Operator Manual - Electric Generators Direct
Contents
1. FIGURE 3 3 SPARK ARRESTOR CLEANOUT PLUG 3 5 REPLACING THE FUEL FILTER See Table 3 1 for scheduled fuel filter replacement A dirty fuel filter may be the cause of a failure to start The fuel filter is accessible through the front access door Figure 3 4 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 switches arc producing equipment and all oth er sources of ignition well away Keep a type ABC fire extinguisher in the vehicle Close any fuel line shutoff valve before discon necting the fuel line from the filter Accidental or remote starting can cause severe personal injury or death Disconnect the nega tive cable at the battery to prevent starting while working on the genset Removing the Fuel Filter Use paper towels to clean the two fuel hose fittings and absorb any fuel that spills To disconnect the FILTER MOUNTING NUT HOSE FROM FUEL PUMP hoses use a flare nut wrench on the hose flare nuts so as not to round the corners and a second wrench on the filter fitting so as not to stress the fitting Re moving the bracket screws first will make the job easier Dirt can damage the fuel system Make sure to wipe dirt off the fuel hose fittings before disconnecting Dispose of the fuel filter and paper towels in accor dance with local regulations Installing the2. Replace the fuel filter p 3 6 OVER VOLTAGE CODE NO 12 After voltage regulation was enabled Output Voltage jumped to more than 125 of rated for 75 millisec onds or to more than 115 of rated for 3 seconds Corrective Action See an authorized Onan dealer 4 3 TABLE 4 1 TROUBLESHOOTING Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions UNDER VOLTAGE CODE NO 13 After voltage regulation was enabled Output Voltage fell to less than 90 of rated for 5 seconds Corrective Action Turn OFF the line circuit breaker on the operator s console If the genset now runs run it with fewer connected loads OVER FREQUENCY CODE NO 14 After the starter was engaged Frequency jumped to more than 70 Hz for 40 milliseconds or to more than 55 66 Hz 50 60 Hz rated for 6 seconds Corrective Action 1 Check for a tripped genset circuit breaker reset it if necessary and run with fewer connected loads A breaker tripping under load can cause genset frequency to overshoot 2 Check all fuel fittings for fuel and air leaks and tighten as necessary Reprime Air bubbles can disrupt frequency UNDER FREQUENCY CODE NO 15 During normal operation Frequency fell to less than 44 54 Hz 50 60 Hz rated for more than 8 second
3. ING PARTS and ELECTRICITY can cause severe personal injury or death To reduce exposure to these hazards always disable automatic genset starting before e Sleeping in vehicle unless vehicle has a working CARBON MONOXIDE detector e Parking vehicle in garage or confined space e Parking vehicle for storage e Servicing genset e Servicing batteries Servicing electrical appliances e Fueling vehicle 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 See Section 4 Troubleshooting 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 2 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
4. It may be necessary to run fewer ap pliances when large motors and air 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 5 percent See Table 2 2 It may be necessary to run fewer ap pliances at higher altitudes TABLE 2 1 TYPICAL APPLIANCE LOADS 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 Coffee Percolator Television 50 200 Electric Drill Electric Broom Electric Blanket TABLE 2 2 POWER VS ALTITUDE Altitude Elevation above Sea Level at below 500 ft 152 m at 2500 ft 762 m at 5500 ft 1676 m 8250 W minus 350 W every 1000 ft 305 m above 5500 ft 1676 m Maximum Power Maximum Power 10 000 W genset rating 12 500 W genset rating 9300 W 11 620 W 8250 W 10 300 W 10 300 W minus 440 W every 1000 ft 805 m Appliance load and genset power are measured in terms of watts W or kilowatts kW where 1 kilowatt kW 1000 watts W 2 5 RESETTING CIRCUIT BREAKERS If a circuit breaker in the main power distribution panel of the vehicle or on the genset Figure 2 2 trips either a circuit shorted or too many appliances were running Note that the genset will continue to ru
5. 12 volts Minimum Battery Capacity CCA Cold Cranking Amps 475 amps down to 0 F 17 C 650 amps down to 20 F 29 C Battery Recharging Installer must provide for battery charging WEIGHT 775 Ibs 351 kg 794lbs 360 kg SIZE L x W x H 41 4 x 24 5 x 27 in 105 x 62 x 68 6 cm SOUND LEVEL 68 dB A 10 ft 3m amp 54 dB A 50 ft 15m in free field site half load 6 Maintenance Record Record all periodic and unscheduled maintenance and service See Section 3 Periodic Maintenance HOUR METER MAINTENANCE OR SERVICE PERFORMED aaa Record the name address and phone number of your authorized Onan service center 6 1 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 2008 Cummins Power Generation Inc All rights reserved
6. To re store blinking press the control switch to STOP Prime until the light comes on 3 to 4 seconds Then press STOP Prime three times to restores blinking Note The last fault logged will blink even though the condition that caused the shutdown may have been corrected TABLE 4 1 TROUBLESHOOTING Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions NO RESPONSE AT CONTROL SWITCH Faulty switch poor or missing connections dead battery Corrective Action 1 Try the genset local control switch if there is no response at the remote control switch and vice versa 2 Check for 12 VDC across genset battery cable terminal block Service as necessary by cleaning and tightening battery cable connections recharging or replacing the battery or replacing damaged or missing battery cables THE STARTER ENGAGES AND DISENGAGES Low cranking voltage Corrective Action 1 Have the vehicle propulsion engine running while trying to start the genset Its charging alternator may be able to maintain a high enough battery terminal voltage to start the genset 2 Service the battery as necessary by cleaning and tightening connections recharging or replacing the battery or replacing damaged battery cables THE STARTING BATTERIES DO NOT MAI
