Operator Manual - Electric Generators Direct
Contents
1. NOTE Fault Code Nos 1 2 and 3 are first level faults Avoid interpreting them as second level Fault Codes 11 22 and 33 The pauses between repetitions of the fault code are longer than the pauses between the tens and units digits of the the code For example Fault Code 33 would appear as blink blink blink pause blink blink blink longer pause blink blink blink pause blink blink blink Restoring Fault Code Blinking The fault code stops blinking after five minutes Press Stop three times within five seconds to restore blinking Note that the last fault logged will blink even after the condition that caused the shutdown has been cor rected TABLE 4 TROUBLESHOOTING Some genset service procedures present hazards that can result in severe per sonal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions GENSET WON T STOP RUNNING STATUS INDICATOR LIGHT ON Faulty Stop Switch or grounded wiring Removing genset panels or disconnecting fuel lines to stop a genset that won t stop can lead to severe personal injury or death from electrocution contact with moving parts or fire Try the genset Stop Switch if the remote Stop Switch does not work and vice versa Otherwise let the genset run out of fuel GENSET WON T STOP RUNNING STATUS INDICATOR LIGHT OFF Binding governor mechanism misadjusted speed2. Corrective Action 1 Clean and tighten the positive and negative battery cable connections at the battery vehicle frame and genset Page 16 2 Recharge or replace the battery Refer to the battery manufacturer s recommendations ENGINE CRANKS BUT DOES NOT START Fuel delivery glow plugs or engine are marginal Corrective Action Check fuel level Note The genset fuel pickup is probably higher than the vehicle engine pickup Prime the engine fuel system by holding the control switch down in its Stop position for at least 1 min ute Check the engine air filter and remove any blockage Page 16 Replace Fuse F3 glow plugs if blown Page 6 STARTER ENGAGES DISENGAGES Cranking voltage dips below 6 volts low battery charge poor connections long cables Corrective Action Have the vehicle propulsion engine running while trying to start the genset the battery charging alternator may be able to maintain starting voltage high enough to get the genset started Clean and tighten the positive and negative battery cable connections at the battery vehicle frame and genset Page 16 Recharge or replace the battery Refer to the battery manufacturer s recommendations Increase battery cable size or run parallel cables NO POWER GENSET RUNNING RUN LIGHT ON Line circuit breaker OFF or tripped or faulty wiring Corrective Action Reset or turn On the line circuit breaker on the genset oper
3. Sparks can ignite battery gas causing severe personal injury Ventilate battery area before working on or near battery Wear safety glasses Do not smoke Switch trouble light ON or OFF away from bat tery Stop genset and disconnect charger be fore disconnecting battery cables Disconnect negative cable first and reconnect last Mechanical Look for mechanical damage Start the genset and look and listen for any unusual noises and vibra tions Check the genset mounting bolts to make sure they are secure Check to see that the genset air inlet and outlet openings are not clogged with debris or blocked Check the engine gauges from time to time while the genset is running if so equipped CHECKING ENGINE OIL LEVEL State and federal agencies have de termined that contact with used engine oil can cause cancer or reproductive toxicity Try to avoid skin contact and breathing of vapors Use rubber gloves and wash exposed skin Park the vehicle on level ground and shut off the genset before checking the engine oil level de Unscrew the oil fill cap pull out the dipstick and wipe off the oil Figure 5 Reinsert the dipstick screw the cap back on remove the dipstick again and check the oil level on the dip stick Add or drain oil as necessary See ENGINE OIL RECOMMENDATIONS Page 5 Keep the oil level between the FULL and ADD marks Too much oil can cause high oil consumption Too little oil can cause se
4. Sopingane GENS See ee ee ee 9 Restarting H GeNSEEAL A ee ee ee bee sede ees 9 Foadiiig the Genset gee cee ee eee eee ee eee ene eee menu 9 Resetting Circuit Breakers 10 Connecting to Utility Power 2 eee eee eee eee 10 Operating in Cold Weather 11 Operating in Hot Weather 0 ee eee eee eee eed 11 Operating at High Altitude 11 Operating in Dusty Environments 11 Breaking ina New Engine 2 5 R R Er AEE Te SREE TEREE S EERE EEE 11 Exercising the Genset eeaeee o e eaa a ue 11 Storing the Gensete ee o aa aa o n E E ni do 12 PERIODIC MAINTENANGES 2s a me ene tay tose 13 Conducting General Inspections ti or moe 14 Checking Engine Oil bevels atta RE uae acters Sears 15 Changing Engine Orland OnliRilter lt 4 au ee oo ate Gan ay ee ae Areas teat ee 16 Maintaining the Battery and Battery Connections 17 Replacing the Air Filter Element 1 4 2 17 Cleaningithe SparksArestOn eee Rte D sen us dc Sa eos 18 Replacingthe Fuel Filter ese n co co 19 Chang OO ean ar ee caer pee ee eee ere eee ee 20 TROUBLESHOOTING reagent seen rete re eae eee ees pret eee eae 22 SPECIFICATIONS E E 31 INFORMATION FOR CALIFORNIA GENSET USERS 33 HOW TO OBTAIN SERVICE 5220880 wi
5. dusty conditions 3 Perform more often when operating in hot weather 4 Perform at least once a year 5 Perform at least once every two years 6 Perform at least once every five years 7 Must be performed by a qualified mechanic authorized Onan dealer 12 CONDUCTING GENERAL INSPECTIONS Inspect the genset before the first start of the day and after every eight hours of operation Oil Level Check engine oil level Page 14 Engine Coolant System CAUTION Operating the genset when coolant level is low can cause serious engine damage Check the coolant level and look for coolant leaks around the bottom of the genset and on the ground below Minor leaks that can be replenished by daily additions of coolant to the recovery tank should be repaired by a qualified service technician as soon as possible Larger leaks are cause for shutting down the genset until it can be repaired Exhaust System EXHAUST GAS IS DEADLY Do not operate the genset if there is an exhaust leak or any danger of exhaust gases entering or being drawn into the vehicle Look and listen for exhaust system leaks while the genset is running Shut down the genset if a leak is found and have it repaired before operating the gen set again Look for openings or holes between the genset compartment and vehicle cab or living space if the genset engine sounds louder than usual Have all such openings or holes closed off or sealed to pre ven
6. monoxide an odorless colorless gas Carbon monoxide is poisonous and can cause unconsciousness and death Symptoms of carbon monoxide poisoning include e Dizziness e Throbbing in Temples e Nausea e Muscular Twitching e Headache e Vomiting e Weakness and Sleepiness Inability to Think Clearly IF YOU OR ANYONE ELSE EXPERIENCES ANY OF THESE SYMPTOMS GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist seek medical attention Shut down the genset and do not op erate it until it has been inspected and repaired Never sleep in the vehicle with the genset running unless the vehicle is equipped with a working car bon monoxide detector Primary protection against poisoning due to inhaling carbon monoxide how ever consists of proper installation of the exhaust system and inspections every day every eight hours of operation for visible and audible exhaust system leaks CONDUCTING THE PRE START CHECKS 1 Push and hold the switch at START until the genset starts The status indicator light on the Before the first start of the day and after every eight switch flashes during preheat and cranking It hours of operation inspect the genset as instructed will come on solid when the starter disconnects under CONDUCTING GENERAL INSPECTIONS indicating that the genset is running Depend Page 13 Keep a log of maintenance and the hours ing on how cold it is preheat can take up to 15 run and perform any maintenance that may be due seconds extend
