CUMMINS HDKCC, HDKCD Operator's Manual

Operator Manual

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.

Table of Contents

SECTION PAGE

Table of Contents i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

1. INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nameplate 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Obtain Service 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

noise 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electromagnetic compatibility 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

i

General Inspection 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Engine Oil Level 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Engine Oil and Oil Filter 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintaining the Battery and Battery Connections 3-6. . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Air Filter Element 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Fuel Filter 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintaining the Coolant System 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii

SAFETY PRECAUTIONS

Thoroughly read the OPERATOR’S MANUAL
before operating the genset. Safe operation and
top performance can only be obtained when
equipment is operated and maintained proper­ly.

Only trained and experienced service person­nel with knowledge of fuels, electricity, and ma­chinery hazards shall remove, dismantle and
dispose of the generator set. See service manu­al.

The following symbols in this manual alert you to
potential hazards to the operator, service person
and equipment.

DANGER

which you must take steps to prevent severe
personal injury or death, as when you are in the
vicinity of High Voltage equipment.

WARNING

safe practice that can result in severe personal
injury or death.

CAUTION

safe practice that can result in personal injury
or equipment damage.

Electricity, fuel, exhaust, moving parts and batter­ies present hazards which can result in severe per­sonal injury or death.

Used to alert you to a leathal hazard

Used to alert you to a hazard or un-

Used to alert you to a hazard or un-

GENERAL PRECAUTIONS

S Keep children away from the genset.

S Do not use evaporative starting fluids. They

are highly explosive.

S To prevent accidental or remote starting while

working on the genset, disconnect the nega­tive (−) battery cable at the battery.

S 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.

S Keep the genset and its compartment clean.

Excess oil and oily rags can catch fire. Dirt and
gear stowed in the compartment can restrict
cooling air.

S Make sure all fasteners are secure and

torqued properly.

S Do not work on the genset when mentally or

physically fatigued or after consuming alcohol
or drugs.

S You must be trained and experienced to make

adjustments while the genset is running—hot,
moving or electrically live parts can cause se­vere personal injury or death.

S 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.

S Ethylene glycol, used as engine antifreeze, is

toxic to humans and animals. Clean up spills
and dispose of used engine coolant in accor­dance with local environmental regulations.

S Keep multi-class ABC fire extinguishers

handy. Class A fires involve ordinary combus­tible materials such as wood and cloth; Class B
fires, combustible and flammable liquid fuels
and gaseous fuels; Class C fires, live electrical
equipment. (ref. NFPA No. 10)

S Genset installation and operation must comply

with all applicable local, state and federal
codes and regulations.

GENERATOR VOLTAGE IS DEADLY

S Disable the automatic genset starting feature

of an inverter-charger or other automatic start­ing device before servicing the genset.

S Generator electrical output connections must

be made by a trained and experienced electri­cian in accordance with applicable codes.

WARNING

and shore power can lead to electrocution of
utility line workers, eqiupment damage and fire.
Use an approved switching device to prevent
interconnections.

S Use caution when working on live electrical

equipment. Remove jewelry, make sure cloth­ing and shoes are dry, stand on a dry wooden
platform or rubber insulating mat and use tools
with insulated handles.

Interconnecting the gnerator set

iii

ENGINE EXHAUST IS DEADLY

S Inspect for exhaust leaks at every startup and

after every eight hours of running.

S Learn the symptoms of carbon monoxide poi-

soning in the Operator’s Manual.

S Never sleep in the vehicle while the genset is

running unless the vehicle is equipped with a
working carbon monoxide detector.

S Do not operate the genset when the vehicle is

in a confined space, such as a garage.

S Disable the automatic genset starting feature

of an inverter-charger or other automatic start­ing device before storing the vehicle or parking
it in a garage or other confined space.

S The exhaust system must be installed in accor-

dance with the genset Installation Manual.

S Engine cooling air must not be used for heating

working or living spaces or compartments.

S Do not wear loose clothing or jewelry near

moving parts such as PTO shafts, fans, belts
and pulleys.

S Keep hands away from moving parts.

S Keep guards in place over fans, belts, pulleys,

and other moving parts.

FLAMMABLE VAPOR CAN CAUSE A

DIESEL ENGINE TO OVERSPEED

WARNING

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.

Do not operate a diesel-powered

DIESEL FUEL IS COMBUSTIBLE

S Do not smoke or turn electrical switches ON or

OFF where fuel fumes are present or in areas
sharing ventilation with fuel tanks or equip­ment. Keep flames, sparks, pilot lights, arc­producing equipment and all other sources of
ignition well away.

S Fuel lines must be secured, free of leaks and

separated or shielded from electrical wiring.

BATTERY GAS IS EXPLOSIVE

S Wear splash−proof safety glasses.

S Do not smoke or permit flames or sparks to oc-

cur neat the battery at any time.

S 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

S Disable the automatic genset starting feature

of an inverter-charger or other automatic start­ing device before servicing the genset.

THE HAZARDS OF CARBON MONOXIDE

Engine−driven generators can produce harmful
levels of carbon monoxide that can injure or kill you.
The nature of boating is such that you can be
harmed by this poisonous gas despite good gener­ator set maintenance and proper ventilation.

ONLY YOU CAN PROTECT YOURSELF

FROM CO POISONING!

S Watch constantly for swimmers when the gen-

erator set is running.

S Make sure exhaust cannot get under the deck,

between hulls or enter the living quarters
through a window, vent or door.

S Make sure all CO detectors and audible alarms

are working properly.

S Pay attention to the signs of CO poisoning.

S 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.

Mobile-8

iv

SUBSTANCE HAZARDOUS TO HEALTH

PROTECTIVE MEASURES

Generator sets use substances, and emit and
create wastes that can cause health risks. Genera­tor set operators must use appropriate personal
protective equipment (such as clothing, gloves,
protective glasses/goggles, and respiration equip­ment) when exposed to fuel, oil, coolant, wet batter­ies, 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 dis­posal 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 liquid, with a mild chemi­cal odour, is soluble in water and harmful. It con­tains ethylene glycol, and diethylene glycol. Ethyl­ene 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 ex­changers. 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 oxi­dants. Moderate explosive hazard in form of vapour
when exposed to heat or flame. Hazardous prod­ucts 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 re­ported to be 100ml.