7. eee 3 7 Ae iO UB RES OO MmINGeemrecrseenaee ie e o caer men ean Tp 4 1 MroubleshootingiMitharablet em Ss cree mente teeter trae 4 1 PaulieCodecBiinkincigee ie SRR E nee et 4 1 Restoring Fault Code Blinking Wee tees re ees so eee eee eee 4 1 S5SSRECIRICATIONS Gm Wh pyeneencerte eevee E ay en cae referee 5 1 SAMAINMENANCE RECORDA AERE eee eee eee ee eee eee eee 6 1 SAFETY PRECAUTIONS Thoroughly read the OPERATOR S MANUAL before operating the genset Safe operation and top performance can only be obtained when equipment is properly operated and main tained The following symbols in this manual alert you to potential 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 inju ry 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 exhaust 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 ina garage or other confined area ENGINE EXHAUST IS DEADLY e Inspect for exhaust leaks at every sta
8. 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 vent 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 3 2 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 o
9. in minerals and cor rosive chemicals A 50 50 mixture is recommended for all climates and is suitable for temperatures down to 34 F 37 C See Section 5 Specifications for coolant capacity STARTING BATTERIES The genset requires a 12 volt battery to power its control and starting circuits Reliable genset starting and starter service life depend upon adequate bat tery system capacity and maintenance See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS p 3 4 and Section 5 Specifi cations for minimum required battery ratings CONTROL PANEL The control panel Figure 2 2 has the following fea tures 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 Lamp This is a lamp in the control switch that blinks rapidly during preheat and cranking It stays on continuously while the genset is running If 2 2 the genset shuts down it will blink a numerical code to indicate the nature of the fault shutdown see Section 4 Troubleshooting Rapid blinking before cranking starts indicates that the glow plugs are preheating the combustion chambers The genset controller automatically var ies the time based on engine temperature Line Circuit Breaker s The line circuit breakers protect the AC power leads connected to the gen set Coolant Recovery Tank Fill Cap The recovery tank provides for coolant expansi
10. monoxide detector The exhaust system must be installed in accordance with the genset Installation Manual Make sure there is ample fresh air when operating the genset in a con fined area PRE START CHECKS Before the first start of the day and after every eight hours of operation inspect the genset as instructed under GENERAL INSPECTION p 3 2 Keep a log of maintenance and the hours run and perform any maintenance that may be due See Returning the Genset to Service p 2 7 if the vehicle has been in storage Before each start 1 Make sure all vehicle carbon monoxide CO detectors are working Check for fuel oil and coolant leaks and dam age to the exhaust system To prevent overheating and to reduce fouling with dust and debris make sure the genset s normal ground clearance is not being reduced by sloping ground curbs logs or other objects Repark the vehicle if necessary and or remove any objects blocking the air inlet or air outlet Turn off air conditioners and other large ap pliances 2 4 PRIMING THE FUEL SYSTEM The fuel system should be primed after replacing 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 half a minute Shut down Code No 57 Overprime occurs after 3 min utes of holding the switch down See Section 4 Troubleshooting MANUAL STARTING The genset can be started and stopped from
11. schedule TABLE 3 1 PERIODIC MAINTENANCE SCHEDULE and by not running the genset out of fuel Note that when the genset and propulsion engine draw from the same fuel tank the fuel dip tubes are usually ar ranged so that the genset will run out of fuel first By marking the genset empty point on the fuel gauge it will be easier to tell when the genset may run out of fuel FAULT CODE BLINKING At fault shutdown the status indicator light will re peatedly blink sets of 1 2 3 or 4 blinks e One blink indicates shutdown due to high en gine coolant temperature 4 1 e Two blinks indicate shutdown due to a loss of engine oil pressure e Three blinks indicate a service fault Press Stop once to cause the two digit second level shutdown code to blink Pressing Stop again will stop the blinking The two digit code con sists of 1 2 3 4 or 5 blinks a brief pause and then 1 to 9 blinks The first set of blinks repre sents the tens digit and the second set of blinks the units digit of the shutdown code number For example shutdown code No 36 appears as blink blink blink pause blink blink blink blink blink blink long pause repeat e Four blinks indicate that cranking time ex ceeded 35 seconds e To avoid the possibility of anyone misinterpreting Code Nos 3 and 4 as Code Nos 33 and 44 the lat ter have not been assigned faults RESTORING FAULT CODE BLINKING Blinking continues for five minutes and stops
12. the genset control panel or from a remote panel 1 Perform the PRE START CHECKS prime the fuel system if necessary and turn off the air conditioners and other large electrical loads Push and hold Start until the genset starts The status lamp will come on when the genset starts and will stay on while it runs While starting it will blink rapidly indicating preheating and crank ing Depending on how cold it is preheating can take up to 15 seconds extending the time that the lamp blinks Excessive cranking can over heat and damage the starter motor Do not crank for more than 30 seconds at a time Wait at least 2 minutes before trying again See Section 4 Troubleshooting if the genset does not start after several tries Let the genset warm up a few minutes until it is running smoothly before connecting the ve hicle electrical loads appliances Check for fuel oil coolant and exhaust leaks Stop the genset immediately if there is leak and have it repaired MANUAL STOPPING Run the genset under no load for a few minutes to allow the engine to cool down and then push and re lease Stop AUTOMATIC STARTING AND STOPPING The vehicle may be equipped with an inverter char ger or other automatic genset starting device AGS Always follow the instructions and safety precautions provided by the manufacturer of the au tomatic starting device when enabling automatic genset starting EXHAUST GAS is deadly MOV