7. s 2 pole 30 amp 2 pole 30 or 35 amp 2 pole 30 or 35 amp ENGINE 3 Cylinder In Line Water Cooled Indirect Injection 4 Stroke Cycle Diesel 2 64 inch 67 mm No load 13 gph 49 I h 13 gph 49 I h 13 gph 49 I h Half load 4000 W 49 gph 1 85 l h 49 gph 1 85 l h 49 gph 1 85 l h Full load 80 gph 3 03 I h 96 gph 3 63 I h 1 02 gph 3 86 I h DC SYSTEM Mini 450 CCA down to 0 F 17 C Weight wet 420 Ibs 191 kg Length x Width x Height 36 3 x 23 6 x 22 3 inch 922 x 599 x 566 mm i See oil filling instructions Includes coolant recovery tank k Cold Cranking Amps 0 F 17 C 31 Information for California Genset Users These gensets meet the requirements of Californi a s Exhaust Emissions Standards as stated on the nameplate Page 3 As a California user of these gensets please be aware that unauthorized modifications or replace ment of fuel exhaust air intake or speed control system components that affect engine emissions are prohibited Unauthorized modification removal or replacement of the genset label is prohibited You should carefully review Operator Owner Installation and other manuals and information you receive with your genset If you are unsure that the installation use maintenance or service of your genset is authorized you should seek assistance from an approved Onan dealer California genset users may use Table 5 as an aid in locating informatio
8. 34 F 37 C Replace the coolant every two years Use ethylene or propylene glycol anti freeze solution that con tains a rust and corrosion inhibitor The anti freeze should not contain a stop leak additive The water used for engine coolant should be clean low in minerals and free of corrosive chemicals Use distilled water if available The cooling system has a 4 2 quart 4 capacity Pressure Cap Replace the pressure cap Figure 10 every two years because its seals can deteriorate and begin to leak Proper cooling system pressure is essential for optimal engine cooling and minimal coolant loss Draining the Cooling System Hot coolant spray can cause severe burns Let the engine cool before releasing the pressure cap or removing the drain cap Allow the engine to cool before removing the pres sure cap Then relieve any remaining pressure by turning the pressure cap slowly without pushing down on it until it catches When the pressure has been relieved remove the pressure cap by pushing 19 down and turning it until it can be withdrawn Then get a suitable container and drain the coolant by re moving the system drain cap Figure 10 Ethylene glycol antifreeze is con sidered toxic Dispose of it according to local regulations for hazardous substances It is recommended that the system be cleaned and flushed before refilling Radiator cleaning chemicals are available at local auto parts stores Follow the
9. Cummins Onan Cummins Power Generation 1400 73rd Ave NE Minneapolis MN 55432 USA Phone 1 763 574 5000 Toll free 1 800 888 6626 Fax 1 763 574 5298 Email www cumminsonan com contact www cumminsonan com Cummins Onan the C logo and Performance you rely on are trademarks of Cummins Inc 2010 Cummins Power Generation Inc All rights reserved
10. EN ERAL INSPECTIONS Page 13 Push the genset line circuit breaker ON Page 9 when the genset is ready to power appliances Periodic Maintenance Periodic maintenance is essential for top perfor mance and long genset life Use Table 3 as a guide for normal periodic maintenance In hot and dusty environments some maintenance procedures should be performed more frequently as indicated by the footnotes in the table Keeping a log of main tenance performed and hours run Page 34 will help you keep genset maintenance regular and pro vide a basis for supporting warranty claims Maintenance replacement or repair of emission control devices and systems may be performed by any engine repair establishment or individual How ever warranty work must be completed by an au thorized Onan dealer TABLE 3 PERIODIC MAINTENANCE SCHEDULE MAINTENANCE PROCEDURE MAINTENANCE FREQUENCY After First 50 Hours eereainsoaion cresttroneoiteet sf crest Erone Cosette x Geen ns crece DE Change Engine Oil and Filter Clean Spark Arrestor Replace Engine Air Filter Replace Fuel Filter Flush Coolant System Replace Coolant Pressure Cap Le Replace Engine V belt Clean Crankcase Breather Replace Coolant Hoses and Thermostat Check Coolant Anti freeze Protection REA eres 1 1 As a part of engine break in change the engine oil after the first 50 hours of operation 2 Perform more often when operating in
11. IPE FLANGE NOT VISIBLE FUEL RECOMMENDATIONS Diesel fuel is combustible and can cause severe personal injury or death Do not smoke near diesel fuel tanks or equipment Keep flames sparks pilot lights electrical arcs switches and arc producing equipment and all other sources of ignition well away Keep a type ABC fire extinguisher in the vehicle Use clean fresh No 2 diesel fuel ASTM 2 D when the outdoor ambient temperature is above freezing and No 1 diesel fuel ASTM 1 D when below freez ing The fuel should have a Cetane number of at least 45 for reliable starting ENGINE OIL RECOMMENDATIONS Use API American Petroleum Institute perfor mance Class CH 4 CG 4 or CF 4 engine oil which may be in combination with performance Class SJ SH or SG for example CH 4 SJ Also look for the SAE Society of Automotive Engineers viscosity grade Referring to Chart 1 choose the viscosity grade appropriate for the outdoor ambient tempera tures expected until the next scheduled oil change STARTING BATTERIES These gensets have a 12 volt direct current DC starting and control system See Specifications Page 30 for minimum battery requirements cold cranking amperes for genset starting Regular monthly maintenance of batteries may be required See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Page 16 and any in structions available from the vehicle manufacturer or battery manufacturer Either the vehicle or t
12. Operator Manual Cummins Onan Performance you rely on RV Generator Set HDKAH HDKAJ HDKAK HDKAT HDKAU HDKAV Spec A M Spec A M Spec A M Spec A M Spec A M Spec A M PP ee ee A mm ee A m English Original Instructions 5 2010 981 0161 Issue 7 California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm A WARNING A Do not use this genset on a boat Such use may violate U S Coast Guard regulations and can result in severe personal injury or death from fire electrocution or carbon monoxide poisoning diesel warnings Table of Contents SAFETY PRECAUTIONS 32 sas meute manne des tes peace eee 2 INTRODUCTION co scare SE EE E a E E E aa 4 About This MaQua T ee eee 4 Model Identificator ee ee 4 TypicaliGenso tmerr D E 5 FuellRecommendations ee ee a T 6 EnginetolRecommendations eee Tenn OS maueeueeeeieeee 6 StaningiBatene Smee o a Hie nentehana aig nesnar aeuere 6 OperatonsiConso em aeae TS Mee oa otc ho mae wea es 7 HMOCICOMOBPAN REERRST SR dlenmenret re einem cesta tae 7 OPERATION eer B actin e SERS ieee cer ea ee eres 8 Conducting the Pre Start Checks 8 priming thesmuel system We RU a 8 SiaingtieGernsehes Ten Beeereee errs eoee eeneers reer meen eG eeeey creae re 8
