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Operator’s Manual

HDKCA, HDKCB

Printed in U.S.A. 08-04 981-0173

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by any means, is strictly prohibited.
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.

diesel warnings

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by any means, is strictly prohibited.
Supplement: 981-1049
Date: 09/04
Insert with-
Manual Number (Date): 981-0173 (08/04) 981-0174 (08/04) 981-0540 (08/04)
981-0170 (11/03) 981-0171 (11/03) 981-0526D (02/04)
981-0166B (06/03) 981-0167B (06/03) 981-0535 (10/02)
981-0161 (08/89) 981-0522B (07/99)

Purpose: These instructions supplement the instructions for filling the engine cooling system found in the
Periodic Maintenance sections of the Operator’s and Service Manuals listed above.

WARNING To prevent severe burns from hot coolant under pressure, carefully observe all of the
Safety Precautions and Instructions in the Manual for handling and filling coolant.

Instructions: Use a funnel when filling the cooling system through the fill opening (Figure 1) to prevent
coolant from entering the vent hose and blocking the escape 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.

CAUTION Coolant trapped in the vent hose will prevent the system from filling to its capacity, which
can lead to serious engine damage.

PRESSURE CAP
AND SYSTEM FILL
OPENING

FIGURE 1. TYPICAL COOLANT FILL OPENING WITH CONNECTED FILL, OVERFLOW AND VENT HOSES

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Table of Contents

SECTION PAGE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii


1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Typical Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Recommended Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Recommended Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Recommended Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Starting Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Remote Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Manual Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Manual Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Automatic Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Loading the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Resetting Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Connecting to Utility Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operating in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operating in Hot Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operating at High Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operating in Dusty Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Breaking In a New Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Exercising the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Storing the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

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SECTION PAGE

3. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1


General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Changing Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Maintaining the Battery and Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Replacing the Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cleaning the Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Maintaining the Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Troubleshooting With Table 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fault Code Blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Restoring Fault Code Blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
5. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
6. MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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Safety Precautions
Thoroughly read the OPERATOR’S MANUAL S Do not work on the genset when mentally or
before operating the genset. Safe operation and physically fatigued or after consuming alcohol
top performance can only be obtained when or drugs.
equipment is operated and maintained proper- S You must be trained and experienced to make
ly. adjustments while the genset is running—hot,
moving or electrically live parts can cause se-
The following symbols in this manual alert you to vere personal injury or death.
potential hazards to the operator, service person
and equipment. S Used engine oil has been identified by some
U. S. state and federal agencies as causing
DANGER alerts you to an immediate hazard cancer or reproductive toxicity. Do not ingest,
that will result in severe personal injury or inhale, or contact used oil or its vapors.
death. S Ethylene glycol, used as engine antifreeze, is
toxic to humans and animals. Clean up spills
WARNING alerts you to a hazard or unsafe and dispose of used engine coolant in accor-
practice that can result in severe personal inju- dance with local environmental regulations.
ry or death. S Keep multi-class ABC fire extinguishers
handy. Class A fires involve ordinary combus-
CAUTION alerts you to a hazard or unsafe
tible materials such as wood and cloth; Class B
practice that can result in personal injury or fires, combustible and flammable liquid fuels
equipment damage. and gaseous fuels; Class C fires, live electrical
equipment. (ref. NFPA No. 10)
Electricity, fuel, exhaust, moving parts and batter-
ies present hazards which can result in severe per- S Genset installation and operation must comply
sonal injury or death. with all applicable local, state and federal
codes and regulations.
GENERAL PRECAUTIONS GENERATOR VOLTAGE IS DEADLY
S Keep children away from the genset. S Disable the automatic genset starting feature
S Do not use evaporative starting fluids. They of an inverter-charger or other automatic start-
are highly explosive. ing device before servicing the genset.
S To prevent accidental or remote starting while S Generator electrical output connections must
working on the genset, disconnect the nega- be made by a trained and experienced electri-
tive (−) battery cable at the battery. cian in accordance with applicable codes.

S Let the engine cool down before removing the S The genset must not be connected to the pub-
coolant pressure cap or opening the coolant lic utility or any other source of electrical power.
drain. Hot coolant under pressure can spray Back-feed could lead to electrocution of utility
out and cause severe burns. personnel and damage to equipment. An ap-
proved switching device must be used to pre-
S Keep the genset and its compartment clean. vent interconnections.
Excess oil and oily rags can catch fire. Dirt and
S Use caution when working on live electrical
gear stowed in the compartment can restrict
equipment. Remove jewelry, make sure cloth-
cooling air.
ing and shoes are dry, stand on a dry wooden
S Make sure all fasteners are secure and platform or rubber insulating mat and use tools
torqued properly. with insulated handles.

