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Owners Manual - AP Electric Generators

1. COOLANT RECOVERY TANK AIR FILTER HOUSING SHOWN CUT AWAY END CAP FIGURE 3 2 REPLACING THE AIR FILTER ELEMENT 3 7 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 3 Diesel fuel is combustible and can cause severe personal injury or death Do not smoke near diesel fuel tanks or Keep flames sparks pilot lights electrical switches arc producing eguipment and all oth er sources of ignition well away Keep a type ABC fire extinguisher in the vehicle Close any fuel line shutoff valve be fore disconnecting the fuel line from the filter 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 Engine components drains filters hoses etc will be hot and can cause severe burns The use of protective gloves is recom mended 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 3 8 Removing the Fuel Filter Disconnect the two fit
2. REMOTE CONTROL PANELS E GenSet There probably is a remote genset control panel in Start side the vehicle Onan offers three remote control kits as follows e Remote switch status lamp Figure 2 3 Remote switch status lamp and hour meter N O Figure 2 4 i e Remote switch status lamp and DC voltmeter FIGURE 2 3 REMOTE SWITCH Figure 2 5 4 N The DC voltmeter indicates whether voltage across GenSet the 12 VDC control system and battery is normal Start the indicator consistently stays above or below the normal zone see MAINTAINING THE BATTERY AND BATTERY CONNECTIONS p 3 6 O O jo 101 10 RL s 1 O TOTAL HOURS QUARTZ Stop N 4 FIGURE 2 4 REMOTE SWITCH HOUR METER N GenSet B VOLTS E o NE M FIGURE 2 5 REMOTE SWITCH DC VOLTMETER 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 Dizziness Headache e Nausea e Weakness and Sleepiness e Vomiting Inability to Think Coherently IF YOU EXPERIENCE ANY OF THESE SYMPTOMS GET INTO FRESH AIR MEDIATELY If symptoms persist seek medical attention
3. 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 10 16 21 27 32 38 43 48 FIGURE 2 1 OIL VISCOSITY VS TEMPERATURE CONTROL 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 lt stays on continuously while the genset is running If the genset shuts down it will blink a numerical code to indicate the nature of the fault shutdown see Section 4 Troubleshooting LINE CIRCUIT BREAKER S CONTROL SWITCH amp STATUS LAMP 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 expansion Replenish the normal loss of coolant by filling here Hour Meter The hour meter records the total ning time of the genset It cannot be reset COOLANT RECOVERY TANK FILL CAP COOLANT RECOVERY TANK FLUID LEVEL HOUR METER FIGURE 2 2 CONTROL PANEL
4. MODEL HDKCC HDKCD 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 12 000 W Voltage 120 240 120 240 Freguency 60 Hz 60 Hz Number of Phases 1 1 Current 41 7 amps per leg 50 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 41 0 48 gph 1 82 Iph 1 01 gph 3 80 Iph 0 11 gph 0 41 0 48 gph 1 82 Iph 1 20 gph 4 54 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 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 Maximum Regulated Charging Current 20 amps WEIGHT 816 lbs 370
5. 12 VDC at P9 3 Start and at P9 1 Stop and for ground continuity at P9 2 Ground If there is B and ground continuity test control switch S1 and replace if necessary If not go to Step 8 Disconnect harness connector P1 from the control board and check for B at P1 10 and for ground continuity at P1 27 If there is B and ground continuity go to Step 9 If not go to Step 10 Check for wiring continuity in the harness between connectors P9 3 and P1 9 Start P9 1 and P1 32 Stop P9 8 and P1 7 Status P9 7 and P1 27 Status Ground and P9 2 and P1 27 Start Stop Ground Repair as necessary Make sure connector pin sockets are not damaged or corroded and that they are fully seated and can t be pulled out Replace the control board if the genset still does not start Remove the top housing panel and check that both harness connectors labeled B1 BAT are secure on the starter solenoid terminal that GND is secure on the chassis ground and that there is wiring continuity in the harness between connectors P1 10 and B1 BAT and between connectors P1 27 and GND Repair as necessary Make sure connector pin sockets are not damaged or corroded and that they are fully seated and can t be pulled out Replace the control board if the genset still does not start Remove the top housing panel and replace broken or missing cables between TB1 and the engine Tighten loose connections 4 2 TABLE 4 1 TROUBLESHOOTING Some genset service
6. tains ethylene glycol and diethylene glycol Ethyl ene glycol is a potentially hazardous constituent The substance has a boiling point of 107 C and a flash point of 121 C It is used as an engine coolant additive and can be found in engine cooling systems and head ex changers Installers operators and maintainers are likely to encounter this substance HAZARDOUS REACTIONS Ethylene glycol is combustible when exposed to heat or flame and can react vigorously with oxi dants Moderate explosive hazard in form of vapour when exposed to heat or flame Hazardous prod ucts resulting from combustion or decomposition include carbon monoxide carbon dioxide and acrid smoke Self contained breathing apparatus must be worn in the event of fume build up Avoid strong oxidizing agents incompatible with sulfuric acid nitric acid caustics and aliphatic amines It may cause neurological signs and symptoms and kidney damage It is also a skin and eye irritant Very toxic in particulate form upon inhalation Harmful if swallowed lethal dose for humans re ported to be 100 PROTECTIVE MEASURES Refrain from eating drinking or smoking when us ing the product Adopt a high standard of personal hygiene In case of skin contact wash immediately with soap and water Ensure good ventilation and avoid heat sources Avoid breathing mist if there is a risk of vapour or particulate use a suitable organic vapour mask Eye p
7. 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 operation 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 6 Mechanical Visually inspect genset for mechanical damage For generat
8. D UTC eee 2 4 Priming the Fuel System a a 2 0 2 4 2 4 Manual Stopping 2 4 Automatic Stanting and Stopping 2 5 2 5 Resetting circuit Breakers eee ctis e si Set ee 2 6 Cionnechndquio Rower e MEL 2 6 Operating Weather 2 6 Operatinguin Hot 2 6 Operating 2 6 Operating Dusty Environments 2 6 Breaking In a New Engine 2 5080055511 ee 2 7 Exercising the Genset ae rn 2 7 Storing the Genset 2 7 3 PERIODIC MAINTENANCE zik t hex dk Sd ecd iet eds dii 3 1 General Inspection ve Be RI RU EIER Seon Pee ta acd Checking Engine Oil Level Changing Engine Oil and Oil Filter Maintaining the Battery and Battery Replacing the Air Filter cc ERE Maintaining the Coolant System 4qROUBLESHOODING JRR Troubleshooting With Table 4 1 eee eee Restoring FaultCode Blinking 5599 55SPEGIEIEANIONS SO LEE SIMAINITENANGEIBECORD 15 333333 SAFETY PRECAUTIONS Thoroughly read the OPERATOR S