13. Remove battery cables with a battery terminal puller 3 Make sure which terminal is positive and which is negative before making battery connections always removing the negative cable first and reconnecting it last to reduce arcing REPLACING THE AIR FILTER ELEMENT Refer to Table 3 for scheduled air filter element re placement In dusty environments the filter element should be inspected and changed more frequently To change the filter element Figure 7 remove the outer and inner cover and reassemble with a new air filter element Turn the inner cover wingnut three to four clicks past seating Make sure the outer cover is seated before tightening its wingnut Check for noise when the genset is running and retighten if necessary SPACER SEAL HOUSING FIGURE 7 REPLACING THE AIR FILTER ELEMENT 16 CLEANING THE SPARK ARRESTOR fler accessible through the air outlet opening in the bottom of the genset Clean out the spark arrestor Refer to Table 3 for scheduled cleaning ofthe spark muffler as follows arrestor muffler which meets U S Forest Service requirements Cleaning is required for maximum 1 Remove the cleanout plug from the muffler genset performance Figure 8 2 Restart the genset and load it nearly to full pow A hot muffler can cause severe er See LOADING THE GENSET Page 8 burns Let the muffler cool down before remov Let the genset run for about five minutes to ex ing or installing the cleano
14. aring ventilation with fuel tanks or equip ment Keep flames sparks pilot lights arc pro ducing equipment and all other sources of igni tion well away Fuel lines must be secured free of leaks and separated or shielded from electrical wiring MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH e Disable the automatic genset starting fea ture AGS of an inverter charger or other auto matic starting device before servicing the gen set to avoid unexpected starting e Do not wear loose clothing or jewelry near mov ing parts such as PTO shafts fans belts and pulleys e Keep hands away from moving parts BATTERY GAS IS EXPLOSIVE e Wear safety glasses e Do not smoke e To reduce arcing when disconnecting or recon necting battery cables always disconnect the negative battery cable first and reconnect it last FLAMMABLE VAPOR CAN CAUSE A DIESEL ENGINE TO OVERSPEED Flammable vapor can cause a diesel engine to overspeed and become difficult to stop resulting in possible fire explosion severe personal injury and death Do not operate a diesel powered genset where a flammable vapor environment can be created by fuel spill leak etc The owners and op erators of the genset are solely responsible for oper ating the genset safely GENERAL PRECAUTIONS e Keep children away from the genset e Do not use evaporative starting fluids They are highly explosive e To prevent accidental or remote starting whi
15. ater than 17 5 volts Corrective Action 1 Check battery bank connections and reconnect if necessary so that the 12 volt batteries serving the genset are connected in parallel 12 volt rather than in series 24 volt 2 Select a lower battery booster charge rate OVERSPEED FAULT CODE NO 31 Engine speed greater than 3600 rpm Corrective Action See an authorized Onan dealer LOW CRANKING SPEED FAULT CODE NO 32 Cranking speed less than 180 rpm for more than 2 seconds Corrective Action Replace Fuse F2 starter solenoid if blown Page 6 Clean and tighten the positive and negative battery cable connections at the battery and at the genset Page 16 Recharge or replace the battery Refer to the battery manufacturer s recommendations Replace the engine oil with oil of proper viscosity for the ambient temperature Page 15 High oil viscosity can slow cranking speed HIGH ENGINE COOLANT TEMPERATURE FAULT CODE NO 33 Engine coolant temperature exceeded design limit Corrective Action Check the engine coolant level and add coolant and repair leaks as necessary Page 19 Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset Reduce the number of appliances connected at the same time Note that high altitude and high am bient temperature decrease engine cooling capacity Clean and flush the cooling system to remove coolant passage fouling I
16. ator s console GENSET HUNTS UNDER FULL LOAD Fuel delivery marginal governor misadjusted Corrective Action Prime the engine fuel system by holding the control switch down in its Stop posi tion for at least 1 minute 23 TABLE 4 TROUBLESHOOTING CONT Some genset service procedures present hazards that can result in severe per sonal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions HIGH TEMPERATURE FAULT CODE NO 1 Engine coolant or inverter heat sink temperature exceeded design limit Corrective Action Check the second level fault code by touching Stop The second level fault will be either No 33 or No 34 LOW OIL PRESSURE FAULT CODE NO 2 Low oil pressure cutoff switch did not open Corrective Action 1 Check engine oil level and add oil as necessary Page 14 2 Drain excess oil above dipstick Full mark SERVICE CHECK FAULT CODE NO 3 A second level fault occurred Corrective Action Check the second level fault code by touching Stop The second level fault will be one of the following in this table OVERLOAD CODE NO 8 Models HDKAH amp HDKAV only Load exceeded110 percent of genset rating for 2 minutes Corrective Action Reduce load and restart OVERCURRENT FAULT CODE NO 11 AC output short Corrective Action 1 Turn off the genset line circuit breaker If the gens
17. codes and regulations Keep guards in place over fans belts pulleys and other moving parts Introduction ABOUT THIS MANUAL This manual covers the operation and maintenance of the generator set genset models on the front cover Study this manual carefully and observe all of its instructions and precautions Keep this manual and the genset Installation Manual with the other ve hicle manuals Operation Periodic Maintenance and Trouble shooting provide the instructions necessary for op erating the genset and maintaining it at top perfor mance The owner is responsible for performing maintenance in accordance with the PERIODIC MAINTENANCE SCHEDULE Page 12 This manual also includes genset specifications infor mation on how to obtain service and information for California users This genset is not a life support sys tem It can stop without warning Children per sons with physical or mental limitations and pets could suffer personal injury or death A per sonal attendant redundant power or an alarm system must be used if genset operation is criti cal MODEL IDENTIFICATION When contacting an Onan dealer for parts service or product information be ready to provide the mod el and serial numbers on the genset nameplate Fig ure 1 illustrates the nameplate and its location The numbers in the gray boxes are typical model and se rial numbers Every character in these numbers is significant The last character o
18. condition ers are cycling on and off Maximum power decreases as altitude increases because air density decreases For every 1000 foot 305 m increase in elevation you can expect power to decrease approximately 3 percent Table 2 shows the results of typical calculations It may be necessary to run fewer appliances at higher alti tudes TABLE 1 TYPICAL APPLIANCE LOADS Coffee Percolator Television Radio Electric Drill Electric Broom 200 500 Electric Blanket 50 200 Appliance Air Conditioner Battery Charger DC Converter Refrigerator Microwave Oven Electric Frying Pan or Wok Electric Stove Element Electric Water Heater Electric Iron Electric Hair Dryer TABLE 2 POWER VS ALTITUDE Elevation above Mean Sea Level up to 500 ft 152 m 2500 ft 762 m Max Genset Power Max Genset Power 7500 watts rated 8000 watts rated 7050 watts 7520 watts 6375watts 6800watts 5500 ft 1676 m 6375watts minus 6800watts minus 225 watts ev 240 watts ev ery1000 ft ery1000 ft 305 m 305 m This table does not take into account the effect cir cuit breakers may have in limiting maximum power Commercial Genset Applications Maximum genset power nameplate rating is 7500 watts in an ambient of 85 F 29 C but only 6000 watts in an ambient of 120 F 50 C the maximum operating temperature Also continuous operation at up to 80 percent of maximum power 6000 watts is acceptabl