13. 5 weight or ultra low sulfur fuel sul fur content less than 15 ppm 0 0015 weight e Non Regulated Areas CF class oil is recom mended when using high sulfur fuel sulfur content between 500 ppm 0 05 weight and 5000 ppm 0 5 weight If CF 4 CG 4 CH 4 or Cl 4 class oil is used the oil and oil filter must be changed twice as often as specified in the PERIODIC MAINTENANCE SCHEDULE Page 3 1 e Non Regulated Areas Use CF CF 4 CG 4 CH 4 or Cl 4 class oil when using high sulfur fuel sulfur content between 5000 ppm 0 5 weight and 10 000 ppm 1 0 weight The oil and oil filter must be changed twice as often as specified in the PERIODIC MAINTENANCE SCHEDULE Page 3 1 Oil Viscosity Look for the SAE Society of Automotive Engineers viscosity grade Referring to Figure 2 1 choose the viscosity grade appropriate for the ambient temper atures expected until the next scheduled oil change Multi grade oils such as SAE 15W 40 are recom mended for year round use z i swo TOAD rowan 5W30 ere erere eer ee ere erere eer ee 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 0 OC 34 29 23 18 12 7 4 4 10 16 2 27 32 38 43 48 FIGURE 2 1 OIL VISCOSITY VS TEMPERATURE RECOMMENDED COOLANT Use the best quality ethylene glycol antifreeze solu tion available It should be fully formulated with rust inhibitors and coolant stabilizers and mixed with fresh distilled water that is low
14. DESIGN AND DEFECT LIMITED WARRANTY FOR C I EN GINES DIESELS that was shipped in the same package as the Operator s Manual FIGURE 1 3 EMISSIONS LABEL LOCATION 1 3 TYPICAL GENSET cooling and ventilating air and the maintenance and service access panels of a typical genset Not Figure 1 4 illustrates the fuel battery remote con shown are the combustion air inlet and oil drain trol and AC output connection points the flow of openings in the base AC OUTPUT AND REMOTE MAINTENANCE FUEL EXHAUST CONTROL CONNECTIONS ACCESS CONNECTIONS CONNECTIONS CONTROL BATTERY PANEL CONNECTIONS COOLING amp VENTILATING AIR IN HOT AIR OUT FIGURE 1 4 TYPICAL GENSET 1 4 2 Operation FUEL RECOMMENDATIONS Diesel fuel is combustible and can cause severe personal injury or death Do not smoke near fuel tanks or fuel burning equip ment or in areas sharing ventilation with such equipment Keep flames sparks pilot flames electrical arcs and switches and all other sources of ignition well away Keep a multi class ABC fire extinguisher handy High quality diesel fuel is necessary for good perfor mance and long engine life e The specifications for the type and sulfur con tent ppm weight of the diesel fuel used must comply with all emissions regulations ap plicable in the areas where the genset is to be operated e Diesel fuels meeting ASTM D975 or EN 590 specifications
15. FUEL IS COMBUSTIBLE Do not smoke or turn electrical switches ON or OFF where fuel fumes are present or in areas sharing ventilation with fuel tanks or equip ment Keep flames sparks pilot lights arc producing equipment and all other sources of ignition 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 feature AGS of an inverter charger or other automat ic starting device before servicing the genset to avoid unexpected starting Do not wear loose clothing or jewelry near moving parts such as PTO shafts fans belts and pulleys Keep hands away from moving parts Keep guards in place over fans belts pulleys and other 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 operators of the genset are solely responsible for operating the genset safely
16. Fuel Filter Rotate the filter half a turn around its mounting stud if the fittings interfere with the bracket It only fits 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 with two wrenches Prime the fuel system for half a minute to fill the new filter with fuel and then secure the access door HOSE TO FUEL ENGINE Pa BRACKET MOUNTING SCREWS FIGURE 3 4 FUEL FILTER MAINTAINING THE ENGINE COOLING SYSTEM Refer to Table 3 1 for scheduled maintenance The engine cooling system is filled at the factory with a 50 50 mixture of ethylene glycol anti freeze and water which is suitable for temperatures down to 34 F 37 C Recommended Coolant See RECOMMENDED COOLANT p 2 2 Pressure Cap Replace the pressure cap Figure 3 5 every two years seals deteriorate and leak Proper cooling system pressure 14 psi is essential for optimal en gine cooling and minimal coolant loss Draining and Cleaning Cooling System Hot coolant spray can cause severe burns Let the engine cool before releasing the pressure cap or removing the drain cap Accidental or remote starting can cause severe personal injury or death Disconnect the nega tive cable at the battery to prevent starting while working on the genset Let the engine cool before removing the pressure cap Relieve any remain
17. 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 while working on the genset disconnect the nega tive battery cable at the battery e 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 Mobile 8 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 readi ly at hand Class A fires involve ordinary com bustible materials such as wood and cloth Class B fires involve combustible