9. MANUAL before operating the genset Safe operation and top performance can only be obtained when eguipment is operated and maintained proper ly Only trained and experienced service person nel with knowledge of fuels electricity and ma chinery hazards shall remove dismantle and dispose of the generator set See service manu al The following symbols in this manual alert you to potential hazards to the operator service person and eguipment Used to alert you to leathal hazard which you must take steps to prevent severe personal injury or death as when you are in the vicinity of High Voltage eguipment Used to alert you to a hazard or un safe practice that can result in severe personal injury or death Used to alert you to hazard or un safe practice that can result in personal injury or eguipment damage Electricity fuel exhaust moving parts and batter ies present hazards which can result in severe per sonal injury or death GENERAL PRECAUTIONS Keep children away from the genset Do not use evaporative starting fluids They are highly explosive 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 Keep the genset and its compartment clean Excess
10. Obtain immediate medical assistance Eyes Flush copiously with water or preferably eye wash solution for at least five minutes Seek medical advice Skin Wash thoroughly with soap and water and seek medical attention if irritation develops Change clothing if necessary and wash before re use Spillage Soak up using an absorbent material and dis pose of this as directed under Storage Trans port Section 5 1 3 GAS OIL This product is also known as Red Diesel Fuel Oil and type 1 or 2 It be pale red or a clear liguid with a characteristic mild odour It contains catalyti cally cracked oil petroleum distillates guinizarin and gas oil maker dye red The catalytically cracked oil and petroleum distillates are potentially hazard ous constituents The substance has an initial boiling point of 180 C a flash point greater than 56 C and a vapour pres sure less than 0 7mm Hg at 20 C and has negligible solubility in water It is used as a fuel for off road diesel powered ve hicles and stationary engines and can be found in fuel tanks pipes and injection systems The sub stance should not be used for any other purpose without contacting the manufacturer or supplier In stallers operators and maintainers are likely to en counter this substance HAZARDOUS REACTIONS This liguid is flammable Avoid smoking heat sources such as welding and naked flames sparks and static electricity build up Th
11. Shut down the genset and do not op erate it until it has been inspected and repaired Never sleep in the vehicle while the genset is running unless the vehicle has a work ing carbon 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 confined 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 2 Check for signs of fuel and exhaust leaks and damage 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 2 4 4 Turn off air conditioners and other large ap pliances 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 half a minute MAN
12. 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 108 VAC 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 1 Push the line circuit breaker to OFF start the genset and measure output voltage If output voltage is normal the problem is in the circuits external to the genset If there is no voltage test for and ser vice a grounded or shorted main field or guadrature windings or grounded or shorted voltage sense transformer 2 Replace the control board OVER FREOUENCY CODE NO 14 After the starter was engaged Freguency jumped to more than 70 Hz for 40 milliseconds or to more than 66 Hz for 6 seconds Corrective Action 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 freguency to overshoot Check all fuel fittings for fuel and air leaks and tighten as necessary Reprime Air bubbles can disrupt freguency Remove the governor actuator test it for proper operation and replace if necessary Check high idle speed and readjust if necessary Replace the control board Service the internal engine governor mechanism according to Engine Workshop Manual 981 0541 UND
13. equipment and all other sources of ignition well away Fuel lines must be secured free of leaks and separated or shielded from electrical wiring BATTERY GAS IS EXPLOSIVE Wear splash proof safety glasses Do not smoke or permit flames or sparks to oc cur neat the battery at any time To reduce arcing when disconnecting or recon necting battery cables always disconnect the negative battery cable first and reconnect it last MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Disable the automatic genset starting feature of an inverter charger or other automatic start ing device before servicing the genset Mobile 8 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 FLAMMABLE VAPOR CAN CAUSE A DIESEL ENGINE TO OVERSPEED Do not operate a diesel powered genset where a flammable vapor environment can be created by fuel spill leak etc Flammable vapor can cause a diesel engine to overspeed and become difficult to stop resulting in possible fire explosion severe personal injury and death The owners and operators of the genset are solely responsible for operating the genset safely THE HAZARDS OF CARBON MONOXIDE Engine driven generators can produce harmful levels of carbon monoxide that can injure or kill you The nature
14. ing device when enabling automatic genset starting EXHAUST GAS is deadly MOV ING PARTS and ELECTRICITY can cause severe personal injury or death To reduce exposure to these hazards always disable automatic genset starting before Sleeping in vehicle unless vehicle has working CARBON MONOXIDE detector e Parking vehicle in garage or confined space Parking vehicle for storage Servicing genset Servicing batteries Servicing electrical appliances Fueling vehicle LOADING THE GENSET The genset can power 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 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
15. internal engine governor mechanism Service a worn engine ON k 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 1 If loose reconnect wiring harness connector E3 1 to engine coolant temperature sender E3 2 Test the temperature sender and replace if necessary 3 Disconnect harness connector P1 from the control board and check for wiring continuity in the har ness between connectors P1 21 and E3 1 Repair as necessary Make sure connector pin sockets are not damaged or corroded and that they are fully seated and can t be pulled out Replace the con trol board if the fault still occurs 4 7 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 VAC SENSE LOST CODE NO 27 The Controller lost VAC sensing during normal voltage regulation when the field was functioning nor mally and freguency was at least 40 Hz Corrective Action See an authorized Onan dealer 1 Disconnect harness connector P1 from the control board and check for electrical resistance between pins P1 33 and P1 34 which should be approxim