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iii by any means, is strictly prohibited.
ENGINE EXHAUST IS DEADLY BATTERY GAS IS EXPLOSIVE
S Inspect for exhaust leaks at every startup and S Wear safety glasses.
after every eight hours of running. S Do not smoke.
S Learn the symptoms of carbon monoxide poi- S To reduce arcing when disconnecting or recon-
soning in the Operator’s Manual. necting battery cables, always disconnect the
negative (−) battery cable first and reconnect
S Never sleep in the vehicle while the genset is
it last.
running unless the vehicle is equipped with a
working carbon monoxide detector. MOVING PARTS CAN CAUSE SEVERE
S Do not operate the genset when the vehicle is PERSONAL INJURY OR DEATH
in a confined space, such as a garage. S Disable the automatic genset starting feature
S Disable the automatic genset starting feature of an inverter-charger or other automatic start-
of an inverter-charger or other automatic start- ing device before servicing the genset.
ing device before storing the vehicle or parking S Do not wear loose clothing or jewelry near
it in a garage or other confined space. moving parts such as PTO shafts, fans, belts
and pulleys.
S The exhaust system must be installed in accor-
dance with the genset Installation Manual. S Keep hands away from moving parts.
S Engine cooling air must not be used for heating S Keep guards in place over fans, belts, pulleys,
working or living spaces or compartments. and other moving parts.

FLAMMABLE VAPOR CAN CAUSE A


DIESEL FUEL IS COMBUSTIBLE DIESEL ENGINE TO OVERSPEED
S Do not smoke or turn electrical switches ON or
OFF where fuel fumes are present or in areas Flammable vapor can cause a diesel engine to
sharing ventilation with fuel tanks or equip- overspeed and become difficult to stop, resulting in
ment. Keep flames, sparks, pilot lights, arc- possible fire, explosion, severe personal injury and
producing equipment and all other sources of death. Do not operate a diesel-powered genset
ignition well away. where a flammable vapor environment can be
created by fuel spill, leak, etc. The owners and
S Fuel lines must be secured, free of leaks and operators of the genset are solely responsible for
separated or shielded from electrical wiring. operating the genset safely.

Mobile-8

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iv by any means, is strictly prohibited.
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). [The engine family designation, engine displacement, state-
ment of compliance with applicable EPA and / or California
WARNING This genset is not a life support sys- emissions regulations appear in this block on the actual name-
plate on the genset.]
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.

WARNING 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 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
FIGURE 1-1. TYPICAL NAMEPLATE
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 MODEL NUMBER: ___________________________
easy to find when needed. Each character in these SERIAL NUMBER: ___________________________
numbers is significant. The last character of the
model number is the specification letter, which is im-
portant for obtaining the right parts. Genuine FIGURE 1-2. RECORD NUMBERS HERE
Onan replacement parts are recommended for
best results. Refer to the genset Parts Catalog.

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HOW TO OBTAIN SERVICE RECREATIONAL VEHICLES − EQUIPMENT,
PARTS AND SERVICE.
When you call for service, parts, or product literature
If you have difficulty in arranging service or resolv-
(such as the Service Manual or Parts Catalog) for
ing a problem, please contact the Service Manager
your genset, contact the nearest authorized distrib-
at the nearest Cummins/Onan distributor for assis-
utor. Onan has factory-trained representatives to
tance.
handle your requests for genset parts and service.
Outside North America
In North America
If you are outside North America, call Onan Corpo-
Call 1-800-888-ONAN to contact the nearest Cum- ration at 1−763−574−5000 from 7:30 AM to
mins/Onan or Onan-only distributor in the United 4:00 PM, Central Standard Time, Monday through
States or Canada. (This automated service utilizes Friday, or fax 1−763−528−7229.
touch-tone phones only). Select OPTION 1
Information to Have Ready
(press 1) to be automatically connected to the dis-
tributor nearest to you. Before calling for service, have the following infor-
mation available:
If you are unable to contact a distributor using the
1. The complete genset model number and serial
automated service, consult the Yellow Pages. Typi-
number. See About This Manual (Page 1-1).
cally, our distributors are listed under:
2. The date of purchase
GENERATORS − ELECTRIC, 3. The nature of the problem. See Section 4. Trou-
ENGINES − GASOLINE OR DIESEL, or bleshooting.

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1-2 by any means, is strictly prohibited.
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 requirements 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
Emissions 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 Requirements
OMMENDATIONS (Page 2-1).
Engine Lubricating Oil Requirements See ENGINE OIL RECOMMENDATIONS (Page 2-1).
High Idle Speed. This is a service procedure requiring trained
Engine Adjustments
personnel and proper tools. See the Service Manual.
The engine emission control system consists of engine design
Engine Emission Control System
and precision manufacture. (IFI)

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1-3 by any means, is strictly prohibited.
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 & VENTILATING AIR IN HOT AIR OUT

FIGURE 1-3. TYPICAL GENSET

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1-4 by any means, is strictly prohibited.
2. Operation
RECOMMENDED FUEL
WARNING 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.
Use clean, fresh No. 2 diesel fuel (ASTM 2-D) when
the outdoor ambient temperature is above freezing, FIGURE 2-1. OIL VISCOSITY VS. TEMPERATURE
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 quality 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 for Section 5. Specifications 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 for Section 5. Specifications oil 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. Specifica-
tions for minimum required battery ratings.

