Onan MicroLite 2800 Series User 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
Manualand becomefamiliarwith itand the ui ment. Safe
proper1 operatad and malntalned. Many accidents are
The followingsymbols. foundthroughoutthismanual,alertyou
topotentiall dangerousconditionstotheoperator,serviceper-
and etnclent opontlon can be achieved on 77 y f the unlt Is
caused ?I y failuretofollowfundamentalrulesand precautions.
sonnel. or
t x eequipment.
Thls symbol warns of lmmedlate haz-
anis whlch wlll result In seven? personal lnjuty or
death.
A+W-AFINING~ Thlssymbol refers to a hazard or unsafe
practlce whlch can result In severe personal lnjqf
ordeath.
&CAUTION? - _.__ Thls symbol refers to a hazard or unsafe
- - .
practice which can result In personal InjuIy orprod-
uct orproperty damage.
FUEL AND FUMESARE FLAMMABLE. Fire, explosion, and
personalinjury can resutt from improper practices.
DO NOTfill fuel tankswhile engineisrunning. Fuelcontact
with hot engine of exhaustisa potentialfire hazard.
DO NOTSMOKE OR USEAN OPEN FLAMEnearthegen-
orator set or fuel
thank
Fuel lines must be adequately secured and free of leaks.
Fuelconnectionat
the engineshouldbe made with an ap-
provedflexible,
nor~~nductive line. Do not use copper pip-
ing on flexiblelines as copper willwork hardenand become
bnttle.
Be sureallfuelsupplieshavea positive shutoff valve.
GASOLINEAND LPG FUEL MAY BEACCIDENTAUY IG
NmEDBYELECTRICALSPARKS, rumntlngthrhuardof
Jury or death. Whon lnrtalllng tho generator set:
fln or explosion, whkh an rosu P t In savere pond In-
Do not tie electrical wiring tofuel lines.
Do not run electrical lines and fuel linesthrough the same
compartment openings.
Keep
electrical and fuel lines as far apart as possible.
Place a physical barrier betweenfuel lines
and electrical
lines wherever possible.
If electrical and fuel lines must pass throughthesame com-
partment opening, make certain that they are physically
ssparated
by rumingthem thrwgh individual channels, or
bypassingeachline through aseparatepieceof tubing.
DO NOT SMOKE while servicing batteries. Leadacid bat-
teriesemit a highlyexplosivehydrogengasthat can be ig-
nited by eiectricai arcing or bysmoking.
EXHAUST GASES ARE DEADLY
0 Neversleep in the vehiclewiththegeneratorsetrunning un-
less vehicle is equipped with anoperating carbon monoxide
detector.
Provide an adequateexhaustsystem to properly expel dis-
chargedgases. Inspect exhaust system daily for leaksper
the maintenanceschedule. Ensurethatexhaust manifokls
are secure
and not warped. Do not use exhaust gases to
heata compartment.
Be sure the unit is well ventilated.
MOVING PARTS CAN CAUSE SEVERE PERSONAL IN-
JURY OR DEATH
Beforestartingworkon the generator set.disconnectbatter-
ies. This will preventaccidentalarcing.
Keepyour handsaway from moving parts.
0 Make sure that fasteners on the generator set are secure.
Tightensupportsandclamps. keep guards inpositionover
fans, drive belts, etc.
0 Do notwear loose clothing or jewelrywhile workingongen-
eratorsets. Looseclothingandjewelrycanbecomecaught
inmovingparts. Jewelry can
short out electricalcontacts
and
cause shock or burning.
0 If adjustment mustbemadewhiletheunitisrunning, use ex-
tremecautionaround hot manifolds,movingparts,etc.
ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL
INJURY OR DEATH
I
I
Disconnect starting battery before removing protective
shields ortouchingelectricalequipment. Userubberinsula-
tive matsplacedon dry wood platformsover floors thatare
metalorconcretewhen
around electrical equipment. Do not
weardarnpclothing(particularlywet
shoes) orallawskinsur-
facesto
be dampwhen handlingelectricalequipment.