19. d contact an authorized Onan dealer See How to Obtain Service Page 33 First note the following e Maintaining engine oil level keeping battery connections clean and tight watching the fuel gauge not overloading the genset etc will prevent most shutdowns e When the genset and vehicle engine share a common fuel tank the fuel dip tubes are usual ly arranged so that the genset will run out of fuel first Marking the genset empty point on the fuel gauge will make it easier to tell when to stop the genset before running it out of fuel First Level Fault Codes The genset controller provides extensive diagnostics by causing the sta tus indicator light on the Control Switch to blink ina coded fashion Following a fault shutdown the indi cator light will repeatedly blink 1 2 or 3 blinks ata time e One blink indicates shut down due to high tem perature 21 e Two blinks indicates shutdown due to a loss of engine oil pressure e Three blinks indicates shutdown due to some other abnormal condition Second Level Fault Codes For a 1 blink or 3 blink first level fault code one touch to Stop brings up a second level fault code This code consists of 1 2 3 or 4 blinks a brief pause and then 1 to 9 blinks The first set of blinks represents the tens digit and the second set of blinks the units digit of the fault code number For example Fault Code No 23 would ap pear as blink blink pause blink blink blink
20. der GENERATORS ELECTRIC ENGINES GASOLINE OR DIESEL or RECREATIONAL VEHICLES EQUIPMENT PARTS AND SERVICE 3 Call 1 800 888 ONAN for the name and tele phone number of the nearest Onan dealer in the United States or Canada This automated service utilizes touch tone phones only By calling this number you can also request a di 33 rectory of authorized RV servicing dealers RV Sales and Service Directory F 919 To get service contact the authorized dealer or dis tributor nearest you explain the problem and make an appointment If you have difficulty in arranging for service or resolving a problem please contact the dealer coordinator or service manager at the nearest Onan dealer for assistance Before calling for service have the following infor mation available 1 The complete genset model number and serial number See Model Identification Page 4 2 The date of purchase 3 The nature of the problem See Troubleshoot ing Page 21 Improper service or replacement of parts can result in severe personal injury death and or equipment damage Service personnel must be qualified to perform electrical and or mechanical service Maintenance Record Record all periodic and unscheduled maintenance and service See Periodic Maintenance Page 12 HOUR DATE METER MAINTENANCE OR SERVICE PERFORMED READING Record the name address and phone number of your authorized Onan service center 34
21. e Appliance load and genset power are measured in terms of watts W or kilowatts kW where 1 kilowatt kW 1000 watts W RESETTING CIRCUIT BREAKERS If a circuit breaker in the main power distribution panel of the vehicle or on the genset Figure 4 trips either a circuit shorted or too many appliances were running Note that the genset will continue to run af ter a circuit breaker trips If a circuit breaker trips disconnect or turn off as many loads as possible and reset the circuit break er Push the circuit breaker to OFF to reset it and then to ON to reconnect the circuit If the circuit breaker trips right away either the electrical dis tribution system has a short or the circuit breaker is faulty Call a qualified electrician If the circuit breaker does not trip reconnect the ap pliances one by one up to a total load that does not overload the genset or cause the circuit breaker to trip If a circuit breaker trips right away when an ap pliance is connected the appliance probably has a short Electrical appliances and tools must be used and maintained properly and be properly grounded to cause the line circuit breakers to trip when short cir Cuits occur Short circuits in electrical ap pliances and tools can cause fire and electrical shock leading to severe personal injury or death Read and follow the equipment and tool manufacturer s instructions and warnings re garding use maintenance and prope
22. e air conditioner and other large ap pliances and let the genset run for two minutes to cool down Then press the switch to STOP to stop the genset RESTARTING THE GENSET See Troubleshooting Page 21 if the genset shuts down abnormally LOADING THE GENSET The genset can power AC motors air conditioners AC DC converters battery chargers and other ap pliances How much appliance load can be pow ered depends upon the genset power rating The genset will shut down or its circuit breakers will trip if the sum of the loads exceeds genset power If the genset shuts down the status light will probably dis play Fault Code No 11 13 22 or 38 See Trouble shooting Page 21 To avoid overloading the genset and causing shut downs compare the sum of the loads of the ap pliances that are likely to be used at the same time to the power rating of the genset Use Table 1 or the ratings on the appliances themselves if so marked to obtain the individual appliance loads It may be necessary to run fewer appliances at the same time the sum of the loads must not be greater than genset rating The genset may shut down due to overload when a large motor or air conditioner is started or cycles off and then on again even though the sum of the loads is less than genset rating The reason for this is that a motor s startup load is much larger than its running load It may be necessary to run fewer ap pliances when large motors and air
23. e vie eel ee eh nee 34 MAINTENANCE RECORD 2005 cess ee kb ee ea we ee ee ee eine 35 Safety Precautions Thoroughly read the OPERATOR S MANUAL before operating the genset Safe operation and top performance can only be obtained when equipment is operated and maintained properly The following symbols in this manual alert you to po tential hazards to the operator service person and equipment alerts you to an immediate hazard that will result in severe personal injury or death alerts you to a hazard or unsafe practice that can result in severe personal injury or death alerts you to a hazard or unsafe practice that can result in personal injury or equipment damage When equipped with an integral or add on Auto matic Generator Starting System AGS control ex haust carbon monoxide CO electric shock and moving parts hazards are possible due to unex pected starting Turn off AGS whenever performing maintenance or service when the vehicle is stored between uses is awaiting service or is parked in agarage or other confined area Electricity fuel exhaust moving parts and batteries present hazards which can result in severe personal injury or death ENGINE EXHAUST IS DEADLY e Inspect for exhaust leaks at every startup and after every eight hours of running e Learn the symptoms of carbon monoxide poi soning in the Operator s Manual e Never sleep in the vehicle while the genset is running unless the