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CONTROL PANEL (Rapid blinking before cranking starts indicates that
the glow plugs are preheating the combustion
The control panel (Figure 2-2) has the following fea- chambers. The genset controller automatically var-
tures: ies the time based on engine temperature.)
Control Switch − This switch is used to start and Line Circuit Breaker(s) − The line circuit breakers
stop the genset, prime the engine fuel system and protect the AC power leads connected to the gen-
restore the fault code (blinking status light). set.
Status Lamp − This is a lamp in the control switch Coolant Recovery Tank Fill Cap − The recovery
that blinks rapidly during preheat and cranking. It tank provides for coolant expansion. Replenish the
stays on continuously while the genset is running. If normal loss of coolant by filling here.
the genset shuts down, it will blink a numerical code
to indicate the nature of the fault shutdown (see Hour Meter − The hour meter records the total run-
Section 4. Troubleshooting). ning time of the genset. It cannot be reset.

LINE CIRCUIT COOLANT RECOVERY


BREAKER(S) TANK FILL CAP

COOLANT RECOVERY
TANK FLUID LEVEL

CONTROL SWITCH
&STATUS LAMP

HOUR METER

FIGURE 2-2. CONTROL PANEL

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REMOTE CONTROL PANELS
There probably is a remote genset control panel in-
side the vehicle. Onan offers three remote control
kits as follows:
S Remote switch / status lamp (Figure 2-3).
S Remote switch / status lamp and hour meter
(Figure 2-4).
S Remote switch / status lamp and DC voltmeter FIGURE 2-3. REMOTE SWITCH
(Figure 2-5).
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).

FIGURE 2-4. REMOTE SWITCH / HOUR METER

FIGURE 2-5. REMOTE SWITCH / DC VOLTMETER

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WARNING EXHAUST GAS is deadly. All en- 4. Turn off air conditioners and other large ap-
gine exhaust contains carbon monoxide; an pliances.
odorless, colorless, poisonous gas that can
cause unconsciousness and death. Symptoms PRIMING THE FUEL SYSTEM
of carbon monoxide poisoning include:
The fuel system should be primed after replacing
• Dizziness • Headache the fuel filter or running the genset out of fuel. To
• Nausea • Weakness and Sleepiness prime the fuel system, hold the control switch down
• Vomiting • Inability to Think Coherently in its Stop position for half a minute.
IF YOU EXPERIENCE ANY OF THESE SYMP-
TOMS, GET INTO FRESH AIR IMMEDIATELY. If MANUAL STARTING
symptoms persist, seek medical attention. Shut
The genset can be started and stopped from the
down the genset and do not operate it until it has
genset control panel or from a remote panel.
been inspected and repaired.
1. Perform the PRE-START CHECKS, prime the
Never sleep in the vehicle while the genset is fuel system if necessary, and turn off the air
running unless the vehicle has a working car- conditioners and other large electrical loads.
bon monoxide detector. The exhaust system
must be installed in accordance with the genset 2. Push and hold Start until the genset starts. The
Installation Manual. Make sure there is ample status lamp will come on when the genset starts
fresh air when operating the genset in a con- and will stay on while it runs. While starting it will
fined area. blink rapidly indicating preheating and crank-
ing. (Depending on how cold it is, preheating
PRE-START CHECKS can take up to 15 seconds, extending the time
that the lamp blinks.)
Before the first start of the day and after every eight
hours of operation, inspect the genset as instructed CAUTION Excessive cranking can over-
under GENERAL INSPECTION (p. 3-2). Keep a log heat and damage the starter motor. Do not
of maintenance and the hours run and perform any crank for more than 30 seconds at a time.
maintenance that may be due. See Returning the Wait at least 2 minutes before trying again.
Genset to Service (p. 2-7) if the vehicle has been in 3. See Section 4. Troubleshooting if the genset
storage. does not start after several tries.
Before each start: 4. Let the genset warm up a few minutes until it is
1. Make sure all vehicle carbon monoxide (CO) running smoothly before connecting the ve-
detectors are working. hicle electrical loads (appliances).

2. Check for signs of fuel and exhaust leaks and 5. Check for fuel, exhaust and coolant leaks. Stop
damage to the exhaust system. the genset immediately if there is a fuel, ex-
haust or coolant leak and have it repaired.
3. To prevent overheating and to reduce fouling
with dust and debris, make sure the genset’s MANUAL STOPPING
normal ground clearance is not being reduced
by sloping ground, curbs, logs or other objects. Run the genset under no load for a few minutes to
Repark the vehicle if necessary and/or remove allow the engine to cool down and then push and re-
any objects blocking the air inlet or air outlet. lease Stop.