Use extreme caution when working on electricalcompo-
nents. Highvoltages cancause injury or death.
FoUowall state and local electrical codes. Haveallelectrical
installations performedby a qualified licensedelectrician.
Tagopenswitchesto avoidaccidentalclosure.
DO NOT CONNECT GENERATOR SE3 DIRECTLY TO
ages can flow from the generatorsetintothe utility line. This
croates a potential for electrocution or property damage.
Connectonlythroughanapproveddevice
and afterbuilding
main switch is open. Consult
an electriaan in regardto
emergencypower
use.
ANY BUILDINGELECTRICALSYSTEM. Hazardousvolt-
GENERAL SAFETY PRECALmONS
Haveafireextinguishernearby. Maintainextinguisherprop-
erly and becomefamiliar with its use. Extinguishers rated
ABC by the NFPAareappropriatefor allapplications. Con-
dt the local fire department for the meet type of extin-
guisher
for various applications.
Hot codants underpressure can cause severe personal in-
jury. DO NOTopenaradiatorpressurecap whii th4 engine
b running. Stop the engineand carefully Meed thesystem
-e-
Benzene andlead.fwnd in some gasdine, have been iden-
tified by some state and federal agencies as causing cancer
orreproductivetoxicity. Whenchecking, drainingor adding
gasoline. take care not to ingest, breathe the fumes, or con-
tact gasdine.
Used engineoilshavebeenidentifiedby some state or fed-
eral agencies as causing cancer or reproductive toxicity.
When chec#ng or changingengine oil.
take care notto in-
gest, breathethe fumes. or contact used oil.
Removeallunnecessarygrease and oilfromthe unit. Accu-
mulatedgrease
and oil can cause overheatingand engine
damage, whichpresentsa potentialfire hazard.
DO NOTstoreanythingin the generatorcompartment such
as oilorgascans, oilyrags,chains,woodenblocks, portable
propane cylinders,etc. A firecouldresuH or the generatoi
set operation (cooling, noise and vibration) may be ad.
verselyaffected. Keep thecompartmentfloorcleananddry.
Do not work onthisequipmentwhen mentallyor physically
fatigued, or afterconsumingany alcoholordrugthat makes
theoperation
of equipmentunsafe.
RV-8

Table of Contents
SECTION
1 .
2 .
3 .
4 .
5 .
6 .
7 .
8 .
9 .
TITLE PAGE
SAFETY PRECAUTIONS .......................... InsideFront Cover
INTRODUCTION ............................................ 1-1
Aboutthis Manual
......................................... 1-1
ModelIdentification
........................................ 1-1
SPECIFICATIONS ........................................... 2-1
DIMENSIONSAND CLEARANCES ............................... 3-1
TORQUE SPECIFICATIONS ................................... 4-1
PREPARING TO SERVICE ..................................... 5-1
Troubleshooting
........................................... 5-1
SpecialTools
............................................. 5-1
SafetyConsiderations
....................................... 5-1
Set Removal
.............................................. 5-2
ENGINE-PRIMARY SYSTEMS .................................. 6-1
Introduction
.............................................. 6-1
TroubleshootingEnginePrimarySystems
........................ 6-1
ExhaustSystem
........................................... 6-5
CoolingSystem
........................................... 6-8
ignitionSystem
............................................ 6-8
CrankcaseVentilationSystem
................................ 6-10
Governor
............................................... 6-10
GasolineFuelSystem
...................................... 6-11
LPG FuelSystem
......................................... 6-18
ElectricStarter
........................................... 6-21
CONTROL ................................................. 7-1
Introduction
.............................................. 7-1
ControlDescription
........................................ 7-1
ControlOperation
- GasolineFueled ............................ 7-1
ControlOperation
- LPG Fueled ............................... 7-3
ControlTroubleshooting
..................................... 7-6
GENERATOR ............................................... 8-1
Introduction
.............................................. 8-1
GeneratorDescription ...................................... 8-1
GeneratorOperation
