Service Manual - campkahler.com

1 RV Electric Generating Set (Spec A-C) Service Manual GenSets 940-0502 7-87 Printed In Redistribution or publication of this documentby any means, is strictly or publication of this documentby any means, is strictly Precautions Boforo oparatlng tho generator set, read the Operator's Manual and become familiar with it and the ui ment. Safe and rffldent oporation can ba achleved oqy 1 the unit Is pmpeq oporatod and maintained. Many accidents are caused y failure to follow fundamental rdes and precautions. The following symbols, found throughout this Manual , alert you to potentiall dangerousconditionsto theqmator, Service per- sonnel, or x e equipment. 77th sjmboi warns of immediate haz- ards which will result In sevete personal Injq or death.

2 IMWAANlNGI~fssym~lrefers to a hazard orunsafe practrce which can result in severe personal Injuty or death. IricAunoNj Thlssymbolrefers to a hazard or unsafe practice whlcb can msult in personal fnjuty orpmd- uct or propew d8mge. FUEL AND FUMES ARE FLAMMABLE. Fire. explosion, and personal injury can result from improper practices. DO NOT fill fuel tanks while engine is running. Fuel cork~ct with hot engine or exhaust is a potential fire hazard. DO NOTSMOKE OR USE AN OPEN FLAME nearthegen- erator set or fuel tank hnl lines must be dquatrly secund and free of leaks. Fuolconnoction at tlw eMne should be made with an ap- prowdllexjble,~uCtiveline. Donotusecopperpip- iq on floxible lines as copper will work harden and become bnttlr.

3 Bo sure dl fuel supplh haw a positivo shutoff valve. -LINE AND LPG FUEL MAY BE ACClDEMALLY IG NlED BY UECTRICALSPARKS, rwmtfngthr hazud of fin or oxp~on, w~ch an muR In mvw. pmona, In- luy M duth. Whm lnthlllng tho genorator Mt: Do not tk electrical wiring to fuel lines. Do not M electrid lines and fuel lines through the same mpartmont openings. Koep rkctrical and fuel lines as far apart as possible. Phco a physical bonier botwaen fuel lines and elsctn'cal Pnawinmfer possible. ll okchical and furl fines mud pass through the mo com- pubnont qning, make certain that they are physically sqamtod by rumingthem through indii channels, or by pusing oach lino through a separate piece of tubing. DO NOT SMOKE while soruicing batteries.

4 Lead aad bat- omit a highly oxplaSiv6 hyiimgen gas that can be g- dod by okctrical arcing or by smoking. EXHAUST GASES ARE DEADLY Now sloop in the vshido with the generator set Nnning un- kvohide is equipped with an operating carbon monoxide dasctor. e Provide an adeqde exhaust system to properly expel dis- charged gases. In exhaust system daily for leaks per am securo and not warped. Do mi use exhaust gases to heat a compartment. e Be sure the unit is well ventilated. JURY OR DEATH e Before starting work on the generator set, disconnect batter- th, maintenance Jz de. Ensure that exhaust manifolds MOVING PARTS CAN CAUSE SEVERE PERSONAL IN- ies. This will prevent acadental arcing. 0 Keep your hands away from moving parts.

5 0 Make sure that fasteners on the generator set are secure. Tighten supports and clamps. keep guards in position over fans, drive belts, etc. 0 Do not wear loose clothing or jewelry while working on gen- erator sets. Loose clothing and jewelry can become caught in moving parts. Jewelry can short out electrical contacts and cause shock or burning. e If adjustment must be made whilethe unit is running, use ex- treme caution around hot manifolds, moving parts, etc. ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH , Disconnect starb'ng battery before removing protective shields or touching electrical equipment Use rubber insula- tive mats placed on dry woad platforms over floors that are metal or concrete when around electrical equipment.