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AUTOMATIC STARTING AND STOPPING and then on again, even though the sum of the loads
is less than genset rating. The reason for this is that
The vehicle may be equipped with an inverter-char- a motor’s startup load is much larger than its running
ger or other automatic genset starting device. Al- load. It may be necessary to run fewer ap-
ways follow the instructions and safety precautions pliances when large motors and air condition-
provided by the manufacturer of the automatic start- ers are cycling on and off.
ing device when enabling automatic genset starting.
Maximum power decreases as altitude increases
WARNING EXHAUST GAS is deadly. MOV- because air density decreases. For every 1000-foot
ING PARTS and ELECTRICITY can cause severe (305 m) increase in elevation you can expect power
personal injury or death. To reduce exposure to to decrease approximately 3.5 percent. Table 2-2
these hazards, always disable automatic genset shows the results of typical calculations. It may be
starting before: necessary to run fewer appliances at higher alti-
tudes.
S Sleeping in vehicle, unless vehicle has a
working CARBON MONOXIDE detector TABLE 2-1. TYPICAL APPLIANCE LOADS
S Parking vehicle in garage or confined space Appliance Load (watts)
S Parking vehicle for storage Air Conditioner 1400-2000
Battery Charger Up to 3600
S Servicing genset
DC Converter 300-900
S Servicing batteries Refrigerator 600-1000
S Servicing electrical appliances Microwave Oven 1000-1500
S Fueling vehicle Electric Frying Pan or Wok 1000-1500
Electric Stove Element 350-1000
LOADING THE GENSET Electric Water Heater 1000-1500
Electric Iron 500-1200
The genset can power AC motors, air conditioners,
AC/DC converters, battery chargers and other ap- Electric Hair Dryer 800-1500
pliances. How much appliance load* can be pow- Coffee Percolator 550-750
ered depends upon the genset power rating. The Television 200-600
genset will shut down or its circuit breakers will trip if Radio 50-200
the sum of the loads exceeds genset power. See Electric Drill 250-750
Section 4. Troubleshooting.
Electric Broom 200-500
To avoid overloading the genset and causing shut- Electric Blanket 50-200
downs, compare the sum of the loads of the ap-
pliances that are likely to be used at the same time to TABLE 2-2. POWER VS. ALTITUDE
the power rating of the genset. Use Table 2-1 or the
Elevation above Sea
ratings on the appliances themselves (if so marked) Level
Maximum Power
to obtain the individual appliance loads. It may be
necessary to run fewer appliances at the same at/below 500 ft (152 m) 12,000 W (rated)
time—the sum of the loads must not be greater at 2500 ft (762 m) 11,280 W
than genset rating. at 5500 ft (1676 m) 10,200 W
The genset may shut down due to overload when a 10,200 W minus 360 W
above 5500 ft (1676 m)
large motor or air conditioner is started or cycles off every 1000 ft (305 m)

* Appliance load and genset power are measured in terms of watts (W) or kilowatts (kW), where 1 kilowatt (kW) = 1000 watts (W).

Redistribution or publication of this document,


2-5 by any means, is strictly prohibited.
RESETTING CIRCUIT BREAKERS OPERATING IN COLD WEATHER
If a circuit breaker in the main power distribution
Make sure the engine oil viscosity is appropriate for
panel of the vehicle or on the genset (Figure 2-2)
the cold weather temperatures. See ENGINE OIL
trips, either a circuit shorted or too many appliances
RECOMMENDATIONS (Page 2-1). Be sure to
were running. Note that the genset will continue to
change the oil if a sudden drop in temperature oc-
run after a circuit breaker trips.
curs.
If a circuit breaker trips, disconnect or turn off as
many loads as possible and reset the circuit break- OPERATING IN HOT WEATHER
er. (Push the circuit breaker to OFF to reset it and
then to ON to reconnect the circuit.) If the circuit Pay particular attention to the following items when
breaker trips right away, either the electrical dis- operating the genset in hot weather:
tribution system has a short or the circuit breaker is
faulty. Call a qualified electrician. 1. Make sure nothing blocks airflow to and from
the genset.
If the circuit breaker does not trip, reconnect the ap-
pliances, one by one, up to a total load that does not 2. Make sure engine oil viscosity is appropriate for
overload the genset or cause the circuit breaker to the ambient temperatures. See ENGINE OIL
trip. If a circuit breaker trips right away when an ap- RECOMMENDATIONS (Page 2-1).
pliance is connected, the appliance probably has a
short. 3. Keep the genset clean.
4. Perform maintenance due. See PERIODIC
Electrical appliances and tools must be used and
MAINTENANCE SCHEDULE (Page 3-1).
maintained properly and be properly grounded to
cause the line circuit breakers to trip when short cir-
cuits occur. OPERATING AT HIGH ALTITUDE

WARNING Short circuits in electrical ap- For the effect of altitude on maximum power, see
pliances and tools can cause fire and electrical LOADING THE GENSET (Page 2-5).
shock leading to severe personal injury or
death. Read and follow the equipment and tool
manufacturer’s instructions and warnings re- OPERATING IN DUSTY ENVIRONMENTS
garding use, maintenance and proper ground-
ing. Pay particular attention to the following items when
operating the genset in dusty environments:
CONNECTING TO UTILITY POWER
1. Do not let dirt and debris accumulate inside the
A vehicle with provisions for connecting utility power genset compartment. Keep the genset clean.
must have an approved device to keep the genset
and utility from being interconnected. See the gen- 2. Perform air cleaner maintenance more often.
set Installation Manual for more information. See PERIODIC MAINTENANCE SCHEDULE
(Page 3-1).
WARNING Interconnecting the genset and the 3. Change engine oil more often. See PERIODIC
public utility (or any other power source) can MAINTENANCE SCHEDULE (Page 3-1).
lead to electrocution of utility line workers,
equipment damage and fire. Use an approved 4. Keep containers of engine oil that have been
switching device to prevent interconnections. opened tightly closed to keep out dust.