24. et no longer shuts down the genset is probably okay check for and repair a short circuit in the vehicle appliances wiring or shorted battery charger transformer Check whether the vehicle engine and genset share the same starting battery If so and this fault occurs when cranking the vehicle engine low battery voltage may be causing this shutdown In crease battery capacity or install a separate battery and battery charging system for the genset 24 TABLE 4 TROUBLESHOOTING CONT Some genset service procedures present hazards that can result in severe per sonal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions INVERTER OVERVOLTAGE FAULT CODE NO 12 Controller not able to regulate to rated voltage Corrective Action Check whether the vehicle engine and genset share the same starting battery If so and this fault occurs when cranking the vehicle engine low battery voltage may be causing this shutdown Increase battery capacity or install a separate battery and battery charging system for the genset INVERTER UNDERVOLTAGE FAULT CODE NO 13 Controller not able to regulate to rated voltage Corrective Action Check whether the vehicle engine and genset share the same starting battery If so and this fault occurs when cranking the vehicle engine low battery voltage may be causing this shutdown Increase batter
25. f the genset is not so equipped 29 Specifications HDKAH HDKAJ HDKAK GENSET CONTROLLER Integrated Microprocessor Based Engine and Generator Controller GENERATOR Brushless Exciterless Bearingless Permanent Magnet Alternator Crimes CC CY Line Circuit Breaker s 2 pole 30 amp 2 pole 30 or 35 amp 2 pole 30 or 35 amp ENGINE 3 Cylinder In Line Water Cooled Indirect Injection 4 Stroke Cycle Diesel PFUELCONSUMPTION OOOO FUEL CONSUMPTION No load 13 gph 49 I h 13 gph 49 I h 13 gph 49 I h Half load 4000 W 49 gph 1 85 l h 49 gph 1 85 l h 49 gph 1 85 I h Full load 80 gph 3 03 I h 96 gph 3 63 I h 1 02 gph 3 86 I h es Nominal Battery Voltage 12 volts 450 CCA down to 0 F 17 T 650 CCA down to 20 F 29 C Sr Fuse F1 control circuit 10 ampere mini bayonet Weight wet 420 Ibs 191 kg Length x Width x Height 36 3 X 23 6 x 22 3 inch 922 x 599 x 566 mm See oil filling instructions Includes coolant recovery tank Cold Cranking Amps 0 F 17 C Minimum Battery Capacity 30 RE EE HDKAT HDKAU GENSET CONTROLLER Integrated Microprocessor Based Engine and Generator Controller GENERATOR Brushless Exciterless Bearingless Permanent Magnet Alternator AC OUTPUT RATINGS Power 1 0 power factor 6000 W 7500 W 8000 W 120 vols 120 volts 120 vols Frequency Number of Phases 500 ampere 625 ampere 66 7 ampere Line Circuit Breaker
26. f the genset overheats only underway see the coach manufacture regarding air baffles or other means to direct cooling air into the genset 27 TABLE 4 TROUBLESHOOTING CONT Some genset service procedures present hazards that can result in severe per sonal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions HIGH INVERTER TEMPERATURE FAULT CODE NO 34 Inverter heat sink temperature exceeded design limit Corrective Action 1 Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset 2 Reduce the number of appliances connected at the same time Note that high altitude and high am bient temperature decrease cooling capacity CONTROL CARD FAILURE FAULT CODE NO 35 Microprocessor EEPROM error during self test Corrective Action See an authorized Onan dealer ENGINE STOPPED FAULT CODE NO 36 Engine stopped without command by controller Corrective Action Check fuel level Note The genset fuel pickup is probably higher than the vehicle engine pickup Prime the engine fuel system by holding the control switch down in its Stop position for at least 1 min ute Check the engine air filter and remove any blockage Page 16 Check for mechanical damage INVALID GENSET CONFIGURATION FAULT CODE NO 37 Genset configuration is preprogrammed at the fact
27. f the model number is the specification letter which is important for ob taining the right parts Record the model and serial numbers in the boxes in Figure 1 so that they are easy to find when you need them IMPORTANT ENGINE INFORMATION CUMMINS POWER GENERATION OREN 1400 73rd Ave NE Minneapolis MN 55432 Model No 80HDKAK11454J Made in USA AC Volts Amps Fuel Options Wiring Diagram Insulation NEMA Class F Ambient 40 C THIS ENGINE MEETS 1995 1999 CALIFORNIA EMISSION REGULATIONS FOR ULGE ENGINES SKB719U6D2RA 719 cc REFER TO OPERATOR S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS 99 2495 URC RECORD NUMBERS HERE MODEL NUMBER SERIAL NUMBER FIGURE 1 TYPICAL NAMEPLATE TYPICAL GENSET The operator s console the components requiring attention during periodic maintenance and other AC TERMINAL BOX COVER features of a typical genset are shown in Figure 2 See the PERIODIC MAINTENANCE SCHEDULE Page 12 OPERATOR S CONSOLE ACCESS DOOR FOR OIL AND FUEL FILTERS OIL DRAIN PLUG COOLING AIR LE _G GRILLE ACCESS TO COOLANT AIR FILTER DRAIN CAP WARM AIR DISCHARGE OPENING FIGURE 2 TYPICAL GENSET LIFTING EYE ACCESS COVER FUEL CONNECTIONS BATTERY CONNECTIONS EXHAUST TAILP
28. he genset will be equipped with a battery charger Reliable genset starting and starter service life de pend upon adequate battery system capacity and proper maintenance CHART 1 OIL VISCOSITY VS TEMPERATURE 30 I 15W40 i 5W30 DOI I I I a 32 OF 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 0 OC 34 29 23 18 12 7 1 4 16 21 27 32 38 43 48 Anticipated Ambient Temperature OPERATOR S CONSOLE The operator s console Figure 3 has the following features Control Switch This switch is used to start and stop the genset prime the engine fuel system and restore the fault code blinking status light Status Light This is an LED light emitting diode in the control switch which blinks rapidly during pre heat and cranking Preheat is the period of time prior to engine cranking when the glow plugs pre heat the combustion chambers The time is auto matically varied by the genset controller on the ba sis of engine temperature After the genset starts up this light stays on continuously indicating that the genset is running and that the starter has dis connected Also if the genset shuts down this light blinks in a coded fashion to indicate the nature of the shutdown see Troubleshooting Page 21 Line Circuit Breaker s The line circuit break er s protect the AC power leads connected to the genset Engine Oil Fill Cap Dipstick The oil dipstick is a
29. ing the time that the light See Returning the Genset to Service Page 11 if blinks the vehicle has been in storage Excessive cranking can over heat and damage the starter motor Do not crank for more than 20 seconds at a time 1 Make sure all vehicle CO detectors are work Wait at least 2 minutes before trying again ing z 2 See Troubleshooting Page 21 if the genset 2 Check for signs of fuel and exhaust leaks and does not start after three tries for damage to the exhaust system Before each start 3 For top performance and engine life especially 3 Turn off the air conditioner and other large ap in colder weather let the engine warm up for pliances two minutes before connecting appliances PRIMING THE FUEL SYSTEM 4 Monitor the engine gauges if the remote panel is so equipped Normal readings during opera The fuel system should be primed after replacing tion are as follows the fuel filter or running the genset out of fuel To prime the fuel system hold the control switch down in its Stop position for at least 1 minute Temperature 160 220 F 71 104 C DC Voltage 14 15 volts 5 Check for fuel exhaust and coolant leaks Stop Start the genset from the genset control panel or re the genset immediately if there is a fuel ex mote control panel inside the vehicle haust or coolant leak and have it repaired Oil Pressure Approximate center of scale STARTING THE GENSET STOPPING THE GENSET Turn off th