16. not leak when the genset is running and has warmed up Pull the hose connected to the pressure cap assembly out as far and as high as it will go and fill the system with coolant When the coolant level reaches the fill opening start and operate the genset for a few min utes and shut it down Add more coolant if neces sary and secure the pressure cap Fill the recovery tank with coolant mixture to the COLD mark 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 Coolant trapped in the vent hose will prevent the system from filling to its capac ity which can lead to serious engine damage Coolant Level Check Check coolant level in the recovery tank Fig ure 3 4 before the first startup of each day and fill to the COLD mark if necessary PRESSURE COOLANT RECOVERY TANK RECOVERY TANK FILL CAP BLUE COOLANT LEVEL AND SYSTEM Q FILL OPENING SA E y os en AN il COOLANT DRAIN PLUG 1 4 INCH HEX SOCKET FIGURE 3 4 ENGINE COOLING SYSTEM 4 Troubleshooting TROUBLESHOOTING WITH TABLE 4 1 To aid troubleshooting the genset controller causes the status indicator lig
17. 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 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 MAINTAIN A CHARGE Marginal battery battery connections or charging system Corrective Action Service the battery as necessary by cleaning and tightening connections recharging or replacing the battery or replacing damaged battery cables Have the battery recharging system serviced Models HDKCA and HDKCB The genset starting battery is recharged by the vehicle engine or separate battery charger Service as reguired Models HDKCC and HDKCD These models have a feature whereby genset battery charging al ternator G1 can be disabled via relay K1 by connecting B to remote connector pin P8 D Service the vehicle engine or separate battery charger if depended upon for recharging the genset starting battery If genset battery charging alternator G1 is not d
18. reason for this is that a motor s startup load is much larger than its running load may be necessary to run fewer ap pliances when large motors and air condition ers are cycling 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 Table 2 2 shows the results of typical calculations It may be necessary to run fewer appliances at higher alti tudes TABLE 2 1 TYPICAL APPLIANCE LOADS Load watts 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 Elevation above Sea Gavel Maximum Power at below 500 ft 152 m 12 000 W rated at 2500 ft 762 m 11 280 W at 5500 ft 1676 m 10 200 W 10 200 W minus 360 W every 1000 ft 305 above 5500 ft 1676 m 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 2 2 trips either a circuit shorted or too many appliances were running Note that the genset will continue t
19. should perform genset service See Safety Precautions FIELD OVERLOAD CODE NO 38 During normal voltage regulation Field Voltage exceeded 180 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 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 3 Test the generator field and stator windings and service as necessary GENERATOR ROTOR SHORT CODE NO 41 While flashing the field the Controller sensed that the rotor circuit was shorted to ground Corrective Action See an authorized Onan dealer 1 Disconnect Generator connector J3 P3 and check for a short to ground at P3 7 and at P3 8 Service or replace brushes slip rings and rotor as necessary 2 Replace the control board 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 Replace the control boardSee an authorized Onan dealer SPEED SENSE LOST CODE 45 After
20. 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 41 0 48 gph 1 82 Iph 1 01 gph 3 8 Iph 0 11 gph 0 41 0 48 gph 1 82 Iph 1 2 gph 4 54 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 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 792 lbs 359 kg 816 Ibs 370 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 SPECIFICATIONS
21. ER FREOUENCY CODE NO 15 During normal operation Freguency fell to less than 54 Hz for more than 8 seconds Corrective Action 1 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 freguency Replace the engine air filter and clean the spark arrest muffler p 3 6 Replace the fuel filter p 3 8 Conduct a fuel flow test and service as necessary Remove the governor actuator test it for proper operation and replace if necessary Check high idle speed and readjust if necessary Replace the control board Service the fuel injectors and injection pump Check fuel injection timing Service the internal engine governor mechanism Service a worn engine 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 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 1 If loose reconnect wiring harness connectors 1 1 a
22. Figure 3 4 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 Engine components drains filters hoses etc will be hot and can cause severe burns The use of protective gloves is recom mended 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 Let the engine cool before removing the pressure cap Relieve any remaining 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 3 10 remove the coolant drain plug Figure 3 4 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 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
23. Operator Manual Cummins Onan Performance you rely on Commercial Mobile Generator Set HDKCC Spec A C HDKCD Spec A C English Original Instructions 11 2009 981 0174 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 Tac A SAPEIAKPRE E Tou rarer oar iii Je IU SiO SIE VERTIT TERES lt a ess 1 1 ADOU TMS 1 1 Name plato Yh JTK 1 1 2 ipe ter EE 1 2 A 1 2 Eleciromagmeticaeompatibility Weser 1 2 Emissions L YSS 1 3 Genset ERI 00 looks oka knn kann akan mI IK M mI 1 4 ERR 580898 tk Ena Ea 2 1 Recommended Fuel 2 1 Recommended Coolant 2 1 Recommended Engine Oil 2 1 Starting Batteries o ae 2 1 Sten ol He scan eco gt 2 2 Remote Control Panels 2 3
24. UAL STARTING The genset can be started and stopped from 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 Visually inspect for fuel exhaust and coolant leaks Do not start the genset if there is a fuel exhaust or coolant leak and have it repaired 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 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 eguipped with an inverter char ger or other automatic genset starting device Al ways follow the instructions and safety precautions provided by the manufacturer of the automatic start
25. an in accordance with applicable codes Interconnecting the gnerator set and shore power can lead to electrocution of utility line workers eqiupment damage and fire Use an approved switching device to prevent interconnections e 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 ENGINE EXHAUST IS DEADLY Inspect for exhaust leaks at every startup and after every eight hours of running Learn the symptoms of carbon monoxide poi soning in the Operator s Manual Never sleep in the vehicle while the genset is running unless the 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 start ing 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 DIESEL 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