Refrain from eating, drinking or smoking when us­ing 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 protection, gloves, overalls, impervious apron
should be used. Avoid contamination inside the
gloves. If overalls become contaminated, discon­tinue use and clean thoroughly.

STORAGE/TRANSPORT

Store and transport only in correctly marked con­tainers. 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 wa­ter−courses.

Contain leak/spill with sand, earth or non−combus­tible, absorbent material to prevent entry of sub­stance 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

S Fire

Extinguishing media: CO
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.

S ngestion

Toxic by ingestion. If swallowed induce vomit­ing only
control centre. Delayed treatment may result in
fatality.

S Inhalation (of vapour)

Remove from further exposure. In case of ir­ritation to lungs or throat, seek medical advice.

S Aspiration (inhalation of liquid)

Obtain immediate medical assistance.

S Eyes

Flush copiously with water or preferably eye−

under the advice of a Doctor or poison

alcohol resistant

2,

v

wash solution for at least five minutes. Seek
medical advice.

S Skin

Wash thoroughly with soap and water, and
seek medical attention if irritation develops.
Change clothing if necessary and wash before
re−use.

S Spillage

Soak−up using an absorbent material and dis­pose of this as directed under Storage/Trans­port (Section 5.1.3)

GAS OIL

This product is also known as Red Diesel, Fuel Oil,
and type A1 or A2. It can be pale red or a clear liquid
with a characteristic mild odour. It contains catalyti­cally cracked oil, petroleum distillates, quinizarin,
and gas oil maker dye red. The catalytically cracked
oil and petroleum distillates are potentially hazard­ous constituents.

The substance has an initial boiling point of 180°C,
a flash point greater than 56°C, and a vapour pres­sure 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 ve­hicles and stationary engines, and can be found in
fuel tanks, pipes and injection systems. The sub­stance should not be used for any other purpose
without contacting the manufacturer or supplier. In­stallers, operators and maintainers are likely to en­counter this substance.

HAZARDOUS REACTIONS

This liquid is flammable. Avoid smoking, heat
sources, such as welding and naked flames,
sparks and static electricity build−up. Thermal de­composition products are hazardous, containing

, NOX and SOX compounds.

CO

X

The vapour is explosive. High vapour concentra­tions 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 pul­monary 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

high level of gas oil is of low order. Prolonged, re­peated 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 en­sure general safety. Do not smoke. Avoid breathing
mist.

When working on, or testing, injection equipment,
special care 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 thoroughly. Contaminated clothing
should be removed, soaked with water, and laun­dered 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 con­tainers. Keep containers closed when not in use.
Keep cool, out of sunlight and away from naked
flames. Electrical continuity is required between the
transport and storage vessels during product trans­fer.

Contain leak/spill with sand, earth or other suitable
material, and prevent entry of substance into drain­age/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

S Fire

Extinguishing media:
Large fire − Foam/water fog. Never use water
jet.

vi

Small fire − foam/dry powder, AAAF, CO2,
sand, earth.
Avoid making sparks. Fire fighters to use self−
contained breathing apparatus. Keep fire ex­posed containers cool, using water fog/spray.
Prevent run−off from entering waterway,
drains and drinking water supplies.

S Ingestion

Do not induce vomiting. Wash the mouth out
with water, and send to hospital immediately.

lubrication oil for use in wide range of diesel en­gines operating under severe conditions. Installers,
operators and maintainers are likely to encounter
this product.

HAZARDOUS REACTIONS

This product is stable although slightly re−active
with oxidising agents. Results of decomposition are
carbon oxides (CO, CO

) and water.

2

S Inhalation (of vapour)

Remove from further exposure. Obtain medi­cal assistance immediately.

S Aspiration (inhalation of liquid)

If, following ingestion of gas oil, vomiting oc­curs, 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.

S Eyes

Irrigate copiously with water or preferably eye−
wash solution for at least five minutes. If irrita­tion persists seek medical advice.

S Skin

Wash thoroughly with soap and water. Change
clothing if necessary.
If high pressure injection has occurred prompt
surgical attention is required.

S Spillage

Absorb using sand, earth or other suitable ma­terial. Dispose of unwanted or absorbed flam­mable 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 liquid with a slight, characteristic odour.
The base oil contains: distillates (petroleum), sol­vent−dewaxed heavy paraffinic. It is not classified
as dangerous according to Directive 1999/45/EC
and its amendments, and is not classified accord­ing to the EU regulations.

It has a boiling point greater than 150°C, a flash
point Open Cup of 220°C (Cleveland), and is insol­uble in cold water.

It is used in engine lubricant oil systems, sump pan
and filters, make−up tanks and piping systems as a

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−prod­ucts 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 wa­ter.

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 con­tainers. Keep containers tightly sealed when not in
use. Keep in a cool, well ventilated area, out of sun­light 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 inert material and dispose
of unwanted or absorbed substance through an au­thorised contractor to a licensed site. Finish clean­ing by spreading water on the contaminated sur­face and allow to evacuate through the sanitary
system.

vii

EMERGENCY ACTION

S Fire

Extinguishing media:
Large fire − Use water spray, fog or foam. Do
not use water jet.
Small fire − Use dry chemical powder or CO
Fire−fighters to use self contained breathing
apparatus and full turnout gear. Keep fire ex-

2

posed containers cool.

S Ingestion

Do not induce vomiting, Obtain medical advice
immediately.

S Inhalation (of vapour)

Remove from further exposure. Obtain medi­cal 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 equipment 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 entanglement in moving parts.

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 care­fully 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 Trouble­shooting provide the instructions necessary for op-

erating the genset and maintaining top perfor­mance. The owner is responsible for performing
maintenance in accordance with the PERIODIC
MAINTENANCE SCHEDULE (p. 3-1).