30. instructions for cleaning and flushing that come with the cleaning solution Refilling the Cooling System Fill the recovery tank with coolant mixture to the COLD mark Secure the system drain cap Fill the cooling system with coolant mixture through the pressure cap fill opening Pull the hose connected to the pressure cap assembly out as far as it will go When coolant fills up to the fill opening start and operate the gen set for a few minutes and shut it down It is recom mended that the air conditioners or other large loads be turned on so that the genset will operate under load causing the engine to run faster and expel trapped air Add more coolant if necessary and se cure the pressure cap Coolant Level Check Check coolant level in the recovery tank Figure 10 before the first startup of each day and fill to the COLD mark if necessary PRESSURE CAP AND SYSTEM FILL OPENING COOLANT RECOVERY TANK FILL CAP BLUE COOLING SYSTEM DRAIN CAP FIGURE 10 ENGINE COOLING SYSTEM FILL AND DRAIN CAPS 20 Troubleshooting AWARNING Hot engine parts can cause severe burns Always allow the engine time to cool be fore performing any maintenance or service TABLE 4 TROUBLESHOOTING lists the Fault Codes in numerical order along with step by step instructions for corrective action If you fail to re solve the problem after taking the corrective actions suggeste
31. le working on the genset disconnect the nega tive battery cable at the battery Mobile 8 Let the engine cool down before removing the coolant pressure cap or opening the coolant drain Hot coolant under pressure can spray out and cause severe burns Keep the genset and its compartment clean Excess oil and oily rags can catch fire Dirt and gear stowed in the compartment can restrict cooling air Make sure all fasteners are secure and torqued properly Do not work on the genset when mentally or physically fatigued or after consuming alcohol or drugs You must be trained and experienced to make adjustments while the genset is running hot moving or electrically live parts can cause se vere personal injury or death Used engine oil has been identified by some U S state and federal agencies as causing cancer or reproductive toxicity Do not ingest inhale or contact used oil or its vapors Ethylene glycol used as engine antifreeze is toxic to humans and animals Clean up spills and dispose of used engine coolant in accor dance with local environmental regulations Keep multi class ABC fire extinguishers handy Class A fires involve ordinary combustible ma terials such as wood and cloth Class B fires combustible and flammable liquid fuels and gaseous fuels Class C fires live electrical equipment ref NFPA No 10 Genset installation and operation must comply with all applicable local state and federal
32. n related to the California Air Re sources Board requirements for emissions control TABLE 5 EMISSIONS CONTROL INFORMATION The California emissions control warranty statement is located in Genset Warranty Information the same packet of information as this manual when the genset is shipped from the factory Engine Valve Clearance Lash Engine Fuel Requirements Engine Lubricating Oil Requirements Engine Adjustments Engine Emission Control System 32 See Specifications Page 30 The engine is certified to operate on diesel fuel See FUEL REC OMMENDATIONS Page 5 See ENGINE OIL RECOMMENDATIONS Page 5 High Idle Speed This is a service procedure requiring trained personnel and proper tools See the Service Manual The engine emission control system consists of engine design and precision manufacture IFI How to Obtain Service When you need parts or service for your genset con tact the nearest authorized dealer or distributor Onan has factory trained representatives to handle your needs for genset parts and service To locate the nearest authorized distributor 1 Check the North American Sales and Service Directory F 118 and the International Sales and Service Directory IN 1013 supplied with your Onan genset These directories list autho rized distributors who will assist you in locating the nearest authorized dealer 2 Consult the Yellow Pages Typically our distrib utors are listed un
33. ory Corrective Action See an authorized Onan dealer OVERCURRENT FAULT CODE NO 38 Too many loads connected Corrective Action Reduce the number of appliances running at the same time especially those with high motor starting loads such as air conditioners Start up with no load and let the genset run for five minutes to cool down the inverter PROCESSOR FAULT CODE NO 42 Microprocessor ROM error during self test Corrective Action See an authorized Onan dealer 28 TABLE 4 TROUBLESHOOTING CONT Some genset service procedures present hazards that can result in severe per sonal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions PROCESSOR FAULT CODE NO 43 Microprocessor RAM error during self test Corrective Action See an authorized Onan dealer INVERTER POWER SUPPLY FAULT CODE NO 46 Low battery voltage or power supply device failure Corrective Action Avoid running the genset while cranking the vehicle engine in installations where the genset batteries are used to supplement the vehicle engine batteries Clean and tighten the positive and negative battery cable connections at the battery vehicle frame and genset Page 16 Recharge or replace the battery Refer to the battery manufacturer s recommendations Install or service a battery charging system in the vehicle i
34. r ground ing CONNECTING TO UTILITY POWER When the vehicle has provisions for connecting to utility power such as a cord for plugging into a pow er outlet receptacle it must also have an approved device to keep the genset and utility from being in terconnected See the genset Installation Manual for more information Interconnecting the genset and the public utility or any other power source can lead to the electrocution of personnel working on the utility lines damage to equipment and fire An approved switching device must be used to prevent interconnections LINE CIRCUIT BREAKER FIGURE 4 LINE CIRCUIT BREAKER OPERATING IN COLD WEATHER Make sure the engine oil viscosity is appropriate for the cold weather temperatures See ENGINE OIL RECOMMENDATIONS Page 5 Be sure to change the oil if a sudden drop in temperature oc curs OPERATING IN HOT WEATHER Pay particular attention to the following items when operating the genset in hot weather 1 Make sure nothing blocks airflow to and from the genset 2 Make sure engine oil viscosity is appropriate for the ambient temperatures See ENGINE OIL RECOMMENDATIONS Page 5 3 Keep the genset clean 4 Perform maintenance due See PERIODIC MAINTENANCE SCHEDULE Page 12 OPERATING AT HIGH ALTITUDE For the effect of altitude on maximum power see LOADING THE GENSET Page 8 OPERATING IN DUSTY ENVIRONMENTS Pay particular attention to