........................................ 8-2
GeneratorTroubleshooting
................................... 8-2
Generator Service
......................................... 8-8
BrushesandSlip Rings
..................................... 8-10
VoltageRegulator (VR1) Test
................................ 8-11
GeneratorTesting
......................................... 8-11
Rotor BearingReplacement ................................. 8-15
ENGINE-BLOCK ASSEMBLY .................................. -9-1
introduction
.............................................. 9-1
Oil Panand Oil LevelSwitch .................................. 9-1
Head Cover
.............................................. 9-2
Cylinder Head
............................................ 9-2
Valve System
............................................. 9-2
CrankcaseCover
.......................................... 9-5
Camshaftand Tappet Removal
................................ 9-5
Governor
................................................ 9-6
PistonAssembly 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
InitialStart Adjustments
........................................................ 10-1
OutputChecks
................................................................. 10-1
ExhaustSystem ................................................................ 10-1
FuelSystem .................................................................... 10-2
Control
......................................................................... 10-2
Mechanical
..................................................................... 10-2
ii

Section 1 Introduction
I
ABOUT THIS MANUAL
This manual providesservice informationfor 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
shouldbethoroughlyfamiliarwiththeprinciplesof gas-
olineengine operationand havea basic knowledge
of
electricalfundamentals.Other Onan publicationssuch
as Electrical/Mechanical Fundamentals (932-0408),
Onan GeneratorTraining Manual(932-0404), and
KV
Operator’sManual (981 -01 29) and InstallationManual
(981 -0626)are recommendedas additionalsourcesof
information.
I
MODEL IDENTIFICATION
WhencontactinganOnandealeror distributor,always
supplythe complete Model numberandSerialnumber
as shown on the Onan nameplate.This information is
necessarytoidentifythesetwhenorderingreplacement
parts.See Figure
1.
Always usegenuineOnan replacementpartsobtained
fromanauthorizedOnandealerordistributor.Universal
replacementtypeparts(usuallyintendedforautomotive
use)oftenlooksimilarbutdonotDerformtoOnanspeci-
fications. Only genuine Onan ieptacement
designedandtestedfor the application. parts are
Read all serviceprocedurescompletely beforebegin-
ninganyrepairworkandobserveallcautionsandwarn-
ings. It is extremely important that the generator set
installation maintain compliance with the applicable
codesand standardsfor
RV installations(see Installa-
tionManual).Themostcriticalareasof concerninclude
theexhaustsystem,fuelsystem,electricalwiring,com-
partmentconstruction,andventilationsystem. Improper
servicecan createan unsafeinstallationthatcanresult
indamage
to thevehicleandequipmentandcancause
severepersonalinjuryor deathto the user.
l AWARNING I
H Serial NO. I
PF Amps Hz
FIGURE 1. ONAN NAMEPLATE
INCORRECTSERVICE OR REPLACEMENTOFPARTS CANRESULTINSEVERE
PERSONAL INJURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PER-
SONNELMUSTBEQUALIFIEDTOPERFORMELECTRICALAND/ORMECHAN-
ICAL SERVICE.
1-1

.

Section 2. Specifications
GENERAL
.
EngineDesign. ............................................... 4-Cycle, Single Cylinder,OverheadValve
GeneratorDesign
.......................................... Onan, RevolvingField,2-Pole, BrushlessAC
StartingSystem
............................................................... .12-V0lt Electric Starter
EngineSpeed
............................................ .60 Hertz . 3600 r/min, 50 Hertz - 3000 r/min
Weight.. .............................................................................. 110 Ib (50 kg)
\
ENGINE DETAILS
Displacement.. ...................................................................... 12ins(197 cm3)
CompressionRatio..
........................................................................... 8.51
Bore..