18. NTAIN A CHARGE Marginal battery battery connections or charging system Corrective Action 1 Service the battery as necessary by cleaning and tightening connections recharging or replacing the battery or replacing damaged battery cables 2 Have the battery recharging system serviced NO AC POWER WHEN GENSET IS RUNNING A Circuit Breaker is OFF tripped or malfunctioning or there are poor AC harness connections Corrective Action 1 Reset or turn ON genset circuit breaker CB1 2 Reset or turn ON any other circuit breaker in the AC power supply system PERSISTENT AUDIBLE ENGINE SURGING WITHOUT FAULT SHUTDOWN Fuel leaks restrictions or air bubbles worn slip rings brushes misadjusted or faulty governor worn generator bearing Corrective Action 1 Check all fuel fittings for fuel and air leaks and tighten as necessary Reprime 2 Replace the fuel filter p 3 6 4 2 TABLE 4 1 TROUBLESHOOTING Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions ENGINE OVER TEMPERATURE CODE NO 1 During normal operation engine coolant temperature exceeded 239 F 115 C for 10 seconds Corrective Action 1 Check engine coolant level add coolant as necessary and repair any leaks 2 Check for and remove any objects blocki
19. Operator Manual Cummins Onan Performance you rely on RV Generator Set HDKCA HDKCB English 1 2009 981 0173 Issue 5 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 Table of Contents SECTION PAGE SAFETY PRECAUL NS et E E iiH 1 INTRODUCTION eee eee ee see 1 1 COOUMIMNS MAC a Ee T 1 1 INAITIG IMC eee nee erences E that aan meter tere 1 1 OW OLO iain Semice ersten UL E 1 2 EnginelEmissionsiCompliance wek waa 1 3 MIVPIGAIGeMcehearece ss TED E ee epee tere ee eee 1 4 ZeOPERABION serra ay e meneame ammare armen a cremnae nena truer ethene 2 1 puellRecommendations Sh mre E rer E nnn nn Winona A E 2 1 Engine Oil Recommendations 0 cece eect eee 2 1 Recommended Coolant 0 00 cece cee eee teens 2 2 Starting Batteuieewe 2 eee eee ene eens 2 2 reg Sle oa one 2 2 Remote Control Panel nara 2 2 SV SRS EL WOM SGKS oa sa oe a ee 2 4 Priming the FueliSysternn e n aa e ante a iyete avenue a taceemre iain tee rn kenaeanes 2 4 Manua Sta A de Orton A are trg oS wear a E reer rhe reine 2 4 Ma
20. affect engine emissions are prohibited by law in the State of California NAMEPLATE Be ready to provide the genset model and serial numbers on the nameplate when contacting Onan for parts service or information Figure 1 1 illus trates the nameplate and its location The gray boxes illustrate where to look for the model and seri al numbers Record these numbers in Figure 1 2 so that they are easy to find when needed Each character in these numbers is significant The last character of the model number is the specification letter which is im portant for obtaining the right parts Genuine Onan replacement parts are recommended for best results Refer to the genset Parts Catalog IMPORTANT CRON Model No S N AC Volts Amps Fuel Options Insulation NEMA Class ENGINE INFORMATION CUMMINS POWER GENERATION 1400 73rd Ave NE Minneapolis MN 55432 Made in U S A PH kVA kW Pf RPM Hz Bat Wiring Diagram Ambient FIGURE 1 1 TYPICAL NAMEPLATE MODEL NUMBER SERIAL NUMBER FIGURE 1 2 RECORD NUMBERS HERE 1 1 HOW TO OBTAIN SERVICE When you call for service parts or product literature such as the Service Manual or Parts Catalog for your genset contact the nearest authorized Cum mins Onan distributor Cummins Onan has factory trained representatives to handle your requests for genset parts and service For information for con tacting our distributo
21. and flam mable liquids and gaseous fuels Class C fires involve live electrical equipment See NFPA No 10 Portable Fire Extinguishers or equiva lent BS EN 3 7 2004 Genset installation and operation must comply with all applicable local state and federal codes and regulations 1 Introduction ABOUT THIS MANUAL This is the Operator s Manual for the generator sets gensets listed on the front cover Read and care fully observe all of the instructions and precautions in this manual Keep this manual and the genset Installation Manual with the other vehicle manuals Operation Periodic Maintenance and Trouble shooting provide the instructions necessary for op erating the genset and maintaining top perfor mance The owner is responsible for performing maintenance in accordance with the PERIODIC MAINTENANCE SCHEDULE p 3 1 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 alarm sys tem must be used if genset operation is critical Improper service or replacement of parts can lead to severe personal injury or death and to damage to equipment and property Ser vice personnel must be qualified to perform electrical and mechanical service Unauthorized modifications or replacement of fuel exhaust air intake or speed control system components that
22. are recommended Use Grade 1 D diesel fuel where ambient temperatures are below 14 F 10 C A minimum Fuel Ce tane Rating of 45 is recommended Where am bient temperatures are below 4 F 20 C or the elevation is above 5000 ft 1500 m a mini mum Cetane Rating of 50 is recommended e Current US EPA regulations for Non Road en gines limit diesel fuel sulfur content to a maxi mum of 500 ppm 0 05 weight Therefore use Grade 2 D S500 or 2 D S15 diesel fuel Where ambient temperatures are below 14 F 10 C use Grade 1 D S500 or 1 D 15 die sel fuel Note that beginning in year 2010 US EPA regulations for Non Road engines will limit diesel fuel sulfur content to a maximum of 15 ppm 0 0015 weight e Do not use diesel fuel having a sulfur content greater than 10 000 ppm 1 0 weight e Diesel fuel must meet the ASTM D975 stan dard for lubricity and pass a minimum load level of 3100 grams as measured by ASTM D6078 or maximum scar diameter of 0 45 mm as mea sured by ASTM D6079 or ISO 12156 1 e B5 Bio Diesel fuel that meets industry specifi cations and quality is suitable for use with this genset 2 1 ENGINE OIL RECOMMENDATIONS Oil Performance Class Use API American Petroleum Institute classified engine oils according to the following guidelines e Emissions Regulated Areas It is mandatory to use CF CF 4 CG 4 CH 4 or Cl 4 class oil with low sulfur fuel sulfur content less than 500 ppm 0 0