Redistribution or publication of this document,


2-6 by any means, is strictly prohibited.
BREAKING IN A NEW ENGINE WARNING CARBON MONOXIDE is deadly
and can accumulate to dangerous levels in
Proper engine break-in on a new genset or on one garages and other confined spaces. Dis-
with a rebuilt engine is essential for top engine per- able the automatic genset starting feature
formance and acceptable oil consumption. Run the of an inverter-charger or other automatic
genset at approximately 1/2 rated power for the first starting device before storing the vehicle.
2 hours and then at 3/4 rated power for 2 more 2. Push the genset line circuit breaker OFF
hours. See LOADING THE GENSET (Page 2-5). (Page 2-6).
3. Change the engine oil and attach a tag indicat-
Proper engine oil and oil level are especially critical ing oil viscosity. See ENGINE OIL REC-
during break-in because of the higher engine tem- OMMENDATIONS (Page 2-1).
peratures that can be expected. Change the oil if not
appropriate for the ambient temperatures during 4. Disconnect the battery cables (negative [−]
break-in. See ENGINE OIL RECOMMENDATIONS cable first) from the starting battery and store
(Page 2-1). Check oil level twice a day or every the battery according to the battery manufac-
4 hours during the first 24 hours of operation and turer’s recommendations. See MAINTAINING
change the oil and oil filter after the first 50 hours of THE BATTERY AND BATTERY CONNEC-
operation. TIONS (Page 3-4).
5. Plug the exhaust tail pipe to keep out dirt, mois-
EXERCISING THE GENSET ture, bugs, etc.
6. Close the fuel supply valve (if so equipped).
Exercise the genset at least 2 hours each month if
use is infrequent. Run the genset at approximately Returning the Genset to Service
1/2 rated power. See LOADING THE GENSET 1. Check the oil tag on the genset and change the
(Page 2-5). A single two hour exercise period is oil if the viscosity indicated is not appropriate for
better than several shorter periods. the temperatures expected. See ENGINE OIL
RECOMMENDATIONS (Page 2-1).
Exercising a genset drives off moisture, re-lubri- 2. Reconnect the starting battery (negative [−]
cates the engine, replaces stale fuel and removes cable last). See MAINTAINING THE BATTERY
oxides from electrical contacts. The result is better AND BATTERY CONNECTIONS (Page 3-4).
starting, more reliable operation and longer engine
life. 3. Remove the plug from the exhaust tailpipe.
4. Change the air filter element if it is dirty
STORING THE GENSET (Page 3-4).
5. Open the fuel supply valve (if so equipped).
Proper storage is essential for preserving top gen- 6. Inspect the genset. See GENERAL INSPEC-
set performance and reliability when the genset TION (Page 3-2).
cannot be exercised regularly and will be idle for
more than 120 days. 7. Push the genset line circuit breaker ON
(Page 2-6) when the genset is ready to power
appliances.
Storing the Genset
8. Enable the automatic genset starting feature of
1. Disable the automatic genset starting feature of an inverter-charger or other automatic starting
an inverter-charger or other automatic starting device following the device manufacturer’s in-
device. structions and safety precautions.

Redistribution or publication of this document,


2-7 by any means, is strictly prohibited.
Redistribution or publication of this document,
by any means, is strictly prohibited.
3. Periodic Maintenance
Periodic maintenance is essential for top perfor- any engine repair establishment or individual. How-
mance and long genset life. Use Table 3-1 as a ever, warranty work must be completed by an au-
guide for normal periodic maintenance. In hot and thorized Onan dealer.
dusty environments some maintenance procedures
should be performed more frequently, as indicated
by the footnotes in the table. WARNING Accidental or remote starting can
cause severe personal injury or death. Discon-
Maintenance, replacement or repair of emission nect the negative (−) cable at the battery to pre-
control devices and systems may be performed by vent starting while working on the genset.
TABLE 3-1. PERIODIC MAINTENANCE SCHEDULE
FREQUENCY

MAINTENANCE TASK After Every


Every Every Every Every Every
First 50 1500 Page
Day Month 250 Hrs 500 Hrs 800 Hrs
Hrs Hrs
General Inspection • 3-2
Check Engine Oil Level • 3-2
Check Engine Coolant Level • 3-7
Check Battery & Battery Connections1 • 3-4
Change Engine Oil & Oil Filter1, 2, 3 • • 3-3
Check Primary V-Belt Tension4 • −
Clean Spark Arrestor3 • 3-5
Replace Engine Air Filter2, 3 • 3-4
Replace Fuel Filter3 • 3-6
Adjust Engine Valve Lash7 • −
Flush Coolant System5 • 3-7
Replace Coolant Pressure Cap5 • 3-7
Replace V-Belts & Coolant Hoses6, 7 • −
Check Fuel Injector Pressure7, 8 • −
1. Perform more often when operating in hot weather.
2. Perform more often when operating in dusty conditions.
3. Perform at least once a year.
4. 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 belt is automatically adjusted.)
5. Perform at least once every two years.
6. Perform at least once every five years.
7. Must be performed by trained and experienced personnel (authorized Onan service representatives).
8. EPA requirement.

Redistribution or publication of this document,


3-1 by any means, is strictly prohibited.
GENERAL INSPECTION Do not operate power ventilators or exhaust fans
while the vehicle is standing with the genset run-
Inspect the genset before the first start of the day ning. The ventilator or fan can draw exhaust gases
and after every eight hours of operation. into the vehicle.