26. ately 586 ohms TX1 secondary winding Go to Step 2 if the secondary circuit of voltage sense transformer TX1 is good If not disconnect the four harness leads from TX1 and test the transformer Replace the transformer if either winding is faulty If the transformer is good check wiring continuity in harness leads P1 33 TX1 RED and P1 34 TX1 GRN Repair or replace components as necessary Make sure connector pin sockets are not damaged or corroded and that they are fully seated and can t be pulled out Make sure the line circuit breaker CB1 CB2 is OFF disconnect the four harness leads from TX1 and test the transformer Replace the transformer if either winding is faulty If the transformer is good check electrical resistance between harness leads TX1 S1 and TX1 S2 which should be approxi mately twice the individual winding resistances in table T1 T2 T3 T4 If not check wiring continu ity in harness leads CB1 LINE TX1 S1 and CB2 LINE TX1 S2 and for proper connections of both sense leads and generator leads to the line terminals on CB1 and CB2 Repair reconnect or replace components as necessary 3 Replace the control board 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 ba
27. ble terminal block Service as necessary by cleaning and tightening battery cable connections recharging or replacing the battery or replacing damaged or missing battery cables Check for 12 VDC across genset battery cable terminal block TB1 f there is no voltage service as necessary by cleaning and tightening battery cable connections recharging or replacing the bat tery or replacing damaged or missing battery cables If there is voltage across TB1 but no response at either remote or local switch go first to Step 4 and then if necessary also to Step 7 Disconnect harness connector P8 from the remote circuits Check for 12 VDC at P8 C Start and at P8 E Stop and for ground continuity at P8 A Ground If there is B and ground continuity service the remote switch and harness If not go to Step 5 Disconnect harness connector P1 from the control board and check for B at P1 10 and for ground continuity at P1 27 If there is B and ground continuity go to Step 6 If not go to Step 10 Check for wiring continuity in the harness between connectors P8 C and P1 9 Start P8 E and P1 32 Stop P8 B and P1 7 Status P8 F and P1 8 Run and P8 A and P1 27 Ground Repair as necessary Make sure connector pin sockets are not damaged or corroded and that they are fully seated and can t be pulled out Replace the control board if the genset still does not start Disconnect harness connector P9 from control switch 51 Check for B
28. 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 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 The fault code stops blinking after five minutes Press Stop three times within three seconas to re store fault code 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 e If there is no response at either remote or local switch go to Step e If there is no response at the remote switch but at the local go to Step 4 e If there is no response at the local switch but at the remote go to Step 7 Check for 12 VDC across genset battery ca
29. d or absorbed substance through an au thorised contractor to a licensed site Finish clean ing by spreading water on the contaminated sur face and allow to evacuate through the sanitary system EMERGENCY ACTION Fire Extinguishing media Large fire Use water spray fog or foam Do not use water jet Small fire Use dry chemical powder or CO gt Fire fighters to use self contained breathing apparatus and full turnout gear Keep fire ex posed containers cool Ingestion Do not induce vomiting Obtain medical advice immediately Inhalation of vapour Remove from further exposure Obtain medi cal attention Generator Set Warning Labels Warning signs are provided on the generator set at or near the point of risk To avoid injury always take the necessary precautions as indicated on the sample signs shown below Caution Warning Indicates a risk of personal injury Caution Warning of Temperature Hazard Indicates a risk of personal injury from high temperature Caution Warning of High Voltage Hazard Indicates a risk of personal injury from electric shock electrocution Caution Warning Indicates a risk of personal injury from eguipment that may be subject to automatic starting or remote starting Caution Warning Indicates to read Operator manual for additional information Caution Warning of Belt and Rotating Part Hazard Indicates a risk of personal injury from entanglemen
30. encounter this product HAZARDOUS REACTIONS This product is stable although slightly re active with oxidising agents Results of decomposition are carbon oxides CO and water Although harmful if swallowed or aspirated breathed in repeated or prolonged exposure is not known to aggravate medical conditions Used oil may contain harmful combustion by prod ucts and unburnt fuel that will cause skin reactions as detailed for fuel Particular care must be taken if oil form a severely overheated engine is handled use impervious gloves lab coat and safety glasses Do not breathe vapour spray PROTECTIVE MEASURES Ensure good ventilation and avoid heat sources Adopt a high standard of personal hygiene In case of skin contact wash thoroughly with soap and wa ter Use safety glasses impervious gloves and lab coat Avoid contamination inside the gloves If overalls become contaminated discontinue use and clean thoroughly No special respiratory precautions are necessary n normal use Do no breathe vapour spray when handling hot materials STORAGE TRANSPORT Store and transport only in correctly marked con tainers Keep containers tightly sealed when not in use Keep a cool well ventilated area out of sun light and away from naked flames Store well away from food stuffs and drinking water Wear splash goggles full suit boots and gloves Absorb leak spill with an material and dispose of unwante
31. 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 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 infreguent 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 accu
32. ermal de composition products are hazardous containing and compounds vapour is explosive High vapour concentra tions can cause respiratory irritation dizziness nausea and loss of consciousness Excessive and prolonged exposure to the mist can cause chronic inflammatory reaction of the lungs and form of pul monary fibrosis Avoid strong oxidising agents e g chlorates which may be use in agriculture Gas oil is slightly irritating to the skin and has a de fatting action Toxicity following single exposure to vi high level of gas oil is of low order Prolonged re peated skin contact may de fat the skin resulting in possible skin irritation and dermatitis In some cases warty cancerous growths have occurred PROTECTIVE MEASURES Ensure good ventilation and avoid heat sources Observance of good housekeeping rules will en sure general safety Do not smoke Avoid breathing mist When working on or testing injection eguipment special is required to avoid perforation of skin by high pressure fuel Use eye protection in the event of suspected high pressure leak Adopt a high standard of personal hygiene In the case of skin contact wash well with soap and water Use glove and overalls and eye protection goggles if there is a risk of splashing Use oil impervious gloves and avoid contamination inside the gloves If overalls become contaminated discontinue use and clean thorou