23. arks can ignite battery gas causing severe personal injury Ventilate battery area before working on or near battery Wear safety glasses Do not smoke Switch work light ON or OFF away from battery Stop genset and dis connect charger before disconnecting battery cables Disconnect negative cable first and reconnect last Refer to Table 3 1 for scheduled battery mainte nance and follow the battery manufacturer s in structions Have the battery charging system ser viced if DC system voltage is consistently low or high Always 1 Keep the battery case and terminals clean and dry and the terminals tight 2 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 1 for scheduled air filter replace ment Replace it more often in dusty environments The air filter is accessible through the front access door Figure 3 2 Loosen the three screws that se cure the coolant recovery tank to the housing top panel and move it out of the way Loosen the two screws that secure the air filter housing to the hous ing top panel so that the spring clips that secure the filter housing end cap can be unlatched Remove the end cap and replace the filter element Secure the filter housing coo
24. ate to dangerous levels in garages and other confined spaces Dis able the automatic genset starting feature of an inverter charger or other automatic starting device before storing the vehicle 2 Push the genset line circuit breaker OFF Page 2 6 3 Change the engine oil and attach a tag indicat ing oil viscosity See ENGINE OIL REC OMMENDATIONS Page 2 1 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 3 4 Plug the exhaust tail pipe to keep out dirt mois ture bugs etc 6 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 2 1 2 Reconnect the starting battery negative cable last See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Page 3 4 3 Remove the plug from the exhaust tailpipe Change the air filter element if it is dirty Page 3 4 5 Open the fuel supply valve if so equipped 6 Inspect the genset See GENERAL INSPEC TION Page 3 2 7 Push the genset line circuit breaker ON Page 2 6 when the genset is ready to power appliances 8 Enable the automatic genset starting feature of an inverter charger or oth
25. boost field voltage to meet the higher demand for current imposed by low power factor 2 Have the air conditioners and other appliances checked for proper operation A locked compressor rotor can cause a very low power factor GENERATOR ROTOR SHORT CODE NO 41 While field flashing during cranking the Controller sensed that the rotor circuit was shorted to ground Corrective Action See an authorized Onan dealer ROM FAULT CODE NO 42 During startup the genset Controller detected a ROM memory error Corrective Action See an authorized Onan dealer RAM FAULT CODE NO 43 During startup the genset Controller detected a RAM memory error Corrective Action See an authorized Onan dealer SPEED SENSE LOST CODE NO 45 After start disconnect the Controller lost speed sense quadrature zero crossings for 0 25 seconds Corrective Action See an authorized Onan dealer 4 6 TABLE 4 1 TROUBLESHOOTING Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions LOSS OF FIELD SENSE CODE NO 48 The field sense circuit on the Controller circuit board failed during normal voltage regulation Corrective Action See an authorized Onan dealer OVERPRIME CODE NO 57 The local or remote control switch was held in the Prim
26. e position for more than 3 minutes Corrective Action Check for and remove any object that may be holding either control switch remote or local in the prime position 4 7 5 Specifications MODEL HDKCA HDKCB GENSET CONTROL Integrated Microprocessor Based Engine and Generator Controller GENERATOR Single Bearing 4 Pole Rotating Field 1800 RPM Power 1 0 power factor 10 000 W 12 500 W Voltage 120 240 120 240 Frequency 60 Hz 60 Hz Number of Phases 1 1 Current 41 7 amps per leg 52 1 amps per leg Line Circuit Breaker 2 pole 45 amp 2 pole 50 amp FUEL CONSUMPTION No load Half load Full load 0 11 gph 0 4 Iph 0 48 gph 1 8 Iph 1 01 gph 3 8 Iph 0 11 gph 0 4 Iph 0 48 gph 1 8 Iph 1 2 gph 4 5 Iph ENGINE 3 Cylinder In Line Water Cooled Indirect Injection IDI 4 Stroke Cycle Diesel Bore 3 43 in 87 mm Stroke 3 64 in 92 4 mm Displacement 100 5 in 1 647 cc Compression Ratio 22 6 1 Fuel Injection Timing BTDC 14 5 Firing Order 1 3 2 Fuel Nozzle Injection Pressure 1991 psi 13 731 mPa Cylinder Compression Test 370 psi 2 55 mPa minimum Valve Lash Intake amp Exhaust cold 0 0071 to 0 0087 in 0 18 to 0 22 mm Oil Capacity with filter 5 9 quart 5 6 liter Cooling System Capacity 6 6 quart 6 2 liter DC SYSTEM Nominal Battery Voltage
27. er automatic starting device following the device manufacturer s in structions and safety precautions 3 Periodic Maintenance Periodic maintenance is essential for top perfor mance and long genset life Use Table 3 1 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 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 Cummins Onan dealer Accidental or remote starting can cause severe personal injury or death Discon nect the negative cable at the battery to pre vent starting while working on the genset TABLE 3 1 PERIODIC MAINTENANCE SCHEDULE FREQUENCY Every Every Every Every Every E eN 250 500 800 1500 3000 Page y Hrs Hrs Hrs Hrs Hrs MAINTENANCE TASK General Inspection LU Check Engine Oil Level Check Engine Coolant Level Check Battery amp Battery Connections Change Engine Oil amp Oil Filter 2 3 4 3 2 3 7 3 4 el E w e e e Clean Spark Arrestor3 PT a 3 5 Replace Engine Air Fite S Jo fo do def T J I Replace Fuet Fite o TT deS T S es Adjust Engine Vawetash Jo fo d S ef S e Fush Coolant System J f d T T def i7 Replace Coolant Pressure Cap fJ f d T T def 87 Replace Bet a
28. ers equipment damage and fire Use an approved switching device to prevent interconnections 2 6 OPERATING IN COLD WEATHER Make sure the engine oil viscosity is appropriate for the cold weather temperatures See ENGINE OIL RECOMMENDATIONS Page 2 1 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 2 1 3 Keep the genset clean 4 Perform maintenance due See PERIODIC MAINTENANCE SCHEDULE Page 3 1 OPERATING AT HIGH ALTITUDE For the effect of altitude on maximum power see LOADING THE GENSET Page 2 5 OPERATING IN DUSTY ENVIRONMENTS Pay particular attention to 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 3 1 3 Change engine oil more often See PERIODIC MAINTENANCE SCHEDULE Page 3 1 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 eng