WARNING

tem. It can stop without warning. Children, per­sons with physical or mental limitations, and
pets could suffer personal injury or death. A per­sonal attendant, redundant power or alarm sys­tem must be used if genset operation is critical.

This genset is not a life support sys-

numbers is significant. The last character of the
model number is the specification letter, which is im­portant for obtaining the right parts. Genuine
Onan® replacement parts are recommended for
best results. Refer to the genset Parts Catalog.

[The engine family designation, engine displacement, state­ment of compliance with applicable EPA and / or California
emissions regulations appear in this block on the actual name­plate on the genset.]

WARNING

This generator set is not “ignition
protected” and shall not be used in a flammable
vapor environment.

WARNING

Improper service or replacement of
parts can lead to severe personal injury or death
and to damage to equipment and property. Ser­vice 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
for parts, service or information. Figure 1-1 illus­trates the nameplate and its location. The gray
boxes illustrate where to look for the model and seri­al numbers.

FIGURE 1-1. TYPICAL NAMEPLATE

MODEL NUMBER: ___________________________

SERIAL NUMBER: ___________________________

Record these numbers in Figure 1-2 so that they are
easy to find when needed. Each character in these

FIGURE 1-2. RECORD NUMBERS HERE

1-1

HOW TO OBTAIN SERVICE

Information to Have Ready

When you call for service, parts, or product literature
(such as the Service Manual or Parts Catalog) for
your genset, contact the nearest authorized distrib­utor. Onan has factory-trained representatives to
handle your requests for genset parts and service.

In North America

Call 1-800-888-ONAN to contact the nearest Cum­mins/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 dis­tributor nearest to you.

If you are unable to contact a distributor using the
automated service, consult the Yellow Pages. Typi­cally, our distributors are listed under:

GENERATORS − ELECTRIC,
ENGINES − GASOLINE OR DIESEL, or
RECREATIONAL VEHICLES − EQUIPMENT,
PARTS AND SERVICE.

If you have difficulty in arranging service or resolv­ing a problem, please contact the Service Manager
at the nearest Cummins/Onan distributor for assis­tance.

Outside North America

If you are outside North America, call Onan Corpo­ration 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.

Before calling for service, have the following infor­mation 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 level and time
of exposure increase, risk of hearing damage in­creases. The Specifications page n the Operator
manual states noise level for this generator set. Se­lect and use personal hearing protection appropri­ate for your exposure to generator set noise.

Note for use in countries where compliance to the
EU Noise directive is required: 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 restric­tions when you operate the generator set.

ELECTROMAGNETIC COMPATIBILITY

Generator sets emit and receive electromagnetic
(radio frequency) energy. If the generator set af­fects operation of nearby devices, or nearby de­vices affect generator set operation, increase the
distance between them.

This generator set has been evaluted for use in in­dustrial environments.

1-2

EMISSIONS

genset is authorized, you should seek assistance
from an approved Onan dealer.

You should carefully review Operator (Owner),
Installation manuals and other information you re­ceive with your genset. If you are unsure that the
installation, use, maintenance or service of your

TABLE 1-1. EMISSIONS CONTROL INFORMATION TABLE

The California emissions control warranty statement is located in

Emissions Warranty Information

Engine Valve Clearance (Lash) See Section 5. Specifications.

Engine Fuel Requirements

Engine Lubricating Oil Requirements See ENGINE OIL RECOMMENDATIONS (Page 2-1).

Engine Adjustments

Engine Emission Control System

the same packet of information as this manual when the genset is
shipped from the factory.

The engine is certified to operate on diesel fuel. See FUEL REC­OMMENDATIONS (Page 2-1).

High Idle Speed. This is a service procedure requiring trained
personnel and proper tools. See the Service Manual.

The engine emission control system consists of engine design
and precision manufacture. (IFI)

California genset users may use Table 1-1 as an aid
in locating information related to the California Air
Resources Board requirements for emissions con­trol.

1-3

TYPICAL GENSET

Figure 1-3 illustrates the fuel, battery, remote con­trol and AC output connection points, the flow of

cooling and ventilating air and the maintenance and
service access panels of a typical genset. Not
shown are the combustion air inlet and oil drain
openings in the base.

AC OUTPUT AND REMOTE

CONTROL CONNECTIONS

COOLING & VENTILATING AIR IN HOT AIR OUT

MAINTENANCE

ACCESS

CONTROL

PANEL

BATTERY

CONNECTIONS

FUEL

CONNECTIONS

EXHAUST

CONNECTIONS

FIGURE 1-3. TYPICAL GENSET

1-4

2. Operation

RECOMMENDED FUEL

WARNING

cause severe personal injury or death. Do not
smoke near fuel tanks or fuel-burning equip­ment 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 multi­class 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 freez­ing. The fuel should have a Cetane number of at
least 45 for reliable starting.

Diesel fuel is combustible and can

RECOMMENDED COOLANT

Use the best quality ethylene glycol antifreeze solu­tion available. It should be fully formulated with rust
inhibitors and coolant stabilizers. Use fresh water
that is low in minerals and corrosive chemicals. Dis­tilled water is best.

See Section 5. Specifications for coolant capacity.

RECOMMENDED ENGINE OIL

FIGURE 2-1. OIL VISCOSITY VS. TEMPERATURE

Use API (American Petroleum Institute) perfor­mance Class CH-4 engine oil or better. Also look for
the SAE (Society of Automotive Engineers) viscos­ity grade. Referring to Figure 2-1, choose the vis­cosity grade appropriate for the ambient tempera­tures expected until the next scheduled oil change.
Multi-grade oils such as SAE 15W-40 are recom­mended for year-round use.

See Section 5. Specifications for 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 bat­tery system capacity and maintenance.

See MAINTAINING THE BATTERY AND BATTERY
CONNECTIONS (p. 3-6) and Section 5. Specifi-
cations for minimum required battery ratings.

2-1

CONTROL PANEL

The control panel (Figure 2-2) has the following fea­tures:

(Rapid blinking before cranking starts indicates that
the glow plugs are preheating the combustion
chambers. The genset controller automatically var­ies the time based on engine temperature.)