35. running fault Corrective Action See an authorized Onan dealer COOLANT TEMPERATURE SENDER FAULT CODE NO 24 Controller did not sense temperature change during first 5 minutes of operation Corrective Action See an authorized Onan dealer ENGINE ABOVE SPEED TARGET FAULT CODE NO 25 Governor unable to regulate to target speed Corrective Action See an authorized Onan dealer ENGINE BELOW SPEED TARGET FAULT CODE NO 26 Governor unable to regulate to target speed Corrective Action 1 Reduce the number of connected appliances especially when air conditioners and battery chargers are running 2 Prime the engine fuel system by holding the control switch down in its Stop position for at least 1 min ute PMA SENSE LOST FAULT CODE NO 27 Controller unable to sense PMA frequency Corrective Action See an authorized Onan dealer DC SENSE LOST FAULT CODE NO 28 Controller unable to sense DC bus voltage Corrective Action Open the circuit breaker If the fault does not persist check for and disconnect ex cessive loads from the genset before starting 26 TABLE 4 TROUBLESHOOTING CONT Some genset service procedures present hazards that can result in severe per sonal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions HIGH BATTERY VOLTAGE FAULT CODE NO 29 Voltage across battery system gre
36. sher handy FUEL FILTER Removing the Fuel Filter To remove the filter dis connect the two fittings at the filter and remove the mounting nut Apply a wrench on the filter fitting as well as on the flare nut so as not to stress the fitting Flare nut wrenches should be used on the flare nuts so as not to round the corners on the nuts Dispose of the fuel filter according to local regulations Installing the Fuel Filter Rotate the filter half a turn around its mounting stud if the fittings interfere with the bracket It only fits properly one way Connect the fuel fittings before tightening the filter mounting nut Take care not to crossthread the fuel fittings Thread them in by hand and tighten one flat past seating Close the access door and prime the fuel system by holding the control switch down in its Stop position for at least 1 minute Priming is necessary to dis place the air in the new filter with fuel FUEL HOSE TO ENGINE FILTER MOUNTING NUT TUBING FROM FUEL PUMP FIGURE 9 FUEL FILTER 18 CHANGING COOLANT Refer to Table 3 for scheduled maintenance The engine cooling system is filled with a 50 50 mixture of ethylene glycol anti freeze and water when the genset leaves the factory which is suitable for tem peratures down to
37. stop Removing genset panels or disconnecting fuel lines to stop a genset that won t stop can lead to severe personal injury or death from electrocution contact with moving parts or fire Let the genset run out of fuel STATUS INDICATOR LIGHT STAYS ON Reversed battery connections Corrective Action Reconnect the battery correctly Page 16 ENGINE CRANKS WHEN BATTERY CONNECTED Faulty Start Switch or grounded wiring Corrective Action See an authorized Onan dealer ENGINE WON T CRANK FUEL PUMP WON T STOP Faulty Stop Switch or grounded wiring Corrective Action See an authorized Onan dealer STATUS INDICATOR LIGHT DEAD Faulty connections no battery voltage Corrective Action Try the genset Start Switch if the remote Start Switch does not work and vice versa Replace Fuse F1 B if blown Page 6 Clean and tighten the positive and negative battery cable connections at the battery vehicle frame and genset Page 16 Recharge or replace the battery Refer to the battery manufacturer s recommendations 22 TABLE 4 TROUBLESHOOTING CONT Some genset service procedures present hazards that can result in severe per sonal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions STARTING BATTERIES RUN DOWN Marginal battery battery connections or charging system or parasitic loads
38. sture re lubri cates the engine replaces stale fuel and removes oxides from electrical contacts The result is better starting more reliable operation and longer engine life STORING THE GENSET Proper storage is essential for preserving top gen set performance and reliability when the genset cannot be exercised regularly and will be idle for more than 120 days Storing the Genset 1 Push the genset line circuit breaker OFF Page 9 Change the engine oil and attach a tag indicat ing oil viscosity See ENGINE OIL REC OMMENDATIONS Page 5 Disconnect the battery cables negative cable first from the starting battery and store the battery according to the battery manufac turer s recommendations See MAINTAINING THE BATTERY AND BATTERY CONNEC TIONS Page 16 Plug the exhaust tail pipe to keep out dirt mois ture bugs etc 11 5 Close the fuel supply valve if so equipped Returning the Genset to Service 1 Check the oil tag on the genset and change the oil if the viscosity indicated is not appropriate for the temperatures expected See ENGINE OIL RECOMMENDATIONS Page 5 Reconnect the starting battery negative cable last See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Page 16 3 Remove the plug from the exhaust tailpipe 4 Change the air filter element if it is dirty Page 16 5 Open the fuel supply valve if so equipped 6 Inspect the genset See CONDUCTING G
39. t tached to the fill cap and is marked ADD and FULL Coolant Recovery Tank Fill Cap The recovery tank provides for coolant expansion Replenish the normal loss of coolant by filling here Coolant Pressure Cap The coolant pressure cap is accessible by removing the access plate on the control console It provides for a pressurized engine cooling system Fill coolant here when refilling the system Fuses F1 F2 and F3 These fuses are accessible by removing the access plate on the control con sole They protect the control circuits of the genset Hour Meter Optional The hour meter records the total running time of the genset It cannot be re set REMOTE CONTROL PANEL The vehicle may be equipped with a remote control panel having a Control Switch and Preheat Diag nostics Light In addition it may have an hour me ter and the following engine gauges Oil Pressure Gauge The oil pressure gauge indi cates the presence of engine oil pressure Water Temperature Gauge The water tempera ture gauge indicates engine coolant temperature Voltmeter The voltmeter indicates battery volt age ACCESS COOLANT PLATE RECOVERY TANK OIL FILL CAP AND DIP STICK YELLOW FILL CAP BLUE ss s CONTROL SWITCH AND STATUS LIGHT HOUR METER OPTIONAL LINE CIRCUIT BREAKER FIGURE 3 OPERATOR S CONSOLE Operation EXHAUST GAS IS DEADLY Exhaust gases contain carbon
40. t exhaust gases from entering the vehicle Replace dented bent or severely rusted sections of the tailpipe and make sure the tailpipe extends at least 1 inch 25 4 mm beyond the perimeter of the vehicle Do not park the vehicle in high grass or brush Contact with the exhaust system can cause a fire Park the vehicle so that the genset exhaust gases can disperse away from the vehicle Barriers such as walls snow banks high grass and brush and oth er vehicles can cause exhaust gases to accumulate in and around the vehicle 13 Do not operate power ventilators or exhaust fans while the vehicle is standing with the genset run ning The ventilator or fan can draw exhaust gases into the vehicle Fuel System Check for leaks at hose tube and pipe fittings in the fuel supply system while the genset is running and while it is stopped Check flexible fuel hose sections for cuts cracks and abrasions Make sure the fuel line is not rubbing against other parts Replace worn or damaged fuel line parts before leaks occur Diesel fuel leaks can lead to fire Do not operate the genset if operation causes fuel to leak Battery Connections Check the battery terminals for clean tight connec tions Loose or corroded connections have high electrical resistance which makes starting harder See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Page 16 Arcing at battery terminals or in light switches or other equipment and flames or