29. ine 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 2 5 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 2 1 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 2 5 A single two hour exercise period is better than several shorter periods Exercising a genset drives off moisture 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 Disable the automatic genset starting feature of an inverter charger or other automatic starting device 2 7 CARBON MONOXIDE is deadly and can accumul
30. ing pressure by turning the pressure cap slowly without pushing down When the pressure has been relieved push down on the cap turn it the rest of the way and withdraw it Then remove the coolant drain plug Figure 3 5 and drain the coolant into a suitable container Ethylene glycol antifreeze is con sidered toxic Dispose of it according to local regulations for hazardous substances 3 7 Flush and clean the cooling system before refilling Radiator cleaning chemicals are available at local auto parts stores Follow the instructions for clean ing and flushing that come with the cleaning solu tion Refilling Cooling System Install the coolant drain plug using pipe thread seal ant Tighten it just enough so that it does not leak when the genset is running and has warmed up Pull the hose connected to the pressure cap assem bly out as far and as high as it will go Figure 3 5 Remove the pressure cap and fill the system using a funnel inserted into the fill hose to prevent coolant from entering the vent hose and blocking the es cape of air as the system fills The system will seem full when it actually is not if the air cannot escape through the vent hose If the vent hose does get blocked pinch the overflow hose and blow the vent hose clear Start and operate the genset for a few minutes while keeping the fill opening elevated to promote venting of air from the coolant Shut down the genset and add coolant as necessary Sec
31. l cap unscrew the oil drain plug and drain all the oil from the engine Reinstall the oil drain plug securely Spin off the oil filter canister and clean the filter mounting surface on the engine block Remove the FULL and ADD marks the old gasket if it remains 4 Reinsert the dipstick and secure the oil fill cap 4 Make sure the gasket is in place on the new fil and front access door ter and apply a thin film of clean oil to the gas ket Spin the new filter on until the gasket just touches the block Turn it an additional 1 2 to 3 4 turn Do not overtighten CHANGING ENGINE OIL AND OIL FILTER Refer to Table 3 1 for scheduled engine oil change Change oil more often in hot and dusty environ 5 Refill with 5 9 quarts 5 6 liters of oil check oil ments level Figure 3 1 and secure the front access door 1 Place a pan under the oil drain plug Fig ure 3 1 run the genset until warm and shut it 6 Dispose of the used oil and oil filter according off to local environmental regulations FILTER WI DIP STICK Q ac D Se DRAIN PLUG 22 MM HEX HEAD FIGURE 3 1 ENGINE OIL MAINTENANCE 3 3 MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Arcing at battery terminals or in light switches or other equipment and flames or sp
32. lant tank and access door COOLANT RECOVERY TANK SHOWN CUT AWAY END CAP AIR FILTER HOUSING UU FIGURE 3 2 REPLACING THE AIR FILTER ELEMENT CLEANING THE SPARK ARRESTOR 1 Remove the top enclosure panel Refer to Table 3 1 for scheduled cleaning of the 2 Remove the cleanout plug from the muffler Se spark arrestor muffler which meets U S Forest cure the top enclosure panel before running the Service requirements Cleaning is required for genset With the cover in place there will be maximum genset performance enough air flow to cool the engine properly and A hot muffler can cause severe carry the soot out of the compartment burns Let the muffler cool down before remov ing or installing the cleanout plug 3 Start the genset and load it nearly to full power Let the genset run for about five minutes to ex The muffler is mounted inside the genset housing pel the soot Figure 3 3 The spark arrestor cleanout plug is lo cated on the side of the muffler and is accessible by 4 Stop the genset allow the muffler to cool down removing the top enclosure panel Clean out the reinstall the cleanout plug and secure the top muffler as follows panel CLEANOUT PLUG 11 16 INCH HEX HEAD REMOVE THIS PANEL f FOR ACCESS
33. mp Coolant Hoses 7 d P lef i Check Fuel injector Pressure fJ f d T f def Bs o i l l i iiO OE Brushes2 7 Replace Generator Bearing 1 1 EC dt f Perform more often when operating in hot weather Perform more often when operating in dusty conditions Perform at least once a year Perform every 125 hours when using high sulfur fuel See ENGINE OIL RECOMMENDATIONS Page 2 1 Perform at least once every two years Perform at least once every five years Must be performed by trained and experienced personnel authorized Onan service representatives EPA requirement ODNEO OI ROIN gt GENERAL INSPECTION Inspect the genset before the first start of the day and after every eight hours of operation Oil Level Check engine oil level Figure 3 1 Engine Coolant System ACAUTION Operating the genset when coolant level is low can cause serious engine damage Check the engine 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
34. n after 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 proper ground ing CONNECTING TO UTILITY POWER A vehicle with provisions for connecting utility power must have an approved device to keep the genset and utility from being interconnected See the gen set Installation Manual for more information Interconnecting the genset and the public utility or any other power source can lead to electrocution of utility line work