Control Switch − This switch is used to start and
stop the genset, prime the engine fuel system and
restore the fault code (blinking status light).

Status Lamp − This is a lamp in the control switch
that blinks rapidly during preheat and cranking. It
stays on continuously while the genset is running. If
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)

Line Circuit Breaker(s) − The line circuit breakers
protect the AC power leads connected to the gen­set.

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 run-
ning time of the genset. It cannot be reset.

COOLANT RECOVERY

TANK FILL CAP

CONTROL SWITCH

&STATUS LAMP

COOLANT RECOVERY

TANK FLUID LEVEL

HOUR METER

FIGURE 2-2. CONTROL PANEL

2-2

REMOTE CONTROL PANELS

There probably is a remote genset control panel in­side 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 2-5).

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. 3-6).

FIGURE 2-3. REMOTE SWITCH

FIGURE 2-4. REMOTE SWITCH / HOUR METER

FIGURE 2-5. REMOTE SWITCH / DC VOLTMETER

2-3

WARNING

EXHAUST GAS is deadly. All en­gine exhaust contains carbon monoxide; an
odorless, colorless, poisonous gas that can
cause unconsciousness and death. Symptoms
of carbon monoxide poisoning include:

• Dizziness • Headache

• Nausea • Weakness and Sleepiness

• Vomiting • Inability to Think Coherently

4. Turn off air conditioners and other large ap­pliances.

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.

WARNING

IF YOU EXPERIENCE ANY OF
THESE SYMPTOMS, GET INTO FRESH AIR IM­MEDIATELY. If symptoms persist, seek medical
attention. Shut down the genset and do not op­erate it until it has been inspected and repaired.

WARNING

Never sleep in the vehicle while the
genset is running unless the vehicle has a work­ing 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.

3. 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.

MANUAL 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.

2. 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.

3. 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 crank­ing. (Depending on how cold it is, preheating
can take up to 15 seconds, extending the time
that the lamp blinks.)

CAUTION

Excessive cranking can over­heat and damage the starter motor. Do not
crank for more than 30 seconds at a time.
Wait at least 2 minutes before trying again.

4. See Section 4. Troubleshooting if the genset
does not start after several tries.

5. Let the genset warm up a few minutes until it is
running smoothly before connecting the ve­hicle 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 re­lease Stop.

2-4

AUTOMATIC STARTING AND STOPPING

The vehicle may be equipped with an inverter-char­ger or other automatic genset starting device. Al­ways follow the instructions and safety precautions
provided by the manufacturer of the automatic start­ing device when enabling automatic genset starting.

WARNING

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:

S Sleeping in vehicle, unless vehicle has a

working CARBON MONOXIDE detector

S Parking vehicle in garage or confined space

S Parking vehicle for storage

S Servicing genset

S Servicing batteries

S Servicing electrical appliances

S Fueling vehicle

LOADING THE GENSET

The genset can power AC motors, air conditioners,
AC/DC converters, battery chargers and other ap­pliances. How much appliance load* can be pow­ered 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 shut­downs, compare the sum of the loads of the ap­pliances that are likely to be used at the same time to
the power rating of the genset. Use Table 2-1 or the
ratings on the appliances themselves (if so marked)
to obtain the individual appliance loads. It may be

necessary to run fewer appliances at the same
time—the sum of the loads must not be greater
than genset rating.

The genset may shut down due to overload when a
large motor or air conditioner is started or cycles off

and then on again, even though the sum of the loads
is less than genset rating. The reason for this is that
a motor’s startup load is much larger than its running
load. It may be necessary to run fewer ap-

pliances when large motors and air condition­ers are cycling on and off.

Maximum power decreases as altitude increases
because air density decreases. For every 1000-foot
(305 m) increase in elevation you can expect power
to decrease approximately 3.5 percent. Table 2-2
shows the results of typical calculations. It may be

necessary to run fewer appliances at higher alti­tudes.

TABLE 2-1. TYPICAL APPLIANCE LOADS

Appliance
Air Conditioner 1400-2000
Battery Charger Up to 3600
DC Converter 300-900
Refrigerator 600-1000
Microwave Oven 1000-1500
Electric Frying Pan or Wok 1000-1500
Electric Stove Element 350-1000
Electric Water Heater 1000-1500
Electric Iron 500-1200
Electric Hair Dryer 800-1500
Coffee Percolator 550-750
Television 200-600
Radio 50-200
Electric Drill 250-750
Electric Broom 200-500
Electric Blanket 50-200

TABLE 2-2. POWER VS. ALTITUDE

Elevation above Sea

Level

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

above 5500 ft (1676 m)

10,200 W minus 360 W

Load (watts)

Maximum Power

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).

2-5

RESETTING CIRCUIT BREAKERS

OPERATING IN COLD WEATHER

If a circuit breaker in the main power distribution
panel of the vehicle or on the genset (Figure 2-2)
trips, either a circuit shorted or too many appliances
were running. Note that the genset will continue to
run after a circuit breaker trips.

If a circuit breaker trips, disconnect or turn off as
many loads as possible and reset the circuit break­er. (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 dis­tribution system has a short or the circuit breaker is
faulty. Call a qualified electrician.

If the circuit breaker does not trip, reconnect the ap­pliances, 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 ap­pliance 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 cir­cuits occur.

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 oc­curs.

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

WARNING

pliances and tools can cause fire and electrical
shock leading to severe personal injury or
death. Read and follow the equipment and tool
manufacturer’s instructions and warnings re­garding use, maintenance and proper ground­ing.

Short circuits in electrical ap-

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 gen­set Installation Manual for more information.

WARNING

public utility (or any other power source) can
lead to electrocution of utility line workers,
equipment damage and fire. Use an approved
switching device to prevent interconnections.

Interconnecting the genset and the

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.

2-6

BREAKING IN A NEW ENGINE

Proper engine break-in on a new genset or on one
with a rebuilt engine is essential for top engine per­formance 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).

WARNING

and can accumulate to dangerous levels in
garages and other confined spaces. Dis­able 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).