Oil Level Fuel System

Check engine oil level (Figure 3-1). Check for leaks at hose, tube and pipe fittings in the
fuel supply system while the genset is running and
Engine Coolant System while it is stopped. Check flexible fuel hose sections
for cuts, cracks, and abrasions. Make sure the fuel
CAUTION Operating the genset when coolant line is not rubbing against other parts. Replace worn
level is low can cause serious engine damage. or damaged fuel line parts before leaks occur.

Check the engine coolant level and look for coolant WARNING Diesel fuel leaks can lead to fire. Do
leaks around the bottom of the genset and on the not operate the genset if operation causes fuel
ground below. Minor leaks that can be replenished to leak.
by daily additions of coolant to the recovery tank
should be repaired by a qualified service technician Prime the fuel system if the genset ran out of fuel.
as soon as possible. Larger leaks are cause for
shutting down the genset until it can be repaired. Battery Connections
Exhaust System Check the battery terminals for clean, tight connec-
tions. Loose or corroded connections have high
WARNING EXHAUST GAS IS DEADLY! Do not electrical resistance which makes starting harder.
operate the genset if there is an exhaust leak or See MAINTAINING THE BATTERY AND BATTERY
any danger of exhaust gases entering or being CONNECTIONS (p. 3-4).
drawn into the vehicle.
Mechanical
Look and listen for exhaust system leaks while the
genset is running. Shut down the genset if a leak is
Look for mechanical damage and listen for unusual
found and have it repaired before operating the gen-
noises. Check the genset mounting bolts.
set again.

Look for openings or holes between the genset To prevent overheating and to reduce fouling with
compartment and vehicle cab or living space if the dust and debris, make sure the genset’s normal
genset engine sounds louder than usual. Have all ground clearance is not being reduced by sloping
such openings or holes closed off or sealed to pre- ground, curbs, logs or other objects. Repark the ve-
vent exhaust gases from entering the vehicle. hicle if necessary and/or remove any objects block-
ing the air inlet or air outlet.
Replace dented, bent or severely rusted sections of
the tailpipe and make sure the tailpipe extends at CHECKING ENGINE OIL LEVEL
least 1 inch (25.4 mm) beyond the perimeter of the
vehicle. WARNING State and federal agencies have de-
termined that contact with used engine oil can
WARNING Do not park the vehicle in high grass cause cancer or reproductive toxicity. Avoid
or brush. Contact with the exhaust system can skin contact and breathing of vapors. Use rub-
cause a fire. ber gloves and wash exposed skin.
1. Park the vehicle on level ground, shut down the
Park the vehicle so that the genset exhaust gases
genset and remove the front access door.
can disperse away from the vehicle. Barriers such
as walls, snow banks, high grass and brush and oth- 2. Pull out the oil dip stick, wipe it clean, reinsert
er vehicles can cause exhaust gases to accumulate it and pull it out again to check the oil level (Fig-
in and around the vehicle. ure 3-1).

Redistribution or publication of this document,


3-2 by any means, is strictly prohibited.
3. Add or drain oil as necessary. See REC- 2. Remove the front access door and the oil fill
OMMENDED ENGINE OIL (p. 2-1). Keep the cap, unscrew the oil drain plug and drain all the
oil level between the FULL and ADD marks. oil from the engine. Reinstall the oil drain
plug securely.
CAUTION Too much oil can cause high oil
consumption. Too little oil can cause severe 3. Spin off the oil filter canister and clean the filter
engine damage. Keep the oil level between 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
CHANGING ENGINE OIL AND OIL FILTER touches the block. Turn it an additional 1/2 to
3/4 turn. Do not overtighten.
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

DIP STICK

FILL CAP

DRAIN PLUG
(22 MM HEX HEAD)

FIGURE 3-1. ENGINE OIL MAINTENANCE

Redistribution or publication of this document,


3-3 by any means, is strictly prohibited.
MAINTAINING THE BATTERY AND 2. Remove battery cables with a battery terminal
BATTERY CONNECTIONS puller.
3. Make sure which terminal is positive (+) and
WARNING Arcing at battery terminals or in which is negative (−) before making battery
light switches or other equipment, and flames or connections, always removing the negative (−)
sparks, can ignite battery gas causing severe cable first and reconnecting it last to reduce
personal injury—Ventilate battery area before arcing.
working on or near battery—Wear safety
glasses—Do not smoke—Switch work light ON REPLACING THE AIR FILTER ELEMENT
or OFF away from battery—Stop genset and dis-
connect charger before disconnecting battery Refer to Table 3-1 for scheduled air filter replace-
cables—Disconnect negative (−) cable first and ment. Replace it more often in dusty environments.
reconnect last. The air filter is accessible through the front access
door (Figure 3-2). Loosen the three screws that se-
Refer to Table 3-1 for scheduled battery mainte- cure the coolant recovery tank to the housing top
nance, and follow the battery manufacturer’s in- panel and move it out of the way. Loosen the two
structions. Have the battery charging system ser- screws that secure the air filter housing to the hous-
viced if DC system voltage is consistently low or ing top panel so that the spring clips that secure the
high. Always: filter housing end cap can be unlatched. Remove
1. Keep the battery case and terminals clean and the end cap and replace the filter element. Secure
dry and the terminals tight. the filter housing, coolant tank and access door.