35. ng the air inlet or outlet openings in the bottom of the genset and clean out dirt fouling the radiator passages 3 Run fewer appliances at the same time to keep down engine temperature Note that high altitude and high ambient temperature decrease engine cooling capacity LOW OIL PRESSURE CODE NO 2 During normal operation engine oil pressure dropped to less than 14 psi 97 kPa for 3 seconds switch closed Corrective Action 1 Check engine oil level add oil as necessary and repair any leaks 2 Drain the excess oil if the level is above Full on the dipstick If the level is too high the crankshaft can whip the oil into foam which the pump can t pump SERVICE CHECK CODE NO 3 A second level fault occurred Corrective Action Check the second level fault code by momentarily pressing Stop The second lev el fault will be one of the following in this table OVER CRANK CODE NO 4 First level fault code Cranking time exceeded 35 seconds Corrective Action 1 Check fuel level and refill as necessary Note The genset fuel pickup is probably higher than the vehicle engine fuel pickup Prime the engine fuel system for one minute p 2 4 Check the engine air filter and remove any blockage p 3 4 Change the engine oil to oil of the proper viscosity for the ambient temperature High oil viscosity can slow down cranking speed Check all fuel fittings for fuel and air leaks and tighten as necessary Reprime
36. nual Stopping 5 acces eects tee caedeye eae vs eee ne relat a ee 2 4 Automatic Staning and StOppIng 4 4 8 ies uae od Swe Se ceed oe cee ees 2 5 Loading the Genset meee cee na bey onan eh eee pe cen eee eee ee 2 5 Resetting Circuit Breakers mere 00 cece cee eee eee eens 2 6 Connecting to Utiity Rower ee soci see ees one ee ee gues an oneen 2 6 Ope ratinignin Cold Wee INC tae Bare cre re ee ete ue reruns eens a trees 2 6 Operating in Hotaveathnei ese ee ers recess eee seers cere cee eect ees es tthe ae 2 6 Operating at High Altitude jcacacn nev eaaae ee Aaee hee hice Rie RRAS Ree hate 2 6 Operating in Dusty Environments 00 eee eee eee eee 2 6 Breaking In a New Engine 00 0020 e cece eee eee eee eee eee 2 7 Exercising the Genset 0 0 cece e eee eee teens 2 7 Storing the Genset 2 6cscescanddsw seduce Svawend tebeiued esces deeded 2 7 3 PERIODIC MAINTENANCE 00 cece cece eee eens 3 1 General INSP CtiOn 2 o essential awh ieee naw bie glee eee eee ee 3 2 Checking Engine Oil Level 0 cece cee eee 3 2 Changing Engine Oil and Oil Filter 2 2 0 eee 3 3 Maintaining the Battery and Battery Connections 00 ee eee 3 4 Replacing the AimsFilter Element 5 25a soe Se ee 3 4 Cleanin mhe Spark Anesioteaete ee eee i a eee 3 5 ReplacingsthetmuelEite na esas me Moe gee 3 6 Maintaining the Engine Cooling System 00 c cee eee
37. on Replenish the normal loss of coolant by filling here Hour Meter The hour meter records the total run ning time of the genset It cannot be reset REMOTE CONTROL PANEL There probably is a remote genset control panel in side the vehicle Three control panel kits are avail able e Remote switch status lamp e Remote switch status lamp and hour meter e Remote switch status lamp and DC voltmeter The DC voltmeter indicates whether voltage across the 12 VDC control system and battery is normal If the indicator consistently stays above or below the normal zone see MAINTAINING THE BATTERY AND BATTERY CONNECTIONS p 3 4 LINE CIRCUIT COOLANT RECOVERY BREAKER S TANK FILL CAP COOLANT RECOVERY TANK FLUID LEVEL CONTROL SWITCH amp STATUS LAMP HOUR METER FIGURE 2 2 CONTROL PANEL 2 3 EXHAUST GAS is deadly All en gine exhaust contains carbon monoxide an odorless colorless poisonous gas that can cause unconsciousness and death Symptoms of carbon monoxide poisoning include e Headache e Nausea e Weakness and Sleepiness e Vomiting e Inability to Think Coherently IF YOU EXPERIENCE ANY OF THESE SYMP TOMS GET INTO FRESH AIR IMMEDIATELY If symptoms persist seek medical attention Shut down the genset and do not operate it until it has been inspected and repaired e Dizziness Never sleep in the vehicle while the genset is running unless the vehicle has a working car bon
38. peration causes fuel to leak Prime the fuel system if the genset ran out of fuel 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 p 3 4 Mechanical Look for mechanical damage and listen for unusual noises Check the genset mounting bolts To prevent overheating and to reduce fouling with dust and debris make sure the genset s normal ground clearance is not being reduced by sloping ground curbs logs or other objects Repark the ve hicle if necessary and or remove any objects block ing the air inlet or air outlet CHECKING ENGINE OIL LEVEL 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 1 Park the vehicle on level ground shut down the genset and remove the front access door 2 Pull out the oil dip stick wipe it clean reinsert it and pull it out again to check the oil level Fig ure 3 1 3 Add or drain oil as necessary See REC OMMENDED ENGINE OIL p 2 1 Keep the oil level between the FULL and ADD marks Too much oil can cause high oil consumption Too little oil can cause severe engine damage Keep the oil level between Remove the front access door and the oil fil
39. rs worldwide go to internet site www cumminsonan com In North America Call 1 800 888 ONAN to contact the nearest Cum mins Onan distributor in the United States or Cana da This automated service utilizes touch tone phones only Select OPTION 1 press 1 to be au tomatically connected to the distributor nearest to you If you are unable to contact a distributor using the automated service consult the Yellow Pages Typi cally our distributors are listed under GENERATORS ELECTRIC ENGINES GASOLINE OR DIESEL or 1 2 RECREATIONAL VEHICLES EQUIPMENT PARTS AND SERVICE If you have difficulty in arranging service or resolv ing a problem please contact the Service Manager at the nearest Cummins Onan distributor for assis tance Outside North America If you are outside North America call Cummins Onan at 1 763 574 5000 from 7 30 AM to 4 00 PM Central Standard Time Monday through Friday or fax 1 763 528 7229 Information to Have Ready Before calling for service have the following infor mation available 1 The complete genset model number and serial number See About This Manual Page 1 1 2 The date of purchase 3 The nature of the problem See Section 4 Trou bleshooting ENGINE EMISSIONS COMPLIANCE The label that states compliance with applicable en gine emissions regulations is located on the side of the Power Unit as shown circled in Figure 1 3 Re fer also to the FEDERAL EMISSION