.............................................................................. .2.64 in (67 mm)
Stroke
............................................................................... .2.2 in(56 mm)
Oil Capacity..
......................................................................... 1.0 qt (0.95 L)
Ventilation (FreeArea). ............................................................. .24 in2 (154.8 cm2)
Fuel
......................................................................... Gasoline/Gasohol/LPG
TUNE-UP SPECS
Spark PlugGap.. .................................................................. 0.025 in(0.64 mm)
Timing..
.................................................................................. .25" BTC
Valve
Lash (Intakeand Exhaust) ..................................................... 0.002 in (0.05 mm)
GENERATOR DETAILS
GasolineModels
.... 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 ..............
BatteryCharge ......
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 HeadDeformation Limit
Section 3. Dimensions and Clearances
INCHES MILLIMETERS
0.00394/3.39370 0.1001100.0
Allowable Limit Intake
Exhaust
Valve Clearance
Torque
I (18-24ftolb) (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 FaceAngle
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 GuideStem
Clearance Between
ReferenceValve Intake 0.00079-0.001 73 0.020-0.044
0.001 57-0.00283 0.040-0.072
Intake
Opening
Valve Opening Closing
ClosingTiming
(whencool) Exhaust
Opening
Closing
78' (58'-70' beforetop dead center)
118' (98"-110° after bottomdead center)
118' (98'-110°after bottomdead center)
78" (58"-70' before
top dead center)
ReferenceValue 1.299-1.319 33.0-33.5
i Allowable Limit 1.287 32.7
Valve Spring
Free Height
ReferenceValue 12.94
Ibf 0.8858 in 5.87 kgff 22.5 m
11.64 lb/0.8858 in 5.28 kgfl22.5 m
Loadand
Height
0.0591 1.5
I
Allowable Squareness Limit
Valve Seat
Intake
Exhaust
Valve Seat Angle 45"
45"
ReferenceValve
I 0.0394-0.051 2 1.0-1.3
3-1

Section 3. Dimensions and Clearances - Continued
ITEM
Valve Lifter
Outer Diameter ReferenceValue
ClearanceBetween
Valve Lifter Allowable Limit
And Guide
Camshaft
StandardJournal Diameter
ClearanceBetweenCamshaft
Journal Bearing(FlywheelSide)
Intake
Value Exhaust
Intake
Limit Exhaust
Reference
Cam Height
Allowable
Allowable SideClearanceLimit
BendingLimit
Timing Gear
Backlash ReferenceValue
Allowable Limit
ReferenceValue
Allowable Limit
Cylinder
Inner Diameter
MinimumClearanceBetween
Cylinder and Piston
Piston
Outer Diameter(Skirt Diameter)
Piston Ring
ReferenceValue
Allowable Limit
Gap
Clearance ReferenceLimit
BetweenRing
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 14.966-14.984
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 0.092-0.141
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
0.0079-0.0157 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

Section 3. Dimensionsand Clearances - Continued
Clearance ReferenceValue
betweensmallend
And Piston Pin Allowable Limit
Bending Limit
Torsion Limit
BoltTighteningTorque
Connecting Rod
ITEM
0.0004-0.001 0 0.01 0-0.025
0.0039 0.1 0
0.001 6 0.04
0.001 6 0.04
(10.1-14.5 ftolb)
(1 3.7-19.6 Nom)
INCHES MILLIMETERS
Crankshaft ReferenceValue
Pin Diameter Wear Limit
ReferenceValue
Crankpinoil
Clearance Allowable Limit
PistonPin Outer Diameter
I 0.5906-0.5907 1 5.000-1 5.005
1.1798-1.1804 29.967-29.982
1.1 780 29.92
0.0007
- 0.0021 0.01 8-0.054
0.0039 0.1
0
Connecting Rod (Small End)
Inner Diameter ReferenceValue
BendingLimit ReferenceValue
Allowable Limit
Axial Play
1 0.5911-0.591 5
0.0008 0.02
0-0.0039
0-0.1 0
0.0079 0.20
15.015-1 5.025
ReferenceValue
I 0.9835-0.9840 24.980-24.993
0.9803 24.9
Journal Dia.
