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Onan MicroLite 4000 Series

Onan MicroLite 4000 Series
158 pages
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Printed U.S.A.
981-0503
297
MicroLite 4000 Series
KY

Table of Contents

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Onan MicroLite 4000 Series Specifications

General IconGeneral
Fuel TypeGasoline
Frequency60 Hz
Rated AC Output4000 Watts
AC Voltage120V
Rated AC Amperage33.3A
Engine TypeOHV
Starting MethodElectric
Noise Level68 dB at 23 ft

Summary

Comprehensive Safety Precautions for Genset Operation

General Precautions

General safety guidelines for genset operation and maintenance.

Electrical Hazards

Warnings regarding generator voltage and electrical safety procedures.

Fuel Hazards

Precautions related to flammable and explosive fuel properties.

Engine Exhaust Hazards

Warnings about dangerous engine exhaust gases like carbon monoxide.

Moving Parts Hazards

Safety advice concerning risks associated with moving engine and generator parts.

Battery Hazards

Precautions when working with batteries, highlighting explosion risks.

1. Introduction to Onan MicroLite RV GenSet Service Manual

Model Number Identification

Explains the breakdown and meaning of the genset model number.

Serial Number Identification

Details the breakdown and meaning of the genset serial number.

2. Onan MicroLite RV GenSet Technical Specifications

3. Dimensions and Clearances for Onan GenSet

4. Torque Specifications for Onan GenSet Components

5. Preparing the Onan GenSet for Service

Troubleshooting Guide Overview

Guide to diagnosing genset problems, divided into four parts: Control, Generator, and Primary Systems.

Special Tools for Service

Lists special tools required for servicing the genset, including engine and generator tools.

General Safety Considerations

Discusses service safety aspects, hazards, and personal protection equipment.

Hazard Avoidance Safeguards

Provides guidelines for personal protection and maintaining a safe work area.

Genset Removal Guidelines

Details procedures for removing the genset from the vehicle for service.

6. Troubleshooting Guide for Onan MicroLite RV GenSets

Troubleshooting Introduction

Guide to diagnosing genset problems, divided into four parts: Control, Generator, and Primary Systems.

Control Troubleshooting

Troubleshooting guide for control system issues.

Generator Troubleshooting

Troubleshooting guide for generator-related problems.

Engine Primary Systems Troubleshooting

Troubleshooting guide for engine primary systems issues.

7. Onan GenSet Control System Operation and Service

Control System Introduction

Covers control operation, component locations, troubleshooting, and test procedures.

Control Component Description

Details the components of the control circuitry, including switches, solenoids, and assemblies.

8. Primary Engine Systems Service

Primary Engine Systems Introduction

Describes service procedures for engine systems: cooling, exhaust, ignition, fuel, and starter.

Cooling System Service

Covers inspection, disassembly, and assembly of the genset's cooling system.

Exhaust System Service

Details service procedures for the exhaust system, including muffler and tailpipe.

Ignition System Service

Explains the ignition system and provides checks for spark plug, coil, and wiring.

Crankcase Ventilation System Service

Explains the crankcase breather system and its service procedure.

Governor Service and Adjustments

Covers governor function, adjustments, and troubleshooting for speed and frequency control.

Fuel System Service

Details service for gasoline and LPG fuel systems, including filters, pumps, and carburetors.

Electric Starter Service

Covers starter voltage checks, disassembly, testing, and re-assembly procedures.

9. Onan GenSet Generator Service and Testing

Generator Description

Describes the generator design, components, and operation.

Stator and Housing Service

Details the construction and function of the generator's stator and housing.

Rotor Service

Explains the rotor's construction, field winding, and connection to the engine.

Generator Cooling System

Describes how the generator's cooling system functions using airflow.

Brushes and Brush Block Service

Covers the function and service of the generator brushes and brush block.

Electronic Voltage Regulator (VR1) Service

Explains the function and testing of the electronic voltage regulator.

Circuit Breaker (CB1) Service

Describes the circuit breaker's protective function for the generator's AC output.

Wiring Harness Service

Details the wiring harness connections and protection for the electrical system.

10. Engine Block Assembly Service and Leak Down Test

Engine Block Assembly Introduction

Covers service procedures for the engine block assembly, including leak down tests.

Leak Down Test Procedure

Procedure for performing a leak down test to determine engine condition and compression.

11. Onan GenSet Post-Service Checklist

General Service Checklist

General checks after service and reinstallation to ensure proper operation.

Mounting Checks

Verify secure mounting and proper tightening of all fasteners.

Lubrication Checks

Check and fill engine oil with recommended classification and viscosity.

Wiring Checks

Verify tight and properly installed wiring connections, checking for damage.

Initial Start Adjustment Precautions

Cautionary advice on disconnecting voltage/frequency-sensitive equipment before adjustments.

Fuel System Checks

Check fuel system for proper adjustment and leaks after service.

Output Check Procedure

Perform a load test to ensure the genset produces its full rated output.

Control System Checks

Verify proper functioning of the genset control and remote control.

Mechanical Checks

Inspect for leaks, loose fasteners, damage, and compartment integrity.

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