBLESHOOTING (CONT.) 10-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Stopped Without Fault Condition – Fault Code 36 10-18 . . . . . . . . . . . . . . . . . . Field Overload (Overvoltage) – Fault Code 38 10-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Rotor Fault – Fault Code 41 10-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Processor Fault – Fault Code 42 10-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Processor Fault – Fault Code 43 10-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Sense Fault – Fault Code 45 10-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Field Sense Fault – Fault Code 48 10-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Processor Failure – Fault Code 51 10-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. SERVICE CHECKLIST 11-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM—60 HERTZ, 120V A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE WIRING HARNESS—60 HERTZ, 120V A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM—50 HERTZ AND 60 HERTZ, 100V A-3 . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE WIRING HARDNESS—50 HERTZ AND 60 HERTZ, 100V A-4 . . . . . . . . . . . . . . . . RECONNECTION DIAGRAMS A-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iv SAFETY PRECAUTIONS Thoroughly read the OPERATOR’S MANUAL before operating the genset. Safe operation and top performance can be obtained only when equipment is operated and maintained properly. The following symbols in this manual alert you to po- tential hazards to the operator, service person and equipment. DANGER 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 S Keep children away from the genset. S Do not use evaporative starting fluids. They are highly explosive. S To prevent accidental or remote starting while working on the genset, disconnect the negative (–) battery cable at the battery. S 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. S Make sure all fasteners are secure and torqued properly. S Do not work on the genset when mentally or physically fatigued or after consuming alcohol or drugs. S You must be trained and experienced to make adjustments while the genset is running—hot, moving or electrically live parts can cause severe personal injury or death. S 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. S Benzene and lead in some gasolines have been identified by some state and federal agencies as causing cancer or reproductive toxicity. Do not to ingest, inhale or contact gasoline or its vapors. S Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible ma- terials such as wood and cloth; Class B fires, combustible and flammable liquid fuels and gaseous fuels; Class C fires, live electrical equipment. (ref. NFPA No. 10) S Genset installation and operation must comply with all applicable local, state and federal codes and regulations. GENERATOR VOLTAGE IS DEADLY! S Disable the automatic genset starting feature of an inverter-charger or other automatic starting device before servicing the genset. S Generator electrical output connections must be made by a trained and experienced electri- cian in accordance with applicable codes. S The genset must not be connected to shore power or to any other source of electrical power. Back-feed to shore power can cause electric shock resulting in severe personal injury or death and damage to equipment. An approved switching device must be used to prevent inter- connections. S Use caution when working on live electrical equipment. Remove jewelry, make sure clothing and shoes are dry, stand on a dry wooden platform or rubber insulating mat and use tools with insulated handles.

v ENGINE EXHAUST IS DEADLY! S Inspect for exhaust leaks at every startup and after every eight hours of running. S Learn the symptoms of carbon monoxide poi- soning in this manual. S Never sleep in the vehicle while the genset is running unless the vehicle is equipped with a working carbon monoxide detector. S Make sure there is ample fresh air when operating the genset in a confined area. S Disable the automatic genset starting feature of an inverter-charger or other automatic starting device before storing the vehicle or parking it in a garage or other confined space. S The exhaust system must be installed in accordance with the genset Installation Manual. S Engine cooling air must not be used for heating the working or living space or compartment. FUEL IS FLAMMABLE AND EXPLOSIVE S Do not smoke or turn electrical switches ON or OFF where fuel fumes are present or in areas sharing ventilation with fuel tanks or equipment. Keep flame, sparks, pilot lights, arc-pro- ducing equipment and switches and all other sources of ignition well away. S Fuel lines must be secured, free of leaks and separated or shielded from electrical wiring. S Leaks can lead to explosive accumulations of gas. Natural gas rises when released and can accumulate under hoods and inside housings and buildings. LPG sinks when released and can accumulate inside housings and base- ments and other below-grade spaces. Prevent leaks and the accumulation of gas. BATTERY GAS IS EXPLOSIVE S Wear safety glasses. S Do not smoke. S To reduce arcing when disconnecting or recon- necting battery cables, always disconnect the negative (–) battery cable first and reconnect it last. MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH S Disable the automatic genset starting feature of an inverter-charger or other automatic starting device before servicing the genset. S Do not wear loose clothing or jewelry near moving parts such as PTO shafts, fans, belts and pulleys. S Keep hands away from moving parts. S Keep guards in place over fans, belts, pulleys, and other moving parts. MOBILE 7