~~ ~ ~
ReferenceValue 0.0008-0.0039 0.02-0.1
0
Allowable Limit 0.0079 0.20
Side Clearance
Ignition Plug StandardGap
I 0.0236-0.0276 0.6-0.7
3-3

Section 4. Torque Specifications
TORQUE
SPECIFICATIONS FOOT-POUNDS NEWTON-METERS
ConnectingRod
HeadCover
10-14 14-20
3.3-6
4.4-8
GeneratorHousing to
EngineMountingNuts
Cylinder Head(Cold)
Endbell
to Stator
Housing MountingScrews
EngineCoolingShrouds
Fan MountingScrews
GearcaseCover
6-7 8-9
18-24 25-33
6-9 8-1
2
6-9 8-12
6-9 8-12
11-14 14-19
IntakeManifold
8-1 5 11 -20
I
CarburetorMountingNut
6-8 7-1 1
Muffler Bktto Engine
5-9 7-12
I
Muffler Flangeto Engine
10-1 4 14-20
____ ~~
Oil Base and Generator
Housingto MountingStud
Oil Baseto Engine
22-27
6-9 8-12
30-37
Oil Drain Plug
OilWatch bolt
RotorThrough-bolt
Spark Plug
Starter Bkt.
to Engine
18-24 25-33
6-9 8-12
40-50 54-68
8-18 10-24
6-9 8-1
3
SpeedAdjust Lever Nut
Vibration Isolators
Starter Bkt.to Starter
8-1 5 11 -20
4-6 5.5-8.0
2.5-3.3 3.4-4.5
~~
Starter Flangeto
EndbellMountingScrews
16-24 22-33
~~ ~
GovernorLever Nut
6-8 7-1 1
4-1

Section 5. Preparing to Service
TROUBLESHOOTING
.
Before starting to service the generator set, follow a
systematictroubleshootingproceduretolocateandiso-
latethe problem.Forservicingpurposes,thegenerator
set can be divided intothe following:
0 Engine - PrimarySystems
0 Control
0 Generator
Engine - BlockAssembly
Thismanualcontainsseparatesectionsthatcovereach
area.
Several troubleshooting guides are included in this
manualto help the servicepersonlocatethe cause of
various malfunctions. Note that some malfunctions
mighthaveseveralpossiblecauses.Forthisreason,the
serviceperson may have to investigate several likely
problemareasinorderto isolatethesourceof the mal-
function. Becauseof the complexity of the product,a
troubleshootingchartcannotlistevery malfunctionand
the cause. In some situations,the serviceperson will
have
to rely on experience and a knowledge of the
product
to locatethe problemandserviceas required.
SPECIAL TOOLS
The following specialtools may be required to service
the generator set. Some
of these tools may be pur-
chasedfromOnanwhileothers maybepurchasedfrom
outsidesuppliers.
A completelistingof thetoolsavaila-
ble from Onan is contained in the Tool Catalog
(900-
0019) which is available from Onan Dealers or
Distributors.
Engine
Tools
Torque wrench (0-50 Ft-Lbs or 0-70 Nom)
Feelergauge
Pressuregauge
Spark plug gap gauge
Flywheelpuller
Gear separator
Cylinderridge reamer
Pistonring compressor
Pistonring spreader
Cylinderhone
Wire brush
Pistongroovecleaner
Outsidemicrometerset
(0 to 4 in.)
Telescoping gauge set
(1 /2 in. to 6 in.)
Holegauge
(0.300 in.to 0.400 in.)