COOLANT
RECOVERY TANK AIR FILTER HOUSING
(SHOWN CUT AWAY) END CAP

FIGURE 3-2. REPLACING THE AIR FILTER ELEMENT

Redistribution or publication of this document,


3-4 by any means, is strictly prohibited.
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
WARNING 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


FOR ACCESS

MUFFLER

FIGURE 3-3. SPARK ARRESTOR CLEANOUT PLUG

Redistribution or publication of this document,


3-5 by any means, is strictly prohibited.
REPLACING THE FUEL FILTER as well as on the flare nut so as not to stress the fit-
ting. Flare nut wrenches should be used on the flare
See Table 3-1 for scheduled fuel filter replacement. nuts so as not to round the corners on the nuts. Dis-
A dirty fuel filter may be the cause of a failure to start. pose of the fuel filter according to local regulations.
The fuel filter is accessible through the front access (Note: Filter removal will be easier if the filter mount-
door (Figure 3-4). ing bracket screws are removed.)

WARNING Diesel fuel is combustible and can CAUTION Wipe dirt off the fuel hose fittings at
cause severe personal injury or death. Do not the fuel filter before disconnecting the hoses so
smoke near diesel fuel tanks or equipment. as to keep dirt out of the fuel system.
Keep flames, sparks, pilot lights, electrical
switches, arc-producing equipment and all oth-
Installing the Fuel Filter
er sources of ignition well away. Keep a type
ABC fire extinguisher in the vehicle.
Rotate the filter half a turn around its mounting stud
if the fittings interfere with the bracket. It only fits one
Close any fuel line shutoff valve before discon-
way.
necting the fuel line from the filter.

Accidental or remote starting can cause severe Connect the fuel fittings before tightening the filter
personal injury or death. Disconnect the nega- mounting nut. Take care not to crossthread the fuel
tive (−) cable at the battery to prevent starting fittings. Thread them in by hand and tighten one flat
while working on the genset. past seating with two wrenches.

Removing the Fuel Filter Prime the fuel system for half a minute to fill the new
filter with fuel.
Disconnect the two fittings at the filter and remove
the mounting nut. Apply a wrench on the filter fitting Secure the access door.

HOSE TO FUEL
ENGINE FILTER

FILTER
MOUNTING NUT

BRACKET
HOSE FROM MOUNTING
FUEL PUMP SCREWS

FIGURE 3-4. FUEL FILTER

Redistribution or publication of this document,


3-6 by any means, is strictly prohibited.
MAINTAINING THE COOLANT SYSTEM cap, turn it the rest of the way and withdraw it. Then
remove the coolant drain plug (Figure 3-5) and
Refer to Table 3-1 for scheduled maintenance. The drain the coolant into a suitable container.
engine cooling system is filled with a 50/50 mixture
of ethylene glycol anti-freeze and water when the WARNING Ethylene glycol antifreeze is con-
genset leaves the factory, which is suitable for tem- sidered toxic. Dispose of it according to local
peratures down to -34° F (-37° C). regulations for hazardous substances.

Recommended Coolant Flush and clean the cooling system before refilling.
Radiator cleaning chemicals are available at local
See RECOMMENDED COOLANT (p. 2-1). auto parts stores. Follow the instructions for clean-
ing and flushing that come with the cleaning solu-
Pressure Cap tion.
Replace the pressure cap (Figure 3-5) every two Refilling Cooling System
years (seals deteriorate and leak). Proper cooling
system pressure (14 psi) is essential for optimal en- Install the coolant drain plug using pipe thread seal-
gine cooling and minimal coolant loss. ant. Tighten it just enough so that it does not leak
when the genset is running and has warmed up. Pull
Draining and Cleaning Cooling System the hose connected to the pressure cap assembly
out as far and as high as it will go and fill the system
WARNING Hot coolant spray can cause severe with coolant. When the coolant level reaches the fill
burns. Let the engine cool before releasing the opening, start and operate the genset for a few min-
pressure cap or removing the drain cap. utes and shut it down. Add more coolant if neces-
sary and secure the pressure cap.
Accidental or remote starting can cause severe
personal injury or death. Disconnect the nega- Fill the recovery tank with coolant mixture to the
tive (−) cable at the battery to prevent starting COLD mark.
while working on the genset.
Coolant Level Check
Let the engine cool before removing the pressure
cap. Relieve any remaining pressure by turning the Check coolant level in the recovery tank (Fig-
pressure cap slowly, without pushing down. When ure 3-5) before the first startup of each day and fill to
the pressure has been relieved, push down on the the COLD mark if necessary.