33. etween connectors J1 12 and K2 85 and for ground continuity at connector K2 86 Repair as necessary Make sure connector pin sockets are not damaged or corroded and that they are fully seated and can t be pulled out Service or replace the starter motor assembly Replace the control board EE CHECKSUM FAULT CODE NO 35 During startup the genset Controller detected EE memory error Corrective Action See an authorized Onan dealer 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 6 Replace the fuel filter p 3 8 Conduct a fuel flow test and service as necessary Remove the governor actuator test it for proper operation and replace if necessary Replace the control board Service the engine O 0 s ON 4 9 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
34. evel and time of exposure increase risk of hearing damage in creases The Specifications page n the Operator manual states noise level for this generator set Se lect and use personal hearing protection appropri ate for your exposure to generator set noise Note for use in countries where compliance to the EU Noise directive is reguired This generator set has not been evaluated and is not marked for use in open air Install the generator set in accordance with the Installation manual Obey local noise restric tions when you operate the generator set ELECTROMAGNETIC COMPATIBILITY Generator sets emit and receive electromagnetic radio freguency energy If the generator set af fects operation of nearby devices or nearby de vices affect generator set operation increase the distance between them This generator set has been evaluted for use in in dustrial environments EMISSIONS genset is authorized you should seek assistance from an approved Onan dealer You should carefully review Operator Owner California genset users may use Table 1 1 as an aid Installation manuals and other information you re in locating information related to the California Air ceive with your genset If you are unsure that the Resources Board reguirements for emissions con installation use maintenance or service of your trol TABLE 1 1 EMISSIONS CONTROL INFORMATION TABLE The California emissions control warranty statement is located in Emissi
35. following ingestion of gas oil vomiting oc curs there is danger of aspiration into the lungs This would cause intense local irritation and chemical pneumonitis that can be fatal Obtain immediate medical assistance Eyes Irrigate copiously with water or preferably eye wash solution for at least five minutes If irrita tion persists seek medical advice Skin Wash thoroughly with soap and water Change clothing if necessary If high pressure injection has occurred prompt surgical attention is reguired Spillage Absorb using sand earth or other suitable ma terial Dispose of unwanted or absorbed flam mable material as directed under Storage Transport Section 5 7 3 LUBRICATION OIL PREMIUM BLUE E 15W40 Also known as oil lube oil sump oil new oil is dark viscous liguid with a slight characteristic odour The base oil contains distillates petroleum sol vent dewaxed heavy paraffinic It is not classified as dangerous according to Directive 1999 45 EC and its amendments and is not classified accord ing to the EU regulations It has a boiling point greater than 150 C a flash point Open Cup of 220 C Cleveland and is insol uble in cold water It is used in engine lubricant oil systems sump pan and filters make up tanks and piping systems as a vii lubrication oil for use in wide range of diesel en gines operating under severe conditions Installers operators and maintainers are likely to
36. ghly Contaminated clothing should be removed soaked with water and laun dered before re use No special respiratory precautions are necessary in normal use DO NOT use as a solvent for removing dirt grease etc from skin STORAGE TRANSPORT Store and transport only in correctly marked con tainers Keep containers closed when not in use Keep cool out of sunlight and away from naked flames Electrical continuity is reguired between the transport and storage vessels during product trans fer Contain leak spill with sand earth or other suitable material and prevent entry of substance into drain age sewerage system water courses and land Dispose of unwanted or absorbed substance through an authorised contractor to a licensed site Inform local and fire authorities should the product reach waterways drains etc EMERGENCY ACTION Fire Extinguishing media Large fire Foam water fog Never use water jet Small fire foam dry powder AAAF CO sand earth Avoid making sparks Fire fighters to use self contained breathing apparatus Keep fire ex posed containers cool using water fog spray Prevent run off from entering waterway drains and drinking water supplies Ingestion Do not induce vomiting Wash the mouth out with water and send to hospital immediately Inhalation of vapour Remove from further exposure Obtain medi cal assistance immediately e Aspiration inhalation of liquid If
37. 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 Check engine coolant level add coolant as necessary and repair any leaks Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset and clean out dirt fouling the radiator passages Run fewer appliances at the same time to keep down engine temperature Note that high altitude and high ambient temperature decrease engine cooling capacity Look for loose or broken fan belts and have them serviced readjust or replace as necessary Clean and flush the cooling system to remove coolant passage fouling p 3 10 Check for air leaks in the housing as a result of missing or loose housing panels and access covers including the access cover for the AC terminals If loose reconnect wiring harness connector E3 1 to engine coolant temperature sender The Controller interprets a loose lead touching ground as high temperature Replace the coolant thermostat which might not be fully opening See Engine Workshop Manual 981 0541 Test temperature sender and replace if necessary LOW OIL PRESSURE CODE NO 2 D
38. her 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 freguently 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 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 After First 50 MAINTENANCE TASK General Inspection Change Engine Oil amp Oil Filter 2 3 FREQUENCY o Se E SEE 2 Replace Fuel Fiter m 4 Replace Coolant Pressure Cap EJ En gt EN Check Generator Slip Rings Brushes Perform more often when operating in hot weather Perform more often when operating in dusty conditions Perform at least once a year Tighten or replace the belt the one closest of the two to the engine in accordance with the Service Manual if it can be deflected more than 1 2 in 12 mm by thumb The tension on the front be