Valve Seal Replacement
Tool
4 Valve seat cutter
Generator and Control Tools
Leador dead-blow hammer
Batteryhydrometer
VOM multi-tester
Frequencymeter
Armaturegrowler
Loadtest panel
Jumper wires
Fan hubassembly holding
tool
SAFETY CONSIDERATIONS
Always consider the safety aspects of any service
procedure.Generatorsets presentseveralhazardsthat
the servicepersonmustbeawareofto safelycomplete
the job. Readthrough the safety precautionslisted on
theinsidecoverandfamiliarizeyourselfwiththevarious
hazards shown in Table
5-1. Once the hazards are
known, approachthe job with a safety conscious atti-
tude.Beingsafetyconscious
is themosteffectivewayto
avoid injury
to yourself or others. Reduce the chance
that an accident will occur by adopting the following
safeguards.
Safeguards to Avoid Hazards
0 Use Personal Protection - Protect your body by
wearingthe appropriatesafety equipment. Protec-
tive clothing includes safety shoes, gloves, safety
glasses,and hard hats. Leave ringsandjewelry off
and do not wear loose clothing that might get
caughton equipment.
0 Work to Reduce the Hazard - The workshop area
andall piecesof equipment usedcancontribute
to
reducing the hazard potential. Keep guards and
shieldsinplaceonmachineryandmaintainequip-
ment in good working condition. Store flammable
liquids in approved containers away from open
flame, spark, pilot light,cigarette, or other ignition
source.Keeptheworkshopcleanandwell-lighted,
and provide adequateventilation. Keep fire extin-
guishersandsafetyequipmentnearbyandbepre-
pared
to respond lo an emergency.
5-1

TABLE 5-1
HAZARDS AND THEIR SOURCE
Fireand Explosions
-Leaking or spilledfuel
-Hydrogen gasfrom battery
-Oily rags improperlystored
-Flammable liquids improperlystored
-Hot exhaust pipes
-Hot engineandgeneratorsurfaces
-Electrical short in
DC wiring system
-Carbon monoxidefrom faulty exhaust
pipes,joints, or hangers
-Operating generator setwhere
exhaustgases can accumulate
Burns
0 PoisonousGases
0 ElectricalShock (AC)
-Improper generatorset loadconnections
-Faulty
RV wiring
-Faulty electricalappliance
-Faulty generatorset wiring
-Working in damp conditions
-Jewelry touching electrical components
-Jewelry or looseclothing catching
0 RotatingMachinery
in movingparts
SlipperySurfaces
Heavy Objects
-Leaking or spilled oil
-Removing generatorsetfrom
RV
-Removing heavy components
0 Develop Safe Work Habits - Unsafe actions are
identifiedas the cause of most accidentsinvolving
the useof
tools and machines. Befamiliarwith the
equipment and know how to use
it safely. Usethe
correct
tool for the job and check its condition
beforestarting.Observethe warningsand cautions
in this manual and take special precautionswhen
working around electrical equipment.
Do not work
alone if possibleanddo nottake risks.
Be prepared
if an accident does occur. Numerous
agenciessuch as the Red Cross and your local police
and fire departments offer basic courses in first aid,
mouth-to-mouth resuscitation, and fire control. Take
advantage
of these offerings so you are ready to
respondwhen an accidenthappens.Learn
to besafety
consciousandmakesafepracticesapartofyour work
routine.
Do notworkwhentiredor after consumingany
alcohol or drug that makes the operation of equipment
unsafe.
SET REMOVAL
Some service procedures will require removing the
generator set from the coach. While there are many
variations, generator set installations are generally
classifiedaseitherconventionalcompartmentmount
or
under-the-floor mount.Inacompartmentmountinstal-
lation, a special compartment(see Figure
5-1) is built
into the coach
to house the generator set. The com-
partment is constructedwith a vapor tight barrierthat
seals
off the generatorset from the coach interior.The
generatorsetisusuallyfastenedtothefloor of thecom-
partmentwhich must be able to supportthe weight
of
the set. Access to the compartment is through a door
locatedin the exteriorof the coach.