CARBON MONOXIDE is deadly

Proper engine oil and oil level are especially critical
during break-in because of the higher engine tem­peratures that can be expected. Change the oil if not
appropriate for the ambient temperatures during
break-in. See ENGINE OIL RECOMMENDATIONS
(Page 2-1). Check oil level twice a day or every
4 hours during the first 24 hours of operation and
change the oil and oil filter after the first 50 hours of
operation.

EXERCISING THE GENSET

Exercise the genset at least 2 hours each month if
use is infrequent. Run the genset at approximately
1/2 rated power. See LOADING THE GENSET
(Page 2-5). A single two hour exercise period is
better than several shorter periods.

Exercising a genset drives off moisture, re-lubri­cates 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 gen­set 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.

3. Change the engine oil and attach a tag indicat­ing oil viscosity. See ENGINE OIL REC­OMMENDATIONS (Page 2-1).

4. Disconnect the battery cables (negative [−]
cable first) from the starting battery and store
the battery according to the battery manufac­turer’s recommendations. See MAINTAINING
THE BATTERY AND BATTERY CONNEC­TIONS (Page 3-6).

5. Plug the exhaust tail pipe to keep out dirt, mois­ture, bugs, etc.

6. Close the fuel supply valve (if so equipped).

Returning the Genset to Service

1. Check the oil tag on the genset and change the
oil if the viscosity indicated is not appropriate for
the temperatures expected. See ENGINE OIL
RECOMMENDATIONS (Page 2-1).

2. Reconnect the starting battery (negative [−]
cable last). See MAINTAINING THE BATTERY
AND BATTERY CONNECTIONS (Page 3-6).

3. Remove the plug from the exhaust tailpipe.

4. Change the air filter element if it is dirty
(Page 3-6).

5. Open the fuel supply valve (if so equipped).

6. Inspect the genset. See GENERAL INSPEC­TION (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 other automatic starting
device following the device manufacturer’s in­structions and safety precautions.

2-7

2-8

3. Periodic Maintenance

Periodic maintenance is essential for top perfor­mance and long genset life. Use Table 3-1 as a
guide for normal periodic maintenance. In hot and

any engine repair establishment or individual. How­ever, warranty work must be completed by an au-

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
control devices and systems may be performed by

TABLE 3-1. PERIODIC MAINTENANCE SCHEDULE

1

After

First 50

Hrs

• • 3-4

Every

MAINTENANCE TASK

General Inspection • 3-2

Check Engine Oil Level • 3-2

Check Engine Coolant Level • 3-10

Check Battery & Battery Connections

Change Engine Oil & Oil Filter

Clean Spark Arrestor

Replace Engine Air Filter

Replace Fuel Filter

Flush Coolant System

Replace Coolant Pressure Cap

3,7

3

5

1, 2, 3

2, 3

5

nect the negative (−) cable at the battery to pre-

vent starting while working on the genset.

FREQUENCY

Day

Every

Month

• 3-6

Every

250 Hrs

• −

Every

500 Hrs

• 3-7

• 3-9

Every

800 Hrs

Every

1500

Hrs

• 3-10

• 3-10

Page

Check Generator Slip Rings/
Brushes

Replace Generator Bearing

2,7

7

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.

• −

• −

3-1

GENERAL INSPECTION

Inspect the genset before the first start of the day
and after every eight hours of operation.

Do not operate power ventilators or exhaust fans
while the vehicle is standing with the genset run­ning. The ventilator or fan can draw exhaust gases
into the vehicle.

Oil Level

Check engine oil level (Figure 3-1).

Engine Coolant System

CAUTION

level is low can cause serious engine damage.

Check the engine coolant level and look for coolant
leaks around the bottom of the genset and on the
ground below. Minor leaks that can be replenished
by daily additions of coolant to the recovery tank
should be repaired by a qualified service technician
as soon as possible. Larger leaks are cause for
shutting down the genset until it can be repaired.

Operating the genset when coolant

Exhaust System

WARNING

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 gen­set 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 pre­vent exhaust gases from entering the vehicle.

Replace dented, bent or severely rusted sections of
the tailpipe and make sure the tailpipe extends at
least 1 inch (25.4 mm) beyond the perimeter of the
vehicle.

WARNING

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 oth­er vehicles can cause exhaust gases to accumulate
in and around the vehicle.

EXHAUST GAS IS DEADLY! Do not

Do not park the vehicle in high grass

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.

WARNING

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 connec­tions. 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
generator 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 out­let 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 ve­hicle if necessary and/or remove any objects block­ing the air inlet or air outlet.

CHECKING ENGINE OIL LEVEL

WARNING

termined that contact with used engine oil can
cause cancer or reproductive toxicity. Avoid
skin contact and breathing of vapors. Use rub­ber gloves and wash exposed skin.

WARNING

hoses, etc) will be hot and can cause severe
burns. The use of protective gloves is recom­mended.

State and federal agencies have de-

Engine components (drains, filters,

3-2

WARNING

Accidental or remote starting can
cause severe personal injury or death. Discon­nect the negative (−) cable at the battery to pre-
vent starting while working on the genset.

WARNING

Do not run the genset with the main­tenance access covers off. Contace with haz­ardous moving parts and hot exhaust manifolds
can cause severe personal injury.

1. Park the vehicle on level ground, shut down the
genset and remove the front access door.

2. Pull out the oil dip stick, wipe it clean, reinsert
it and pull it out again to check the oil level (Fig­ure 3-1).

3-3

3. Add or drain oil as necessary. See REC­OMMENDED ENGINE OIL (p. 2-1). Keep the
oil level between the FULL and ADD marks.

CAUTION

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.

WARNING

Do not run the genset with the main­tenance access covers off. Contace with haz­ardous 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 environ­ments.

4. Reinsert the dipstick and secure the oil fill cap
and front access door.

CHANGING ENGINE OIL AND OIL FILTER

WARNING

termined that contact with used engine oil can
cause cancer or reproductive toxicity. Avoid
skin contact and breathing of vapors. Use rub­ber gloves and wash exposed skin.

WARNING

hoses, etc) will be hot and can cause severe
burns. The use of protective gloves is recom­mended.