6 Do not wear dampclothing (particu1arlywetshoes)orallowskinsur- faces to be damp when handling electrid equipment. Use extreme caution when working on electrical compo- nents. High voltages can cause injury or death. Follow all state and local ekctrical des. Havo dl electrical installations perform4 by a qualied licensed electrician. Tag open switches to avoid accidental closure. DO NOT CONNECT GENERATOR SET DIRECTLY TO agescanflowfrom thegeneratorsotintotheutilityline. This creates a potential for electrocution oc pmporty damage. Con& only through an apprwed device and after building nuin switch is Consult an electriaan m regard to -rgsncyponnr-. ANY BUILDING ELECTRICAL SYSTEM. Hazard- vdt- 'GENERAL SAFl3Y PRECAUTDNS ~ave afire oxtinguisimr new.

7 ~aintainoxtinguistmr prOp edy and become familiar with its use. Extbrguishers rated ABC by the NFPA are appropriate for all appliations. Con- sdt the Id fire department for the correct type of extin- guisher for various applications. Hot coolants under prossure can cause sovom porsolwl in- juty. DONOTo~aradiatorpre~ruecepwtriktheengine is running. Stop the engine and carefdly bbd th. systom pnsue. Benzene and bad, found in mo gasoline, haw boon idon- Wkdbysane~eandf~eralagenciesas~ng~r or reproduCtive toxicity. When checking, draining or adding gasoline, take care not to ingest, breathe tha fumes, or con- tact gasdine. Used engine oils have been identified by 801110 st& or fad- ed agencies as causing cancer or reproductivb toxicity.

8 When checkjng or changing engine oil, take cam not to in- gest. breathe the fumes, or contact used oil. Remove all unnecessary grease and oil unit. Accu- mulated grease and oil can cause overheating and engine damage, which presents a potential fire hazard. DO NOTstore anything in the generator compartment such as oil or gas cans, oily rags, chains, wooden blocks, portable propane cylinders, etc. A fire could result or tho generator set operation (cooling, noise and vibration) may be ad- versely affected. Keepthe compartment floor doan and dry. Do not work on this equipment when mentaliy or physically fatigued. or after consuming any alcohol or drug that makes the operation of equipment unsafe. I 1. RV-9 Redistribution or publication of this documentby any means, is strictly or publication of this documentby any means, is strictly 940-1039 Date: 8-85 Insert with - Ti NHE/NHEL Service Manual Number: 940-0502.

9 This supplement includes latest starter repair informa- tion for models NHE/NHEL RV gensets. FIGURE 1. 191-1667 STARTER =16M ELECTRIC STARTER The following procedures cover the disassembly and testing of electric starter. Disassembly Use the following procedure to remove and disassem- ble the starter. 1. Disconnect the generator set negative (-) battery 2. Disconnect the generator set positive (+) battery cable from the set starting battery. cable from the starter lug terminal. SUPPORT PLASTIC RETAINER WITH A VISE OR OTHER SOUD SURFACE USE CARE NOT TO HAVE SPRING RETURN ~__ ~ RETAINER & SUPPORT WHEN DRIVING OUT ROLL PIN. 3. Remove the starter mounting screws and then care- fully disengage the starter from the stator housing.

10 4. Remove starter through-bolts and carefully separ- ate the brush end cap housing and armature assembly. 5. Use a 1 /8 to 5/32 inch nail set to remove roll pin. Remove return spring, gear and clutch assembly as required. When reassembling always usea new roll pin. See Figure 2. n 5/32" lo 118 NAIL SET, "LEG" BETWEEN THE PLASTIC SOLID SUPPORT FIGURE 2. DRIVING ROLL PIN OUT 1 Redistribution or publication of this documentby any means, is strictly or publication of this documentby any means, is strictly Armature lor Grounds: Touch one ohmmeter lead to a commutator bar and then touch the other lead to armature shaft and core laminations. Alow resistance reading indicates a grounded armature. Replace grounded armature with a new part.