41. the following items when operating the genset in dusty environments 1 Do not let dirt and debris accumulate inside the genset compartment Keep the genset clean 2 Perform air cleaner maintenance more often See PERIODIC MAINTENANCE SCHEDULE Page 12 10 3 Change engine oil more often See PERIODIC MAINTENANCE SCHEDULE Page 12 4 Keep containers of engine oil that have been opened tightly closed to keep out dust BREAKING IN A NEW ENGINE Proper engine break in on a new genset or on one with a rebuilt engine is essential for top engine per formance and acceptable oil consumption Run the genset at approximately 1 2 rated power for the first 2 hours and then at 3 4 rated power for 2 more hours See LOADING THE GENSET Page 8 Proper engine oil and oil level are especially critical during break in because of the higher engine tem peratures that can be expected Change the oil if not appropriate for the ambient temperatures during break in See ENGINE OIL RECOMMENDATIONS Page 5 Check oil level twice a day or every 4 hours during the first 24 hours of operation and change the oil and oil filter after the first 50 hours of operation EXERCISING THE GENSET Exercise the genset at least 2 hours each month if use is infrequent Run the genset at approximately 1 2 rated power See LOADING THE GENSET Page 8 A single two hour exercise period is bet ter than several shorter periods Exercising a genset drives off moi
42. ut plug pel the soot in the muffler The muffler is mounted inside the genset housing 3 Stop the genset allow the muffler to cool down The cleanout plug is located on the side of the muf and then reinstall the plug CLEANOUT PLUG FIGURE 8 SPARK ARRESTOR CLEANOUT PLUG 17 REPLACING THE FUEL FILTER Refer to Table 3 for scheduled replacement of the fuel filter Figure 9 A dirty fuel filter may be the cause if the engine fails to start The fuel filter is ac cessible through the maintenance access door in the skid base Squeeze the latches together to open the door Wipe dirt off the fuel hose connec tions at the fuel filter before disconnecting the hoses so as to keep dirt out of the fuel system Diesel fuel is combustible and can cause severe personal injury or death Do not smoke Keep flames sparks pilot lights electri cal arcs switches and arc producing equip ment and all other sources of ignition well away Keep a type ABC fire extingui
43. vehicle is equipped with a working carbon monoxide detector Do not operate the genset when the vehicle is in a confined space such as a garage Disable the automatic genset starting feature of an inverter charger or other automatic starting device before storing the vehicle or parking it in a garage or other confined space The exhaust system must be installed in accor dance with the genset Installation Manual Engine cooling air must not be used for heating working or living spaces or compartments GENERATOR VOLTAGE IS DEADLY Disable the automatic genset starting fea ture AGS of an inverter charger or other auto matic starting device before servicing the gen set to avoid electric shock from an unexpected Start Generator electrical output connections must be made by a trained and experienced electri cian in accordance with applicable codes The genset must not be connected to the public utility or any other source of electrical power Back feed could lead to electrocution of utility personnel and damage to equipment An ap proved switching device must be used to pre vent interconnections Use caution when working on live electrical equipment Remove jewelry make sure cloth ing and shoes are dry stand on a dry wooden platform or rubber insulating mat and use tools with insulated handles DIESEL FUEL IS COMBUSTIBLE Do not smoke or turn electrical switches ON or OFF where fuel fumes are present or in areas sh
44. ver tighten Close the access door making sure it latches securely Refill with 3 quarts 2 6 of oil See ENGINE OIL RECOMMENDATIONS Page 5 Check the oil level and add or drain oil as necessary Too much oil can cause high oil consumption Too little oil can cause severe engine damage Keep the oil level between the FULL and ADD marks Reinsert the dipstick and screw the oil fill cap back on securely Dispose of the used oil and oil filter in accor dance with local environmental regulations OIL FILTER OIL DRAIN PLUG FIGURE 6 OIL DRAIN PLUG AND OIL FILTER 15 MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Arcing at battery terminals or in light switches or other equipment and flames or sparks can ignite battery gas causing severe personal injury Ventilate battery area before working on or near battery Wear safety glasses Do not smoke Switch trouble light ON or OFF away from bat tery Stop genset and disconnect charger be fore disconnecting battery cables Disconnect negative cable first and reconnect last Refer to Table 3 for scheduled battery maintenance and follow the battery manufacturer s instructions Have the battery charging system serviced if DC system voltage is consistently low or high Always 1 Keep the battery case and terminals clean and dry and the terminals tight OUTER COVER INNER COVER FILTER ELEMENT 2
45. vere engine damage Keep the oil level between the FULL and ADD marks Reinsert the dipstick and screw the oil fill cap back on securely 14 FIGURE 5 CHECKING ENGINE OIL LEVEL CHANGING ENGINE OIL AND OIL FILTER State and federal agencies have de termined that contact with used engine oil can cause cancer or reproductive toxicity Avoid skin contact and breathing of vapors Use rub ber gloves and wash exposed skin Refer to Table 3 for scheduled engine oil change Change oil more often in hot and dusty environ ments 1 Run the engine until warm stop it and remove the oil fill cap and dipstick Figure 5 Place a pan underneath the genset and un screw the oil drain plug Figure 6 Let all oil drain from the engine Reinstall the oil drain plug and tighten it secure ly to prevent oil leakage Squeeze the access door latches together and let the door swing down Figure 6 Spin off the oil filter canister Thoroughly wipe off the filter mounting surface and remove the ACCESS DOOR 10 old gasket if it does not come off with the filter canister Make sure the new gasket is in place on the new filter canister and apply a thin film of oil to the gasket The replacement filter canister has a larger diameter than the original filter cannis ter but will fit Spin on the new filter canister by hand until the gasket just touches the mounting pad and then turn it an additional 1 2 to 3 4 turn Do not o
46. y capacity or install a separate battery and battery charging system for the genset INVERTER OVERFREQUENCY FAULT CODE NO 14 Controller not able to regulate to rated frequency Corrective Action Reduce the number of connected appliances especially when air conditioners and battery chargers are running INVERTER UNDERFREQUENCY FAULT CODE NO 15 Controller not able to regulate to rated frequency Corrective Action 1 Reduce the number of connected appliances especially when air conditioners and battery chargers are running 2 Have air conditioners and other appliances checked for proper operation A locked compressor ro tor can cause very low power factor GOVERNOR ACTUATOR FAULT CODE NO 19 Controller sensed open or short circuit Corrective Action See an authorized Onan dealer GOVERNOR ACTUATOR OVERLOAD FAULT CODE NO 22 Duration of operation at or near full duty cycle beyond design limit Corrective Action Reduce the number of connected appliances especially when air conditioners and battery chargers are running 25 TABLE 4 TROUBLESHOOTING CONT Some genset service procedures present hazards that can result in severe per sonal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions LOW OIL PRESSURE CUTOFF SWITCH FAULT CODE NO 23 Controller sensed switch still open during start not a
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