Onan 4000 genset service manual

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Remove the carburetor mounting screws from the left side of the endbell. This assembly consists of the carburetor and the in- 4. Close the choke and throttle plates by rotating take manifold assembly. It is easier their shafts in a counterclockwise direction. Page 80 Carburetor Replacement Beginning Spec D Other than turning the altitude adjust knob shown in Figure which changes the main fuel mixture within a limited range , fuel mixture adjustments should not be attempted.

Nor should the carburetor be overhauled. Instead, a malfunctioning carbure- tor should be replaced. Page 81 Carburetor Mixture Screw Adjustments 3. Turn the main adjustment screw inward until voltage or frequency drop and then outward Does Not Apply to Spec D and Later until voltage or frequency drop again. Locate The most common causes of poor carburetion are the point where voltage and frequency are the the idle and main mixture screws being out of ad- highest.

Soak all metal components to be reused in car- seat. Turn them in until only light tension buretor cleaner. Do not soak rubber or plastic can be felt.

Allow the genset to cool down consists of a bimetal choke coil, coil housing, heater before handling the choke assembly. Remove choke linkage from the bimetal coil gine operation. If the choke does not open properly, and install linkage on the new coil.

The output pressure from an automotive FSs pump is much higher and can cause carburetor flooding or fuel leakage, creating a fire hazard. Page 87 Figure The pump will not place fuel pump with an Onan-supplied pump. Page 90 Checking and Adjusting Regulator Lock-off the adjusting screw locknut and test lock- Pressure: Lock-off pressure is determined as fol- off pressure again. Repeat the procedure lows by pressurizing the back vent side of the reg- if necessary.

If there is a smell of gas when the genset is not running, or any other reason to suspect that the valve is leaking, connect the inlet of the valve to a source of air pressure regu- lated to not more than 14 inches WC mm WC and disconnect the outlet hose. Ad- just the stop screw to obtain a setting of 55 " See Figure If low or no voltage is measured check the starting battery, start solenoid, and control A volt electric starter with a negative ground is wiring.

When the starter is energized, an inertial engagement system causes the starter pinion gear to engage the ring gear on the fan hub assembly. Page 94 Starter Disassembly Remove the engine bracket behind the starter from the engine Torx T and muffler. The genset must be removed from the vehicle be- 4. Remove the starter mounting nuts bolts on fore the starter can be serviced. See Section 5. Pre- Spec A. Page 95 Testing Armature for Grounds Touch one ohmmeter lead to a commutator bar, touch the other lead to the armature shaft and the core laminations.

A low resistance reading indi- cates a grounded armature. Replace a grounded armature with a new one. Testing Armature for Shorts Use a growler Figure to locate shorts in the armature. Page 96 Starter Re-assembly 4. Insert the brush springs into brush holders. In- sert the brush tabs into the spring ends and Use this procedure to return the electric starter as- slide brushes into brush holders in endcap. Make sure all brush wires are facing up.

Page 97 1. Place a spring washer and a flat washer on the B. With the chamfered side of the shaft hole shaft, as shown in Figure Page 98 1. Carefully mount the starter on the endbell and 3. Mount the housing on the genset and install the genset into the vehicle.

Page 99 Redistribution or publication of this document, by any means, is strictly prohibited. Page Generator 9. Output voltage is controlled by an elec- ing.

Wiring Sche- tion. Page 8. Connect a lifting hoist to the lifting eye on the 8. Remove the air housing assembly from the top of the endbell and slowly raise the genera- endbell Figure on Page Page Prepare the brushes for endbell removal. Remove the stator mounting screws. Carefully disconnect the wire harness leads Carefully pull the stator straight out from the from the brush block and pull each brush out- housing. If the stator will not slide out, tap on ward from the holder and at the same time in- generator housing while pulling on the stator to sert a piece of wire into the small hole in the Page Generator Assembly 6.

Install the fan hub assembly onto the rotor shaft and align the key slot on the fan hub with the Use the following procedures to assemble the gen- key slot in the rotor shaft. Install the key into the erator: key slot.