WARNING

cause severe personal injury or death. Discon­nect the negative (−) cable at the battery to pre-
vent starting while working on the genset.

State and federal agencies have de-

Engine components (drains, filters,

Accidental or remote starting can

1. Place a pan under the oil drain plug (Fig­ure 3-1), run the genset until warm and shut it
off.

2. Remove the front access door and the oil fill
cap, unscrew the oil drain plug and drain all the
oil from the engine. Reinstall the oil drain
plug securely.

3. Spin off the oil filter canister and clean the filter
mounting surface on the engine block. Remove
the old gasket if it remains.

4. Make sure the gasket is in place on the new fil­ter and apply a thin film of clean oil to the gas­ket. 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.

5. Refill with 5.9 quarts (5.6 liters) of oil, check oil
level (Figure 3-1) and secure the front access
door.

6. Dispose of the used oil and oil filter according
to local environmental regulations.

3-4

FILL CAP

FILTER

DIP STICK

DRAIN PLUG

(22 MM HEX HEAD)

FIGURE 3-1. ENGINE OIL MAINTENANCE

3-5

MAINTAINING THE BATTERY AND

BATTERY CONNECTIONS

WARNING

light switches or other equipment, and flames or
sparks, can ignite battery gas causing severe
personal injury—Ventilate battery area before
working on or near battery—Wear safety
glasses—Do not smoke—Switch work light ON
or OFF away from battery—Stop genset and dis­connect charger before disconnecting battery
cables—Disconnect negative (−) cable first and
reconnect last.

Refer to Table 3-1 for scheduled battery mainte­nance, and follow the battery manufacturer’s in­structions. Have the battery charging system ser­viced if DC system voltage is consistently low or
high. Always:

1. Keep the battery case and terminals clean and
dry and the terminals tight.

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.

Arcing at battery terminals or in

REPLACING THE AIR FILTER ELEMENT

WARNING

hoses, etc) will be hot and can cause severe
burns. The use of protective gloves is recom­mended.

WARNING

tenance access covers off. Contact with hazar­douse moving parts and hot exhaust manifolds
can cause severe personal injury.

WARNING

cause severe personal injury or death. Discon­nect the negative (−) cable at the battery to pre-
vent starting while working on the genset.

Refer to Table 3-1 for scheduled air filter replace­ment. 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 se­cure 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 hous­ing 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.

Engine components (drains, filters,

Do not run the genset with the main-

Accidental or remote starting can

3-6

COOLANT

RECOVERY TANK

(SHOWN CUT AWAY)

AIR FILTER HOUSING

END CAP

FIGURE 3-2. REPLACING THE AIR FILTER ELEMENT

3-7

REPLACING THE FUEL FILTER

Removing 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).

WARNING

Diesel fuel is combustible and can
cause severe personal injury or death. Do not
smoke near diesel fuel tanks or equipment.
Keep flames, sparks, pilot lights, electrical
switches, arc-producing equipment and all oth­er sources of ignition well away. Keep a type
ABC fire extinguisher in the vehicle.

WARNING

Close any fuel line shutoff valve be­fore disconnecting the fuel line from the filter.

WARNING

Accidental or remote starting can
cause severe personal injury or death. Discon­nect the negative (−) cable at the battery to pre-
vent starting while working on the genset.

WARNING

Engine components (drains, filters,
hoses, etc) will be hot and can cause severe
burns. The use of protective gloves is recom­mended.

Disconnect the two fittings at the filter and remove
the mounting nut. Apply a wrench on the filter fitting
as well as on the flare nut so as not to stress the fit­ting. Flare nut wrenches should be used on the flare
nuts so as not to round the corners on the nuts. Dis­pose of the fuel filter according to local regulations.
(Note: Filter removal will be easier if the filter mount­ing bracket screws are removed.)

CAUTION

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.

WARNING

Accidental or remote starting can
cause severe personal injury or death. Discon­nect the negative (−) cable at the battery to pre-
vent starting while working on the genset.

Prime the fuel system for half a minute to fill the new
filter with fuel.

Secure the access door.

3-8

FILTER

MOUNTING NUT

HOSE TO

ENGINE

FUEL

FILTER

HOSE FROM

FUEL PUMP

FIGURE 3-3. FUEL FILTER

BRACKET

MOUNTING

SCREWS

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 tem­peratures down to -34

° F (-37° C).

Recommended Coolant

See RECOMMENDED COOLANT (p. 2-1).

remove the coolant drain plug (Figure 3-4) and
drain the coolant into a suitable container.

WARNING

Ethylene glycol antifreeze is con­sidered 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 clean­ing and flushing that come with the cleaning solu­tion.

Pressure Cap

Replace the pressure cap (Figure 3-4) every two
years (seals deteriorate and leak). Proper cooling
system pressure (14 psi) is essential for optimal en­gine cooling and minimal coolant loss.

Draining and Cleaning Cooling System

WARNING

burns. Let the engine cool before releasing the
pressure cap or removing the drain cap.

WARNING

hoses, etc) will be hot and can cause severe
burns. The use of protective gloves is recom­mended.

WARNING

cause severe personal injury or death. Discon­nect the negative (−) cable at the battery to pre-
vent starting while working on the genset.

Hot coolant spray can cause severe

Engine components (drains, filters,

Accidental or remote starting can

Refilling Cooling System

Install the coolant drain plug using pipe thread seal­ant. Tighten it just enough so that it does not leak

when the genset is running and has warmed up. Pull
the hose connected to the pressure cap 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 min­utes and shut it down. Add more coolant if neces­sary and secure the pressure cap.

Fill the recovery tank with coolant mixture to the
COLD mark.

WARNING

cause severe personal injury or death. Discon­nect the negative (−) cable at the battery to pre-
vent starting while working on the genset.

WARNING

will prevent the system from filling to its capac­ity, which can lead to serious engine damage.

Accidental or remote starting can

Coolant trapped in the vent hose

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

Coolant Level Check

Check coolant level in the recovery tank (Fig­ure 3-4) before the first startup of each day and fill to
the COLD mark if necessary.

