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Portable Generator
MicroLite 4000 Series
Onan MicroLite 4000 Series User Manual
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Printed U
.S.A.
981-0503
297
MicroLite
4000 Series
KY
2
Table of Contents
Default Chapter
2
Default Chapter
2
Table of Contents
2
Safety Precautions
4
General Precautions
4
Typical Nameplate
6
1 Introduction
6
Model Number Identification
7
Serial Number Identification
7
2 Specifications
8
3 Dimensions and Clearances
10
4 Torque Specifications
14
Engine Torque Specifications
14
Generator Torque Specifications
15
Metric Bolt Torque Specifications - no Grade or 8.8 Grade
15
Metric Bolt Torque Specifications - 10.9 Grade
15
5 Preparing for Service
16
Troubleshooting
16
Special Tools
16
Safety Considerations
16
Hazards and Their Sources
17
Set Removal Guidelines
17
Fire and Explosions
17
Electrical Shock (AC)
17
Typical Compartment Mount Installation
18
Typical Under-Floor Mount Installation
18
Disconnecting Set from Vehicle Systems
19
Set Removal
20
Compartment Mount
20
Under-Floor Mount
21
Complete Genset Removal
21
6 Troubleshooting
22
Introduction
22
Component Locations – Gasoline-Fueled Spec a Models
23
Component Locations – Gasoline-Fueled Models, Beginning with Spec B
24
Spec a Start - Cranking Mode
25
Spec a Control Troubleshooting – Cranking Mode
26
Spec a Start - Ignition Mode
27
Spec a Control Troubleshooting – Ignition Mode
28
Spec a Start - Field Flash Mode
29
Spec a Control Troubleshooting – Field Flash Mode
30
Spec a Run Mode
31
Spec a Control Troubleshooting – Run Mode
32
Spec a Battery Charge Mode
33
Spec a Control Troubleshooting – Battery Charge Mode
34
Spec a Stop Mode
35
Spec a Control Troubleshooting – Stop Mode
36
Begin Spec B Start - Cranking Mode
37
Begin Spec B Control Troubleshooting – Cranking Mode
38
Begin Spec B Start - Ignition Mode
39
Begin Spec B Control Troubleshooting – Ignition Mode
40
Begin Spec B Start - Field Flash Mode
41
Begin Spec B Control Troubleshooting – Field Flash Mode
42
Begin Spec B Run Mode
43
Begin Spec B Control Troubleshooting – Run Mode
44
Begin Spec B Battery Charge Mode – 50 Hz Only
45
Begin Spec B Control Troubleshooting – Battery Charge Mode
46
Begin Spec B Stop Mode
47
Begin Spec B Control Troubleshooting – Stop Mode
48
Generator Troubleshooting
49
Spec a Generator AC Output Mode
50
Spec B Generator AC Output Mode
51
Engine Primary Systems Troubleshooting
53
Control Description
58
Start/Stop Switch
58
Spec a Control Component Location
58
Introduction
58
Start Solenoid (K1)
59
Control Fuse (F1)
59
Circuit Breaker (CB1)
59
Control Assembly (A1)
59
Control Operation
60
Optional Remote Control (A2, A3)
60
Rectifier Bridge (Cr1) – Spec a Only
60
Start Mode
60
Run Mode
61
Charging Circuit
61
Stopping
61
Control Component Tests
62
Spec a Control Outputs
64
Begin Spec B Control Outputs
64
Control Assembly (A1) Check
64
Resistor (R1) – Spec a Only
65
Diode Bridge (CR1)
65
Diode Bridge CR1 Check
65
Battery Charger Assembly (VR2) – Begin Spec B, 50 Hz Only
66
Battery Charger Assembly (VR2)
66
Transformer (T1) – Begin Spec B, 50 Hz Only
67
8 Primary Engine Systems
68
Cooling System Disassembly
68
Cooling System Inspection
68
Introduction
68
Cooling System Assembly
69
Exhaust System
69
Muffler Disassembly
69
Compartment Mount Exhaust System
70
Muffler Assembly
70
Tailpipe Recommendations
71
Departure Angle and Ramp Angle
72
Ignition Coil (T1)
73
Ignition System
73
Measuring Plug Gap
73
Spark Plug (E2)
73
Ignition Wiring
74
Crankcase Breather Service Procedure
75
Crankcase Breather System
75
Crankcase Ventilation System
75
Magneto Assembly (G2)
75
Governor
76
Governor Adjustments
76
Checking Voltage and Speed/Frequency
77
Air Filter and Preheater Assembly
78
Gasoline Fuel System
78
Carburetor and Intake Manifold Assembly
79
Carburetor Replacement
80
Carburetor Mixture Screw Adjustments
81
Mixture Screw Adjustment
81
Carburetor Overhaul
82
Carburetor Reassembly
83
Cleaning and Repair Procedure
83
Float Installation
83
Choke Assembly
84
Fuel Filter
86
Fuel Filter Replacement
86
Fuel Pump
86
Fuel Pump Test
88
Demand Regulator with Automatic Priming Solenoid
89
Lpg Fuel System
89
Top View of Demand Regulator with Automatic Priming Solenoid
89
Automatic Priming Solenoid
90
Checking and Adjusting Regulator Lock-Off
90
Fuel Solenoid Valve
91
Fuel-Shutoff Solenoid Valve
91
Lpg Carburetor
91
LPG Carburetor (Beginning Spec E)
91
LPG Carburetor (Prior to Spec E)
92
Lpg Carburetor Adjustments
92
Electric Starter
93