39. ht 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 Many genset shutdowns can be avoided by perform ing periodic maintenance on 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 arranged 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 One blink indicates shutdown due to high en gine coolant temperature 4 1 Two blinks indicate shutdown due to a loss of engine oil pressure 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
40. isabled continue with Step 5 Remove the top housing panel and check for wiring continuity in the harness between charging alter nator G1 and starter solenoid terminal B BAT Repair as necessary Check for proper operation of relay K1 and replace if necessary Check for wiring continuity in the harness between connectors G1 VR and K1 87a Repair as neces sary Disconnect harness connector P1 from the control board Check for wiring continuity in the harness between connectors P1 24 and K1 30 Repair as necessary Make sure connector pin sockets are not damaged or corroded and that they are fully seated and can t be pulled out Replace battery charging alternator G1 NO AC POWER WHEN GENSET IS RUNNING A Circuit Breaker is OFF tripped or malfunctioning or there are poor AC harness connections Corrective Action Reset or turn ON genset circuit breaker CB1 Reset or turn ON any other circuit breaker in the AC power supply system Check voltage at genset AC output terminal block TB2 when the genset is running If there is approxi mately 120 VAC across TB2 1 and TB2 3 and across TB2 2 and TB2 3 repair or reconnect the wir ing between the genset and the main vehicle distribution panel If there is no voltage go to Step 4 Check for proper AC harness connections and repair as necessary Test each circuit breaker and replace if necessary 4 3 TABLE 4 1 TROUBLESHOOTING Some genset service procedures present
41. kg 816 lbs 370 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 E 50 ft 15m in free field site half load 5 2 6 Maintenance Record Record all periodic and unscheduled maintenance and service See Section 3 Periodic Maintenance HOUR METER MAINTENANCE OR SERVICE PERFORMED 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 logo and Performance you rely on are trademarks of Cummins Inc 2009 Cummins Power Generation Inc All rights reserved
42. l away Keep a multi class fire extinguisher handy 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 RECOMMENDED COOLANT Use the best guality ethylene glycol antifreeze solu tion available It should be fully formulated with rust inhibitors and coolant stabilizers Use fresh water that is low in minerals and corrosive chemicals Dis tilled water is best See Section 5 Specifications for coolant capacity RECOMMENDED ENGINE OIL Use API American Petroleum Institute perfor mance Class CH 4 engine oil or better Also look for the SAE Society of Automotive Engineers viscos ity grade Referring to Figure 2 1 choose the vis cosity grade appropriate for the ambient tempera tures expected until the next scheduled oil change Multi grade oils such as SAE 15W 40 are recom mended for year round use See Section 5 Specifications for oil capacity STARTING BATTERIES The genset reguires a 12 volt battery to power its control and starting circuits Reliable genset starting and starter service life depend upon adeguate bat tery system capacity and maintenance See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS p 3 6 and Section 5 Specifi cations for minimum reguired battery ratings 2 1 sv 1003 rowan 5W30
43. literature such as the Service Manual or Parts Catalog for your genset contact the nearest authorized distrib utor Onan has factory trained representatives to handle your reguests for genset parts and service In North America Call 1 800 888 ONAN to contact the nearest Cum mins Onan or Onan only distributor in the United States or Canada This automated service utilizes touch tone phones only Select OPTION 1 press 1 to be automatically connected to the dis tributor 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 RECREATIONAL VEHICLES EOUIPMENT 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 Onan Corpo ration 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 1 2 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 NOISE Generator sets emit noise As noise l
44. lt is automatically adjusted 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 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 CAUTION 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 gualified 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 vent exhaust gases from entering the vehicle
45. mulate 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 6 Plug the exhaust tail pipe to keep out dirt mois ture bugs etc 6 Close the fuel supply valve if so eguipped 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 6 3 Remove the plug from the exhaust tailpipe Change the air filter element if it is dirty Page 3 6 5 Open the fuel supply valve if so eguipped 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 ot
46. nd E1 2 to the governor actuator If they were found connected disconnect the wiring harness and measure electrical resistance across the actua tor leads Replace the actuator if resistance is not 2 8 to 2 9 ohms Disconnect harness connector P1 from the control board and check for wiring continuity in the har ness between connectors P1 28 and E1 1 and for ground continuity at connector E1 2 Repair as necessary Make sure connector pin sockets are not damaged or corroded and that they are fully seated and can t be pulled out Replace the control board if the fault still occurs 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 Check all fuel fittings for fuel and air leaks and tighten as necessary Reprime Replace the engine air filter and clean the spark arrest muffler p 3 6 Replace the fuel filter p 3 8 Conduct a fuel flow test and service as necessary Remove the governor actuator test it for proper operation and replace if necessary Check high idle speed and readjust if necessary Service the fuel injectors and injection pump Check fuel injection timing Service the
47. ne Reinstall the oil drain plug securely Spin off the oil filter canister and clean the filter mounting surface on the engine block Remove the old gasket if it remains Make sure the gasket is in place on the new fil 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 Refill with 5 9 guarts 5 6 liters of oil check oil level Figure 3 1 and secure the front access door Dispose of the used oil and oil filter according to local environmental regulations MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Arcing at battery terminals or in light switches or other eguipment 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 work light ON or OFF away from battery Stop genset and dis connect charger before disconnecting battery cables Disconnect negative cable first and 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 l