Withthe under-the-floor mountinstallation(seeFigure
5-2), special bracketsare usedto suspendthegenera-
tor set under the floor of the vehicle. The mounting
bracketsboltto specialsupport membersthat are built
intothevehicleframework.Thegeneratorsetismounted
near the exterior
of the vehicle. Access is provided
througha door located in the exterior of the vehicle.
Becauseof the wide variety
of generator set installa-
tions,
it is not possible to specify the exact removal
proceduresfor each generator set.
If, after examining
the installation,a satisfactory methodfor removingthe
set cannotbedetermined,contactthe
RV coachmanu-
facturer to obtain their recommendations before
attempting
to removethe set from the coach.
~WARN~NG Generafor sets are heavy and can
m result in severe personal injury if
droppedduringremoval.
Use adequatelining devices
to provide sufficienf support for the set. Keep hands
and feet clear while lining.
Special fuel handling procedures are required when
removing an LP gas (propane) powered set. The fuel
systemmustbepurgedof
LP gasbeforethe set canbe
safely removed from the coach. Follow the purging
procedure before attempting to remove an LP gas
poweredset
If thegeneratorsetispoweredbygasoline,
proceedto the appropriateset removalsection.
AWARN~NG LP-Gas (Propane)is exfremelyflam-
m mableandpoisonous,and can result
in severe personal injury or deafh
if accidentally
ignited or inhaled. Eliminate all possible sources of
ignition such as open flame, sparks, pilot lights,
cigarettes,and arc-producing machinery
or switches
before purging LP-gas from the fuel system. Provide
adequate uenfilafion to dissipate LP-gas as
it is
released. (Propanegas will sink to the ground and is
not easi/ydetected.)
b
5-2

-
FLOOR
FIGURE 5-1. TYPICAL COMPARTMENTMOUNT INSTALLATION
M-1723
5 -3

DisconnectingSet from RV Systems
Disconnectthefollowing itemsfrom thegenerator set.
Refer
to Figures 5-1 and 5-2 forcomponentlocationsin
typical generatorset installations.
Someinstallationsmayrequirepartialremovaloftheset
to gain access
to the batterycable, fuel line, and other
connections. Read this section before starting set
removal.
1. Disconnectthevehiclenegative (-) batterycableat
thebattery terminal.
2. Disconnectthe generator set negative (-) battery
cable at the batteryterminal.
3. Disconnect the generator set positive (+) battery
cable from the wire harness.
4. Disconnectthe remote control wire plug from the
generator set housing.
5. Disconnectthegenerator loadwiresattheRVelec-
tricalsystemjunction box.Tagthe
RV circuit wires
for positiveidentificationwhen reconnecting.
6. Loosen the conduit connector and pull the load
wires and flexible conduitfree of thejunctionbox.
7. Disconnect the tailpipefrom the muffler or discon-
nect any support brackets or hangers attached
to
the tailpipe to allow set removal.
8. Disconnect the fuel line at the generator set hous-
ing. Securely plugtheendof thefuel lineto prevent
fuel leakageor an accumulation of explosive gaso-
line vapor.
Gasoline vapor is extremely flam-
mable and can result in severe per-
sonalinjuryordeathifignited. Makecertainallfuelline
openings areplugged toprevent gasoline vapor from
accumulating. Before disconnecting the fuel line, be
certain there are no ignition sources such
as flame,
spark,pilotlight,cigarette,etc.,nearthegeneratorset.
Keep an
AEC type fire extinguishernearby.
LP-Gas(Propane)PurgingProcedure
To purgetheLP-gasfrom thesetfuelsystem,closethe
shut-offvalveatthefueltank andthenstartthegenera-
torset. Allowthegeneratorsettooperateuntilitrunsout
of fuel. Crank the seta few times after it stops to make
surethefuel system
is completelypurgedof all LP-gas
fuel.
If the generator set cannot be operated, move the RV
coachto an outdoor locationthatiswell-ventilatedand
isaway from fire or flame. Disconnectboththe vehicle
negative
(-) batterycableandthegenerator setnegative
(-) batterycablefromtheir respectivebatteryterminals.