1-1 1. Introduction This is the service manual for the generator set (genset) model series listed on the front cover. Read and carefully observe all of the instructions and precautions in this manual. Model KY gensets differ from Model KYD gensets mainly by having an internally mounted muffler. WARNING Improper service or replacement of parts 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 This genset is not a life support system. It can stop without warning. Children, per- sons with physical or mental limitations, and pets could suffer severe personal injury or death. A personal attendant, redundant power or an alarm system must be used if genset operation is critical. See the Operator’s Manual for instructions concerning operation, maintenance and storage and for rec- ommendations concerning engine lubricating oil and fuel. See the Installation Manual for important recom- mendations concerning the installation and for a list of the installation codes and standards for safety that 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 and product infor- mation, be ready to provide the model and serial numbers on the genset nameplate (Figure 1-1). Ev- ery character in these numbers is significant. (The last character of the model number is the specifica- tion letter, which is important for obtaining the right parts.) [THE ENGINE FAMILY DESIGNATION, ENGINE DISPLACEMENT, STATEMENT OF COMPLIANCE WITH THE APPLICABLE EPA AND / OR CALIFORNIA EMISSIONS REGULATIONS, INCLUDING THE COMPLIANCE PERIOD OR CATEGORY, APPEAR IN THIS BLOCK ON THE ACTUAL NAMEPLATE ON THE GENSET.] FIGURE 1-1. TYPICAL NAMEPLATE

2-1 2. Specifications GASOLINE MODELS LPG MODELS 4KY 3.6KY 3.6KY 3.3KY GENERATOR: 2-Pole Revolving Field, Self-Excited, 1-Phase, Microprocessor Regulated Power 4000 watts 3600 watts 3600 watts 3300 watts Frequency 60 Hertz 50 Hertz 60 Hertz 50 Hertz Voltage 120 volts 1 230 volts 1, 2 120 volts 230 volts 2 Current 33.3 amperes 15.7 amperes 30 amperes 14.3 amperes Speed 3600 rpm 3000 rpm 3600 rpm 3000 rpm FUEL CONSUMPTION: 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 (0.79l/h) 0.37 gph (1.4 l/h) 0.58 gph (2.2 l/h) 1.5 lbs/h (0.7 kg/h) 2.2 lbs/h (1.0 kg/h) 3.3 lbs/h (1.5 kg/h) 1.1 lbs/h (0.5 kg/h) 2.0 lbs/h (0.9 kg/h) 2.9 lbs/h (1.3 kg/h) ENGINE: 1-Cylinder, 4-Stroke Cycle, Spark-Ignited, OHV, Air Cooled, Mechanically Governed 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 1.6 quart (1.5 l) 1.6 quart (1.5 l) Intake Valve Lash (Cold) 0.002 inch (0.05 mm) 0.002 inch (0.05 mm) Exhaust Valve Lash (Cold) 0.002 inch (0.05 mm) 0.002 inch (0.05 mm) Spark Plug Tightening Torque 13 lbs-ft (17 N-m) 13 lbs-ft (17 N-m) Ignition Timing (magneto) 25° BTDC, non-adjustable 25° BTDC, non-adjustable Ignition Coil Air Gap 0.009-0.015 inch (0.23-0.38 mm) 0.009-0.015 inch (0.23-0.38 mm) Spark Plug Gap 0.025 inch (0.64 mm) 0.020 inch (0.51 mm) DC SYSTEM: Nominal Battery Voltage 12 volts 12 volts Min. Battery Rating: Cold Cranking Amps (CCA) @ 0° F (–18° C) 450 450 Battery Charging Current – 10 amp (regulated) – 10 amp (regulated) INSTALLATION: Weight (with engine oil) 174 pounds (79 Kg) 184 pounds (84 Kg) 174 pounds (79 Kg) 184 pounds (84 Kg) Minimum Compartment Size (H x D x W) 3 14.4 inch x 20 inch x 30.5 inch (366 mm x 508 mm x 775 mm) 14.4 inch x 20 inch x 30.5 inch (366 mm x 508 mm x 775 mm) Minimum Free Air Inlet Area 40 inch 2 (258 cm 2 ) 40 inch 2 (258 cm 2 ) Muffler Outlet Collar O. D. 1.13 inch 1.13 inch Fuel Connection 1/4 inch barb fitting for gasoline hose 5/8-18UNC, SAE 45° Flare Fitting LPG Vapor Supply Pressure – 9-13 inch (228-330 mm) Water Column (WC) 1. Also available for 100 volts, with grounded or isolated neutral. 2. Reconnectable. See the Installation Manual. 3. See the Installation Manual for additional considerations when sizing the genset compartment.

Onan RV GenSet KY/KYD Gensets OEM Service & Repair Manual

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