48. nifolds can cause severe personal injury 3 3 3 Add drain as necessary 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 the FULL and ADD marks Reinsert the dipstick and secure the oil fill cap and front access door 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 Engine components drains filters hoses etc will be hot and can cause severe burns The use of protective gloves is recom mended 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 3 4 Do notrun the genset with the main tenance access covers off Contace with haz ardous moving parts and hot exhaust manifolds can cause severe personal injury Refer to Table 3 1 for scheduled engine oil change Change oil more often in hot and dusty environ ments 1 Place a pan under the oil drain plug Fig ure 3 1 run the genset until warm and shut it off Remove the front access door and the oil fill cap unscrew the oil drain plug and drain all the oil from the engi
49. ntrol board and check for wiring continuity in the harness between connectors P1 23 and K3 85 and between P1 10 and K3 30 Repair as necessary Make sure connector pin sockets are not dam aged or corroded and that they are fully seated and can t be pulled out Replace the control board if there still is no B at the glow plug bus bar during cranking Remove the governor actuator test it for proper operation and replace if necessary The engine can not start if the actuator fails to pull in its spring loaded plunger Service the fuel injectors and injection pump Service the internal engine governor mechanism Service a worn engine OVER VOLTAGE CODE NO 12 After voltage regulation was enabled Output Voltage jumped to more than 150 VAC 125 of rated for 75 milliseconds or to more than 138 VAC 115 of rated for 3 seconds Corrective Action See an authorized Onan dealer 1 Push the line circuit breaker to OFF start the genset and measure output voltage If output voltage is normal the problem is in the circuits external to the genset If there is no voltage test for and ser vice a grounded or shorted main field or guadrature windings or grounded or shorted voltage sense transformer 2 Replace the control board 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
50. o run 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 gualified 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 eguipment 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 w
51. of boating is such that you can be harmed by this poisonous gas despite good gener ator set maintenance and proper ventilation ONLY YOU CAN PROTECT YOURSELF FROM CO POISONING e Watch constantly for swimmers when the gen erator set is running Make sure exhaust cannot get under the deck between hulls or enter the living quarters through a window vent or door Make sure all CO detectors and audible alarms are working properly Pay attention to the signs of CO poisoning Check the exhaust system for corrosion ob struction and leaks each time you start the generator set and every eight hours if you run it continuously SUBSTANCE HAZARDOUS TO HEALTH Generator sets use substances and emit and create wastes that can cause health risks Genera tor set operators must use appropriate personal protective eguipment such as clothing gloves protective glasses goggles and respiration equip ment when exposed to fuel oil coolant wet batter ies grease cleaning agents or other substances exposed to lungs eyes or skin use appropriate containers for transport storage and disposal of waste substances Follow local regulations for dis posal and recycling ANTIFREEZE FLEETGUARD ES COMPLEAT EG PREMIX This antifreeze is also know as an ethylene glycol based coolant summer coolant coolant additive It is purple coloured viscous liguid with a mild chemi cal odour is soluble in water and harmful It con
52. 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 torgued 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 combus tible materials such as wood and cloth Class B fires combustible and flammable liguid fuels and gaseous fuels Class C fires live electrical eguipment ref NFPA No 10 Genset installation and operation must comply with all applicable local state and federal codes and regulations GENERATOR VOLTAGE IS DEADLY Disable the automatic genset starting feature of an inverter charger or other automatic start ing device before servicing the genset Generator electrical output connections must be made by a trained and experienced electri ci
53. onnect them and power the pump directly with a 12 volt battery Replace the fuel pump if it does not operate If the pump operates disconnect P1 from the control board and check for wiring continuity in the harness between connectors P1 24 and E2 1 and for ground continuity at connector E2 2 Repair as necessary Make sure connector pin sockets are not damaged or cor roded and that they are fully seated and can t be pulled out Replace the control board if the fuel pump still does not operate Check the engine air filter and remove any blockage p 3 6 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 Replace the fuel filter p 3 8 Conduct a fuel flow test and service as necessary If loose reconnect wiring harness connector HR 1 to the glow plug bus bar If it was found connected check for B on the glow plug bus bar while cranking If there is B remove the glow plug bus bar and check for electrical continuity between each glow plug terminal and ground Replace all three glow plugs if any glow plug is open If there is no B check for proper operation of glow plug relay K3 If the relay functions properly check for wiring continuity in the harness between connectors HR1 and K3 87 and for ground continuity at K3 86 If good disconnect harness connector P1 from the co
54. ons Warranty Information the same packet of information as this manual when the genset is shipped from the factory Engine Valve Clearance Lash See Section 5 Specifications The engine is certified to operate on diesel fuel See FUEL REC Engine Fuel Reguirements OMMENDATIONS Page 2 1 Engine Lubricating Oil Reguirements See ENGINE OIL RECOMMENDATIONS Page 2 1 High Idle Speed This is a service procedure requiring trained 9 personnel and proper tools the Service Manual The engine emission control system consists of engine design TOPO ontjksystem and precision manufacture IFI 1 3 TYPICAL GENSET cooling and ventilating air and the maintenance and service access panels of a typical genset Not Figure 1 3 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 3 TYPICAL GENSET 1 4 2 Operation RECOMMENDED FUEL Diesel fuel is combustible and can cause severe personal injury or death Do not smoke near fuel tanks or fuel burning eguip ment or in areas sharing ventilation with such eguipment Keep flames sparks pilot flames electrical arcs and switches and all other sources of ignition wel