Starter Voltage Check
93
Driving Roll Pin out of Starter Assembly
94
Starter Disassembly
94
Brush Inspection
95
Testing Armature for Grounds
95
Testing Armature for Opens
95
Testing Armature for Shorts
95
Brush Endcap
96
Starter Re-Assembly
96
Starter Assembly
97
Generator Cooling
100
Generator Description
100
Rotor
100
Stator and Housing
100
Generator Disassembly / Base Removal
101
Generator Operation
101
Generator Service
101
Spec a Generator Components
102
Begin Spec B Generator Components
103
Pulling the Fan Hub Assembly
104
Brush Block
105
Rotor Removal
105
Generator Assembly
106
Field Voltage Test
107
Generator Testing
107
Voltage Regulator Connector Plug
107
Grounded Rotor Test
108
Rotor Test
108
Open or Shorted Rotor Test
109
Stator Test
109
Open or Shorted Stator Windings Test
110
Stator Assembly
110
Stator Ground Test
110
Stator Open or Shorted Winding Test
110
Brush Replacement
111
Brush Wear Check
111
Brushes and Slip Rings
111
Voltage Regulator (VR1) Test
111
Rotor Bearing Replacement
112
Rotor Bearing Spacing
112
Slip Ring Service
112
Rotor Bearing Removal
113
Engine Block Assembly
114
Leak down Test
114
Typical Leak down Tester
114
Leak down Check Points
115
Oil Pan and Oil Level Switch
115
Head Cover
115
Head Cover Removal
115
Rocker Arms, Push Rods and Cylinder Head
116
Rocker Arm and Push Rod Removal
116
Cylinder Head Tightening Sequence
116
Valve System
117
Valve Removal
117
Overhead Valve System
117
Valve Face, Stem, and Guide
118
Valve Spring Checks
118
Valve Seat Surface Width
119
Regrinding Seat Surface
119
Valve Clearance Adjustment
120
Intake Valve Seal Replacement
120
Valve Seal Installation
120
Crankcase Cover
121
Camshaft, Tappet and Balancer Removal
122
Piston and Crankshaft
122
Removing Wear Ridge
122
Inspection of Engine Parts
123
Cylinder Head
123
Cylinder Block
123
Piston Removal
123
Measuring Cylinder Wear
124
Cylinder Bore Deglazing
125
Piston, Rings, and Connecting Rod
125
Crosshatching
125
Removing Piston Rings
125
Piston and Connecting Rod Inspection
126
Cleaning Ring Grooves
126
Checking Ring Land
126
Piston Skirt O.D. Measurement
127
Piston Boss I.D.
127
Piston Ring Gap
127
Piston Skirt Measurement
127
Piston Ring Thickness
128
Piston Assembly
128
Clearance between Piston Pin and Connecting Rod Small End Bore
128
Ring Thickness
128
Clearance between Crank Pin and Connecting Rod Big End Bore
129
Side Clearance of Connecting Rod on Crank Pin
129
Cam Heights for Intake and Exhaust
129
Piston and Crankshaft Installation
130
Side Clearance of Crankshaft
130
Rod Cap Assembly
130
Crankpin Clearance
131
Measuring Crankpin Clearance
131
Bearings
132
Oil Seal
132
Compression Release System
133
11 Service Checklist
134
Mounting
134
Lubrication
134
Initial Start Adjustments
134
General
134
Wiring
134
Fuel System
135
Mechanical
135
Exhaust System
135
Output Check
135
Control
135
Wiring Schematic/Diagram
136
Wiring Schematic 611-1194 (Microlite, Spec a – 60 Hertz)
137
Wiring Diagram 611-1194 (Microlite, Spec a – 60 Hertz)
138
Wiring Schematic 611-1225 (Microlite, Spec B through E – 60 Hertz)
139
Wiring Diagram 612-1225 (Microlite, Spec B through E – 60 Hertz)
140
Wiring Schematic 611-1226 (Microlite, Spec B through E – 50 Hertz)
141
Wiring Diagram 612-1226 (Microlite, Spec B through E – 50 Hertz)
142
Voltage Reconnection Diagram 612-1226 (Microlite, Spec B through E – 50 Hertz)
143
Wiring Schematic 611-1245 (Microlite, Begin Spec F – 50 Hertz)
144
Wiring Diagram 611-1245 (Microlite, Begin Spec F – 50 Hertz)
145
Voltage Reconnection Diagram 612-1245 (Microlite, Begin Spec F – 50 Hertz)
146
Wiring Schematic 612-1246 (Microlite, Begin Spec F – 60 Hertz)
147
Wiring Diagram 612-1246 (Microlite, Begin Spec F – 60 Hertz)
148
Wiring Schematic 612-1255 (Microlite, Begin Spec F – 60 Hz/100 V)
149
Wiring Diagram 612-1255 (Microlite, Begin Spec F – 60 Hz/100 V)
150
Voltage Reconnection Diagram 612-1255 (Microlite, Begin Spec F – 50 Hz/100 V)
151
Wiring Schematic 611-1264 (Microlite, Bigin Spec G – 50 Hertz)
152
Wiring Diagram 611-1264 (Microlite, Begin Spec G – 50 Hertz)
153
Voltage Reconnection Diagram 611-1264 (Microlite, Begin Spec G – 50 Hertz)
154
Wiring Schematic 611-1265 (Microlite, Begin Spec G – 60 Hertz)
155
Wiring Diagram 611-1265 (Microlite, Begin Spec G – 60 Hertz)
156
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Onan MicroLite 4000 Series Specifications
General
Brand
Onan
Model
MicroLite 4000 Series
Category
Portable Generator
Language
English
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