Begin with the Field Voltage personal injury or death. Use extreme caution Test, following, to help locate possible problems. Page Test A: Connect a DC voltmeter into the back side and Figure on Page show the rotor re- of the voltage regulator connector J4 as follows: At- moved from the genset for testing. Page Open or Shorted Test: To test for open windings, set the ohmmeter on the highest resistance scale. Place the test prods on the slip rings as shown in Figure The ohmmeter should indicate continu- ity between the slip rings of approximately 19 to 27 ohms.

If stator tests indicate a shorted winding, replace the stator. Always re- Confirm that the voltage regulator is faulty before place the brush springs when installing new replacing it. Use a meter with a diode checking func- brushes to maintain proper tension on the brushes. Page Rotor Bearing Replacement 2.

Place the rotor in the machine lathe and center. Turn the rotor and use a commutator stone Onan tool — against the rotating slip rings to clean and true the slip rings. Turn the rotor until all grooves or roughness are smoothed out. Page 2. Use a small puller with grips that will fit between the bearing and the collector ring assembly Figure or use an arbor press to remove the bearing.

Cover the end of the rotor shaft with a steel plate to prevent deformation of the shaft during removal. Page Engine Block Assembly Feeling compression air escaping the spark plug hole. This section covers service procedures for the en- C. Using a tester with a T. A leak down test can be per- ture. Remove the rocker arm mounting nuts. Re- move the rocker arms and push rods Figure It may also be due to weak valve springs, insufficient tappet clearance, This engine uses an overhead valve design, as warping, and misalignment.

A properly functioning valve system is essential for good engine performance. Page Too much clearance in the intake guide admits air and oil into the combustion chamber, affecting car- buretion, increasing oil consumption, and making heavy carbon deposits. Clean metal is a good heat conductor but carbon insulates and retains the heat.

This increases combustion chamber temper- ature which causes warping and burning. Page Valve Seat Surface Width 7. Use a grinding compound to finish the seat sur- face. Clean the valve seat surface. Valve stem guides or valve seats that are worn, 2. Use a vernier caliper to measure the valve seat loose, cracked, or severely pitted should be re- width Figure Page Valve Clearance Adjustment The valve clearance can be checked and adjusted.

Adjust the valve clearance only when the engine is at ambient temperature. Follow head cover removal instructions in the Head Cover section on Page Inspect the valve stems for proper alignment with the rocker arms.

The crankcase cover is located in two places with dowel pins Figure Do not attempt to pry the crankcase cover off or damage can result. Remove the crankcase cover mounting bolts.

Hold the crankcase cover and lightly tap the end of the crankshaft with a plastic ham- mer. Place the engine cylinder down on a clean flat surface Figure Carefully pull out the camshaft assembly.

Remove the valve tappets. Mark the tappets because tappet clearances differ and the tap- pets must be reassembled in their original posi- tions. Page Inspection Of Engine Parts 1. Remove the two bolts from the connecting rod cap.

Mark direction of assembly for connecting the rod, cap, and splasher. Remove the rod cap from the rod and push the piston assembly out the top of the cylinder Fig- ure Page Inspection: When rebuilding the engine, thorough- ly inspect the block for any condition that would make it unfit for further use.

This inspection must be made after all parts have been removed and the block has been thoroughly cleaned and dried. Page Cylinder Bore Deglazing Before installing new rings, deglaze the cylinder bore. Make sure that there are no scuff marks and no wear or out-of-round beyond the specifications. Deglazing gives a fine finish but does not enlarge the cylinder diameter, so the original pistons with new rings can be used.

Page Remove the piston pin retainer from each side, heat the piston to F C and push the piston pin out. Remove dirt and deposits from the piston sur- faces with parts cleaning solvent. Clean the piston ring grooves with a groove cleaner Figure or the end of a piston ring filed to a sharp point.

Page Piston Skirt O. Measurement: 1. Measure the piston skirt O. If the measurement is less than the allowable limit, replace the piston. Piston Boss I. Measure the piston boss I.

Page Piston Ring Thickness: 1. Measure the piston ring thickness with an out- side micrometer see Figure If the thickness is less than the allowable limit, replace the ring.