Redistribution or publication of this document,


3-7 by any means, is strictly prohibited.
PRESSURE CAP
COOLANT RECOVERY AND SYSTEM
TANK FILL OPENING

RECOVERY TANK
FILL CAP (BLUE)

COOLANT
LEVEL

COOLANT DRAIN PLUG


(1/4 INCH HEX SOCKET)

FIGURE 3-5. ENGINE COOLING SYSTEM

Redistribution or publication of this document,


3-8 by any means, is strictly prohibited.
4. Troubleshooting
TROUBLESHOOTING WITH TABLE 4-1 S Two blinks indicate shutdown due to a loss of
engine oil pressure.
To aid troubleshooting the genset controller causes
S Three blinks indicate a service fault. Press
the status indicator light to blink the numeric code
Stop once to cause the two-digit, second-level
assigned to the fault that caused shutdown. For a
shutdown code to blink. (Pressing Stop again
brief description of the fault and step-by-step cor-
will stop the blinking.) The two-digit code con-
rective action, refer to TABLE 4-1. TROUBLE-
sists of 1, 2, 3, 4 or 5 blinks, a brief pause, and
SHOOTING, which lists the fault codes in numerical
then 1 to 9 blinks. The first set of blinks repre-
order.
sents the tens digit and the second set of blinks
If you are unable to resolve the problem after taking the units digit of the shutdown code number.
the corrective actions suggested, contact an autho- For example, shutdown code No. 36 appears
rized Onan dealer. See HOW TO OBTAIN SER- as:
VICE (p. ). blink-blink-blink—pause—blink-blink-blink-blink-blink-blink—
long pause—repeat
Many genset shutdowns can be avoided by perform-
ing periodic maintenance on schedule (TABLE 3-1. S Four blinks indicate that cranking time ex-
PERIODIC MAINTENANCE SCHEDULE) and by not ceeded 35 seconds.
running the genset out of fuel. Note that when the • To avoid the possibility of anyone misinterpreting
genset and propulsion engine draw from the same
Code Nos. 3 and 4 as Code Nos. 33 and 44, the lat-
fuel tank, the fuel dip tubes are usually arranged so
ter have not been assigned faults.
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. RESTORING FAULT CODE BLINKING

FAULT CODE BLINKING The fault code stops blinking after five minutes.
Press Stop three times within three seconds to re-
At fault shutdown, the status indicator light will re- store fault code blinking.
peatedly blink sets of 1, 2, 3 or 4 blinks.
Note: The last fault logged will blink even though the
S One blink indicates shutdown due to high en- condition that caused the shutdown may have been
gine coolant temperature. corrected.

Redistribution or publication of this document,


4-1 by any means, is strictly prohibited.
TABLE 4-1. TROUBLESHOOTING
WARNING 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 MAINTAIN A CHARGE


(Marginal battery, battery connections or charging system)
Corrective Action: Service the battery as necessary by cleaning and tightening connections, recharg-
ing or replacing the battery or replacing damaged battery cables.
1. 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.

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 blocking 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.)
4. Look for loose or broken fan belts and have them serviced.

Redistribution or publication of this document,


4-2 by any means, is strictly prohibited.
TABLE 4-1. TROUBLESHOOTING
WARNING 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.

LOW OIL PRESSURE—CODE NO. 2


(During normal operation engine oil pressure dropped to less than 14 psi 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.)
2. Prime the engine fuel system for one minute (p. 2-4).
3. Check the engine air filter and remove any blockage (p. 3-4).
4. Change the engine oil to oil of the proper viscosity for the ambient temperature. High oil viscosity
can slow down cranking speed.
5. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime.
6. Replace the fuel filter (p. 3-6).

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.

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.

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4-3 by any means, is strictly prohibited.
TABLE 4-1. TROUBLESHOOTING
WARNING 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 FREQUENCY—CODE NO. 14


(After the starter was engaged Frequency jumped to more than 70 Hz
for 40 milliseconds or to more than 66 Hz 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 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.
2. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime. (Air bubbles can dis-
rupt frequency.)
3. Replace the engine air filter and clean the spark-arrest muffler (p. 3-4).
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).

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.

Redistribution or publication of this document,


4-4 by any means, is strictly prohibited.
TABLE 4-1. TROUBLESHOOTING
WARNING 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 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 viscosity 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.

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.)
2. Prime the engine fuel system for one minute (p. 2-4).
3. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime.
4. Check the engine air filter and remove any blockage (p. 3-4).
5. Replace the fuel filter (p. 3-6).

Redistribution or publication of this document,


4-5 by any means, is strictly prohibited.
TABLE 4-1. TROUBLESHOOTING
WARNING 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.

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.)

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.

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.

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.

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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 0.11 gph (0.41 lph) 0.11 gph (0.41 lph)
Half-load 0.48 gph (1.82 lph) 0.48 gph (1.82 lph)
Full-load 1.01 gph (3.8 lph) 1.2 gph (4.54 lph)
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 in3 (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 & 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 475 amps down to 0° F (−17° C)
CCA (Cold Cranking Amps) 650 amps down to −20° F (−29° C)
Battery Recharging Installer must provide for battery charging
WEIGHT: 792 lbs (359 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) & 54 dB(A) @ 50 ft (15m)—in “free field site” @ half load

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Redistribution or publication of this document,
by any means, is strictly prohibited.
6. Maintenance Record

Record all periodic and unscheduled maintenance and service. See Section 3. Periodic Maintenance.

HOUR
DATE METER MAINTENANCE OR SERVICE PERFORMED
READING

Record the name, address, and phone number of your authorized Onan service center.

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6-1 by any means, is strictly prohibited.
Redistribution or publication of this document,
by any means, is strictly prohibited.
Redistribution or publication of this document,
by any means, is strictly prohibited.
Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
763-574-5000
Fax: 763-528-7229

Cummins and Onan are registered trademarks of Cummins Inc.

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by any means, is strictly prohibited.