55. or sets with a sound shield install service doors before running the generator set to listen for unusual noises Check the genset mounting bolts Check to see that the generator set air inlet and out let openings are not clogged with debris or blocked Keep the generator set compartment clean 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 Engine components drains filters hoses etc will be hot and can cause severe burns The use of protective gloves is recom mended Accidental or remote starting 1 Park the vehicle on level ground shut down the cause severe personal injury or death Discon genset and remove the front access door nect the negative cable at the battery to pre 2 Pull out the oil dip stick wipe it clean reinsert vent starting while working on the genset it and pull it out again to check the oil level Fig Do not run the genset with the main ure 3 1 tenance access covers off Contace with haz ardous moving parts and hot exhaust ma
56. orkers eguipment 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
57. ow 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 3 6 REPLACING THE AIR FILTER ELEMENT Engine components drains filters hoses etc will be hot and can cause severe burns The use of protective gloves is recom mended Do not run the genset with the tenance access covers off Contact with hazar douse moving parts and hot exhaust manifolds can cause severe personal injury 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 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 coolant tank and access door
58. replacement of fuel exhaust air intake or speed control system components that 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 the specification letter which is im portant for obtaining the right parts Genuine replacement parts are recommended for best results Refer to the genset Parts Catalog IMPORTANT S N AC Volts ENGINE INFORMATION CUMMINS POWER GENERATION 1400 73rd Ave NE Minneapolis MN 55432 Made in U S A KVA Pf Hz Amps Fuel Options Wiring Diagram Insulation NEMA Class Ambient The engine family designation engine displacement state ment of compliance with applicable EPA and or California emissions regulations appear in this block on the actual name plate on the genset FIGURE 1 1 TYPICAL NAMEPLATE MODEL NUMBER SERIAL NUMBER FIGURE 1 2 RECORD NUMBERS HERE 1 1 When you call for service parts or product
59. rotection gloves overalls impervious apron should be used Avoid contamination inside the gloves overalls become contaminated discon tinue use and clean thoroughly STORAGE TRANSPORT Store and transport only in correctly marked con tainers Keep containers closed when not in use Keep cool out of sunlight away for naked flames and strong acids do not freeze Store well away from food stuffs and drinking water Take special care to avoid discharge into drains sewers and wa ter courses Contain leak spill with sand earth or non combus tible absorbent material to prevent entry of sub stance into drainage sewerage system water courses and land Eliminate all ignition sources use plastic shovel to transfer to suitable container and dispose of unwanted or absorbed substance through and authorised contractor to a licensed site EMERGENCY ACTION e Fire Extinguishing media CO alcohol resistant foam dry powder or water spray Fire fighters to use self contained breathing apparatus Keep fire exposed containers cool Prevent run off from entering waterways drains and drinking water supplies ngestion Toxic by ingestion If swallowed induce vomit ing only under the advice of a Doctor or poison control centre Delayed treatment may result in fatality Inhalation of vapour Remove from further exposure In case of ir ritation to lungs or throat seek medical advice Aspiration inhalation of liquid
60. start disconnect the Controller lost speed sense quadrature zero crossings for 0 25 seconds Corrective Action See an authorized Onan dealer See an authorized Onan dealer 1 Disconnect Generator connector J3 P3 and check for open and shorted field P3 7 P3 8 and guadrature P3 3 P3 6 windings Service or replace brush block slip rings rotor or stator as nec essary 2 Replace the control board 4 10 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 Prime 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 11 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 Freguency 60 Hz
61. t in moving parts gt 2 gt gt gt Caution Warning of Pressure Hazard Indicates a risk of personal injury from pressurized fluids viii 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 This is the Service Manual for the generator sets gensets listed on the front cover 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 This generator set is not ignition protected and shall not be used in a flammable vapor environment 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
62. tings 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 fit ting Flare nut wrenches should be used on the flare nuts so as not to round the corners on the nuts Dis pose of the fuel filter according to local regulations Note Filter removal will be easier if the filter mount ing bracket screws are removed Wipe dirt off the fuel hose fittings at the fuel filter before disconnecting the hoses so as to keep dirt out of the fuel system Installing the 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 Secure the access door HOSE TO FUEL ALK FILTER MOUNTING NUT HOSE FROM FUEL PUMP FIGURE 3 3 FUEL FILTER 3 9 MAINTAINING THE COOLANT SYSTEM Refer to Table 3 1 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 34 F 37 Recommended Coolant See RECOMMENDED COOLANT p 2 1 Pressure Cap Replace the pressure cap
63. tteries serving the genset are connected in parallel 12 volt rather than in series 24 volt 2 Select a lower battery booster charge rate 4 8 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 STARTING FAULT CODE NO 32 The Controller could not detect cranking speed guadrature zero crossings for 12 seconds Corrective Action 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 Service the battery as necessary by cleaning and tightening connections recharging or replacing the battery or replacing damaged battery cables Change the engine oil to oil of the proper viscosity for the ambient temperature High oil viscosity can slow down cranking speed Remove the top housing panel and check for wiring continuity in the harness between connectors SW starter solenoid and K2 87 starter pilot relay and between K2 30 and B BAT starter sole noid Repair as necessary Check for proper operation of starter pilot relay K2 and replace if necessary Disconnect harness connector P1 from the control board and check for wiring continuity in the har ness b
64. uring normal operation engine oil pressure dropped to less than 14 psi for 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 3 Test low oil pressure cutoff switch S2 and replace if necessary 4 Service the engine See Engine Workshop Manual 981 0541 SERVICE 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 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 should perform genset service See Safety Precautions OVER 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 2 Prime the engine fuel system for one minute 2 4 If the fuel pump does not operate check for loose wiring harness connectors E2 1 and E2 2 and reconnect them to the pump If they were found connected disc

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