3-10

RECOVERY TANK

FILL CAP (BLUE)

COOLANT

LEVEL

COOLANT RECOVERY

TANK

PRESSURE CAP

AND SYSTEM

FILL OPENING

COOLANT DRAIN PLUG

(1/4 INCH HEX SOCKET)

FIGURE 3-4. ENGINE COOLING SYSTEM

3-11

3-12

4. Troubleshooting

TROUBLESHOOTING WITH TABLE 4-1

To aid troubleshooting the genset controller causes
the status indicator light to blink the numeric code
assigned to the fault that caused shutdown. For a
brief description of the fault and step-by-step cor­rective action, refer to TABLE 4-1. TROUBLE­SHOOTING, which lists the fault codes in numerical
order.

If you are unable to resolve the problem after taking
the corrective actions suggested, contact an autho­rized Onan dealer. See HOW TO OBTAIN SER­VICE (p. ).

Many genset shutdowns can be avoided by perform­ing 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.

S Two blinks indicate shutdown due to a loss of

engine oil pressure.

S 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 con­sists of 1, 2, 3, 4 or 5 blinks, a brief pause, and
then 1 to 9 blinks. The first set of blinks repre­sents the tens digit and the second set of blinks
the units digit of the shutdown code number.
For example, shutdown code No. 36 appears
as:

blink-blink-blink—pause—blink-blink-blink-blink-blink-blink—

long pause—repeat

S Four blinks indicate that cranking time ex-

ceeded 35 seconds.

•

To avoid the possibility of anyone misinterpreting
Code Nos. 3 and 4 as Code Nos. 33 and 44, the lat­ter have not been assigned faults.

RESTORING FAULT CODE BLINKING

FAULT CODE BLINKING

At fault shutdown, the status indicator light will re­peatedly blink sets of 1, 2, 3 or 4 blinks.

S One blink indicates shutdown due to high en-

gine coolant temperature.

The fault code stops blinking after five minutes.
Press Stop three times within three seconds to re­store fault code blinking.

Note: The last fault logged will blink even though the
condition that caused the shutdown may have been
corrected.

4-1

TABLE 4-1. TROUBLESHOOTING

WARNING

Some genset service procedures present hazards that can result in severe per­sonal 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.

• If there is no response at either remote or local switch, go to Step 3.

• If there is no response at the remote switch but at the local, go to Step 4.

• If there is no response at the local switch but at the remote, go to Step 7.

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.

3. Check for 12 VDC across genset battery cable terminal block TB1. If there is no voltage, service
as necessary by cleaning and tightening battery cable connections, recharging or replacing the bat­tery 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.

4. Disconnect harness connector P8 from the remote circuits. Check for B+ (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.

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.

6. 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.

7. Disconnect harness connector P9 from control switch S1. Check for B+ (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.

8. Disconnect harness connector
continuity at P1-27. If there is B+ and ground continuity, go to Step 9. If not, go to Step 10.

9. 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.

10. 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.

11. Remove the top housing panel and replace broken or missing cables between TB1 and the engine.
Tighten loose connections.

P1 from the control board and check for B+ at P1-10 and for ground

4-2

TABLE 4-1. TROUBLESHOOTING

WARNING

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.

Some genset service procedures present hazards that can result in severe per-

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: .

1. Service the battery as necessary by cleaning and tightening connections, recharging or replacing
the battery or replacing damaged battery cables.

2. Have the battery recharging system serviced.

3. Models HDKCA and HDKCB − The genset starting battery is recharged by the vehicle engine or
separate battery charger. Service as required.

4. Models HDKCC and HDKCD − These models have a feature whereby genset battery charging al­ternator 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 disabled, continue with Step 5.

5. Remove the top housing panel and check for wiring continuity in the harness between charging alter­nator G1 and starter solenoid terminal B+ (BAT). Repair as necessary.

6. Check for proper operation of relay K1 and replace if necessary.

7. Check for wiring continuity in the harness between connectors G1-VR and K1-87a. Repair as neces-
sary.

8. 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.

9. 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: .

1. Reset or turn ON genset circuit breaker CB1.

2. Reset or turn ON any other circuit breaker in the AC power supply system.

3. Check voltage at genset AC output terminal block TB2 when the genset is running. If there is approxi­mately 120 VAC across TB2-1 and TB2-3 and across TB2-2 and TB2-3, repair or reconnect the wir­ing between the genset and the main vehicle distribution panel. If there is no voltage, go to Step 4.

4. Check for proper AC harness connections and repair as necessary.

5. Test each circuit breaker and replace if necessary.

4-3

TABLE 4-1. TROUBLESHOOTING

WARNING

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.

Some genset service procedures present hazards that can result in severe per-

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. readjust or replace as necessary.

5. Clean and flush the cooling system to remove coolant passage fouling (p. 3-10).

6. 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.

7. If loose, reconnect wiring harness connector E3-1 to engine coolant temperature sender E3. (The
Controller interprets a loose lead touching ground as high temperature.)

8. Replace the coolant thermostat, which might not be fully opening. See Engine Workshop Manual
981-0541.

9. Test temperature sender E3 and replace if necessary.

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.)

3. Test low oil pressure cutoff switch S2 and replace if necessary.

4. Service the engine. See Engine Workshop Manual 981-0541.

SERVICE CHECK—CODE NO. 3

(A second-level fault occurred)

Corrective Action: Check the second-level fault code by momentarily pressing Stop. The second-lev­el fault will be one of the following in this table.

4-4

TABLE 4-1. TROUBLESHOOTING

WARNING

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.

Some genset service procedures present hazards that can result in severe per-

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).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, disconnect 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 cor­roded and that they are fully seated and can’t be pulled out. Replace the control board if the fuel pump
still does not operate.

3. Check the engine air filter and remove any blockage (p. 3-6).

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. 3-8).

7. Conduct a fuel flow test and service as necessary.

8. 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
control 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 dam­aged 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.

9. Remove the governor actuator, test it for proper operation and replace if necessary. (The engine can­not start if the actuator fails to pull in its spring-loaded plunger.)