Closethefuel shutoff valvesatthefueltankfor boththe
generator set fuel supply system and the appliance
(stove,heater,etc.) fuelsupplysystem.Inaddition,close
the fuel shutoff valves at each appliance.
L P-Gas (Propane)is extremelyilam-
@@!@%I mableandpoisonous,andcanresult
in severe personal injury or death if accidentally
ignited or inhaled. Eliminate all possible sources of
ignition such as open ilame, sparks, pilot lights,
cigarettes,and arc-producing machinery or switches
before purging
L P-gas from the fuel system. Provide
adequate ventilation to dissipate LP-gas as it is
released. (Propanegas will sink
to the ground and is
not easilydetected.)
Slightly open the fuel line where it connects to the
generatorsetjust enoughtoallowthe LP-gas
to slowly
escape. Don’topenthefitting
too muchoralargequan-
tity of gas will be released.
Disconnectthe fuel supply hose from the carburetor
andholditclear
of theset. Pressinandholdtheprimer
buttonon the regulatorto release LP gas from the set
fuel system. When
no moregas canbeheardescaping
fromtheopenendofthefuelsupplyhose,reconnectthe
hose
to the carburetor and proceedto theappropriate
set removalsection.
Removing ConventionalCompartment Mounted
Set from
RV
Whenthegeneratorsethasbeendisconnectedfromthe
electrical, exhaust, and fuel systems, examine the set
mountingandsupportsystem.Locateall mountingbolts
andsupport membersfor the set. Inmost installations,
the generator set housingwill be bolted
to the coach
framework. Depending on the installation, the set may
be removablefrom the side, back, or bottom.
Verify that the generator set is adequately supported
before looseningany of the mounting bolts or support
members.The mostsatisfactoryway to lift or movethe
generator set is
to usea forklifttruck.
The generafor set is heavy and can
liGZi%l result in severe personal injury if
dropped during removal. Use the recommendedremo-
val techniques and keep hands and
feet clear while
removing mountingbolts.
RemovingUnderfloor MountedSet From RV
Whenthegeneratorset has beendisconnectedfromthe
electrical, exhaust, and fuel systems, the set may be
removed for major service work. The generator set is
mounted on support brackets that are bolted
to the
underside
of the floor on the vehicle or trailer and to the
generator set housing.
The generator set iscompletely suspended underneath
the floor
of the RV by the support brackets. To avoid
dropping the set during removal, follow the recom-
mendedset removal procedures.
.
5-4

The generator set is heavy and can
ljiEiSl result in severe personal injury if
droppedduring removal. Usefherecommendedremo-
val techniques and keep hands and feet clear while
removingmountingbolts.
Park the recreationalvehicle on as level a surface as
possible.Then followthesesteps very carefully.
1. Put the vehicle in its park position,lock the brakes,
and remove the keys (if applicable). Make sure no
one moves the vehicle while performing this
procedure.
Dropping the generator set can
lAWARNlNGI result in severe personal injury
or death. Make sure no one moves the vehicle
during this procedure and that the procedure
is
performed very carefullyand only as instructed.
2.
3.
4.
5.
6.
Useaforklifttruckto supporttheweightofthegener-
ator set atthe pointsshown in Figure 5-3.
Raise the forklift just so it makes contact with the
bottom of thegeneratorset housing,then puta little
upwardpressureundertheset. Verifythattheweight
ofthegeneratorset
is supportedbytheforksbefore
proceeding.
Removethe boltsthat secure the generator set to
the side mounting brackets and rear mounting
braces.
Slowly lower the generator set until it clears all
obstructions and can be safely
moved out from
underthe vehicle.
When reinstallingthegeneratorset, besurethatall
bolts,brackets,andelectrical,exhaust, andfuelsys-
tem components are connected exactly as they
were beforeremoval.
M-1725
5-5