40. rtup and after every eight hours of running e Learn the symptoms of carbon monoxide poi soning in the genset Operator s Manual e Never sleep in the vehicle while the genset is running unless the vehicle is equipped with a working carbon monoxide detector e Do not operate the genset when the vehicle is parked in a confined space such as a garage e Disable the AGS feature of an inverter charger or other automatic starting device before stor ing the vehicle or parking it in a garage or other confined space e The exhaust system must be installed in accor dance with the genset Installation Manual Engine cooling air must not be used for heating the vehicle GENERATOR VOLTAGE IS DEADLY Disable the automatic genset starting feature AGS of an inverter charger or other automat ic starting device before servicing the genset 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 shore power utility Back feed to shore power can cause electrocution and damage to equip ment An approved switching device must be used to prevent 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
41. s Corrective Action Push the line circuit breaker to OFF and restart the genset If the genset now runs run it with fewer connected loads especially those with high motor starting loads such as air conditioners Check all fuel fittings for fuel and air leaks and tighten as necessary Reprime Air bubbles can dis rupt frequency Replace the engine air filter and clean the spark arrest muffler p 3 4 Replace the fuel filter p 3 6 ACTUATOR SHORTED OR OPEN CODE NO 19 At startup the Controller sensed an open or shorted governor actuator harness Corrective Action See an authorized Onan dealer ACTUATOR OVERLOAD CODE NO 22 Due to connected overload or low engine performance the Controller maintained the governor actuator at full duty cycle maximum pulse width modulated square wave signal PWM for 60 consecutive seconds Corrective Action 1 Reduce the number of appliances running at the same time especially those with high motor starting loads such as air conditioners 2 Check all fuel fittings for fuel and air leaks and tighten as necessary Reprime 3 Replace the engine air filter and clean the spark arrest muffler p 3 4 4 Replace the fuel filter p 3 6 4 4 TABLE 4 1 TROUBLESHOOTING Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards
42. scosity for the ambient temperature High oil viscosity can slow down cranking speed EE CHECKSUM FAULT CODE NO 35 During startup the genset Controller detected an EE memory error Corrective Action See an authorized Onan dealer 4 5 TABLE 4 1 TROUBLESHOOTING Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions MECHANICAL FAULT CODE NO 36 The Controller declared this fault because engine speed fell below 1000 RPM for 0 5 seconds though not by Controller action Corrective Action 1 Check fuel level and refill as necessary Note The genset fuel pickup is probably higher than the vehicle engine fuel pickup Prime the engine fuel system for one minute p 2 4 Check all fuel fittings for fuel and air leaks and tighten as necessary Reprime Check the engine air filter and remove any blockage p 3 4 Replace the fuel filter p 3 6 FIELD OVERLOAD CODE NO 38 During normal voltage regulation Field Voltage exceeded 150 VAC for 10 seconds Corrective Action 1 Reduce the number of air conditioners running at the same time and other appliances that cause low power factor The lower the power factor of a motor or compressor the more current it draws per kilowatt The genset Controller in turn must
43. should perform genset service See Safety Precautions FAULTY ENGINE TEMPERATURE SENDER CODE NO 24 After 10 minutes of normal operation the Controller checked for and sensed an open temperature sender harness Corrective Action See an authorized Onan dealer VAC SENSE LOST CODE NO 27 The Controller lost VAC sensing during normal voltage regulation when the field was functioning nor mally and frequency was at least 40 Hz Corrective Action See an authorized Onan dealer HIGH BATTERY VOLTAGE CODE NO 29 During startup the Controller sensed that battery system voltage was greater than 19 2 volts for 5 milli seconds or greater than 19 2 volts for 1 second will running 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 STARTING FAULT CODE NO 32 The Controller could not detect cranking speed quadrature zero crossings for 12 seconds Corrective Action 1 Have the vehicle propulsion engine running while trying to start the genset Its charging alternator may be able to maintain a high enough battery terminal voltage to start the genset 2 Service the battery as necessary by cleaning and tightening connections recharging or replacing the battery or replacing damaged battery cables 3 Change the engine oil to oil of the proper vi
44. ure the pressure cap and fill the recovery tank to the COLD mark Coolant trapped in the vent hose will prevent the system from filling to its capacity which can lead to serious engine damage Coolant Level Check Check coolant level in the recovery tank Fig ure 3 5 before the first startup of each day and fill to the COLD mark if necessary with Recommended Coolant PRESSURE CAP COOLANT RECOVERY AND SYSTEM TANK FILLOPENING RECOVERY TANK FILL CAP BLUE COOLANT LEVEL f pgp _ Ey i NINES emi 4 bed KX Ae DB mat heal ji il COOLANT DRAIN PLUG 1 4 INCH HEX SOCKET FIGURE 3 5 ENGINE COOLING SYSTEM 3 8 4 Troubleshooting TROUBLESHOOTING WITH TABLE 4 1 To aid troubleshooting the genset controller causes the status indicator light to blink the numeric code assigned to the fault that caused shutdown For a brief description of the fault and step by step cor rective action refer to TABLE 4 1 TROUBLE SHOOTING which lists the fault codes in numerical order If you are unable to resolve the problem after taking the corrective actions suggested contact an autho rized Onan dealer See HOW TO OBTAIN SER VICE p 1 2 Note Many genset shutdowns can be avoided by performing periodic maintenance on
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