10. Service the fuel injectors and injection pump.

11. Service the internal engine governor mechanism.

12. 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 ser­vice a grounded or shorted main, field or quadrature windings or grounded or shorted voltage sense
transformer.

2. Replace the control board.

4-5

TABLE 4-1. TROUBLESHOOTING

WARNING

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.

Some genset service procedures present hazards that can result in severe per-

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 ser­vice a grounded or shorted main, field or quadrature windings or grounded or shorted voltage sense
transformer.

2. Replace the control board.

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.)

3. Remove the governor actuator, test it for proper operation and replace if necessary.

4. Check high-idle speed and readjust if necessary.

5. Replace the control board.

6. Service the internal engine governor mechanism according to Engine Workshop Manual 981-0541.

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 dis­rupt frequency.)

3. Replace the engine air filter and clean the spark-arrest muffler (p. 3-6).

4. Replace the fuel filter (p. 3-8).

5. Conduct a fuel flow test and service as necessary.

6. Remove the governor actuator, test it for proper operation and replace if necessary.

7. Check high-idle speed and readjust if necessary.

8. Replace the control board.

9. Service the fuel injectors and injection pump.

10. Check fuel injection timing.

11. Service the internal engine governor mechanism .

12. Service a worn engine.

4-6

TABLE 4-1. TROUBLESHOOTING

WARNING

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.

Some genset service procedures present hazards that can result in severe per-

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 E1-1 and E1-2 to the governor actuator. If they were
found connected, disconnect the wiring harness and measure electrical resistance across the actua­tor leads. Replace the actuator if resistance is not 2.8 to 2.9 ohms.

2. 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.

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. 3-6).

4. Replace the fuel filter (p. 3-8).

5. Conduct a fuel flow test and service as necessary.

6. Remove the governor actuator, test it for proper operation and replace if necessary.

7. Check high-idle speed and readjust if necessary.

8. Service the fuel injectors and injection pump.

9. Check fuel injection timing.

10. Service the internal engine governor mechanism.

11. Service a worn engine.

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 con­trol board if the fault still occurs.

4-7

TABLE 4-1. TROUBLESHOOTING

WARNING

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.

Some genset service procedures present hazards that can result in severe per-

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.

1. Disconnect harness connector P1 from the control board and check for electrical resistance between
pins P1-33 and P1-34, which should be approximately 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.

2. 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 continu­ity 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 batteries 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

WARNING

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.

Some genset service procedures present hazards that can result in severe per-

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.

4. 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 sole­noid). Repair as necessary.

5. Check for proper operation of starter pilot relay K2 and replace if necessary.

6. Disconnect harness connector P1 from the control board and check for wiring continuity in the har-
ness between 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.

7. Service or replace the starter motor assembly.

8. Replace the control board.

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. 3-6).

5. Replace the fuel filter (p. 3-8).

6. Conduct a fuel flow test and service as necessary.

7. Remove the governor actuator, test it for proper operation and replace if necessary.

8. Replace the control board.

9. Service the engine.

4-9

TABLE 4-1. TROUBLESHOOTING

WARNING

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.

Some genset service procedures present hazards that can result in severe per-

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 NO. 45

(After 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
quadrature (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

WARNING

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.

Some genset service procedures present hazards that can result in severe per-

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

4-12

5. Specifications

MODEL:

GENSET CONTROL: Integrated Microprocessor-Based Engine and Generator Controller

GENERATOR: Single-Bearing, 4-Pole Rotating Field, 1800 RPM

Power (@1.0 power factor) 10,000 W 12,500 W
Voltage 120 / 240 120 / 240
Frequency 60 Hz 60 Hz
Number of Phases 1 1
Current 41.7 amps per leg 52.1 amps per leg
Line Circuit Breaker 2-pole, 45 amp 2-pole, 50 amp

FUEL CONSUMPTION:

No-load
Half-load
Full-load

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)

Oil Capacity (with filter)

Cooling System Capacity

DC SYSTEM:

Nominal Battery Voltage

Minimum Battery Capacity
CCA (Cold Cranking Amps)

Battery Recharging

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

HDKCA HDKCB

0.11 gph (0.41 lph)

0.48 gph (1.82 lph)

1.01 gph (3.8 lph)

0.11 gph (0.41 lph)

0.48 gph (1.82 lph)

1.2 gph (4.54 lph)

0.0071 to 0.0087 in (0.18 to 0.22 mm)

5.9 quart (5.6 liter)

6.6 quart (6.2 liter)

12 volts

475 amps down to 0° F (−17° C)

650 amps down to −20° F (−29° C)

Installer must provide for battery charging

5-1

SPECIFICATIONS

MODEL:

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
Frequency 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

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)

Oil Capacity (with filter)

Cooling System Capacity

DC SYSTEM:

Nominal Battery Voltage

Minimum Battery Capacity
CCA (Cold Cranking Amps)

Maximum Regulated Charging Current

WEIGHT: 816 lbs (370 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

HDKCC HDKCD

0.11 gph (0.41 lph)

0.48 gph (1.82 lph)

1.01 gph (3.80 lph)

0.11 gph (0.41 lph)

0.48 gph (1.82 lph)

1.20 gph (4.54 lph)

0.0071 to 0.0087 in (0.18 to 0.22 mm)

5.9 quart (5.6 liter)

6.6 quart (6.2 liter)

12 volts

475 amps down to 0° F (−17° C)

650 amps down to −20° F (−29° C)

20 amps

5-2

6. Maintenance Record

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

HOUR

DATE

METER

READING

MAINTENANCE OR SERVICE PERFORMED

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

6-1

6-2

Cummins Power Generation

1400 73rd Ave. NE
Minneapolis, MN 55432 USA

Phone [phone]
Toll-free 1 800 888 6626
Fax [phone]
Email www.cumminsonan.com/contact
www.cumminsonan.com

CumminsR, OnanR, the “C” logo, and “Performance you rely on.”
are trademarks of Cummins Inc.

E2009 Cummins Power Generation, Inc. All rights reserved.