Onan Mobile GenSet Owner's Manual

KY

Printed in U.S.A. 981-0159D

11-04

!!

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

gasoline warnings

Table of Contents

SECTION PAGE

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

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

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

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

Typical Genset 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Recommendations 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil Recommendations 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Batteries 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Control Panel 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Control Panel 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. OPERATION 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conducting the Pre-Start Checks 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Priming the Fuel System 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Genset 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping the Genset 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Restarting the Genset 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loading the Genset 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resetting Circuit Breakers 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting to Utility Power 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating in Cold Weather 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating in Hot Weather 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Altitude Adjustment 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating in Dusty Environments 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Breaking in a New Engine 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exercising the Genset 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storing the Genset 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Returning the Genset to Service 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i

SECTION PAGE

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

Conducting General Inspections 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Changing Engine Oil 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintaining the Battery and Battery Connections 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Air Filter Element 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Spark Plug 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Spark Arrestor 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. TROUBLESHOOTING 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. SPECIFICATIONS 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. INFORMATION FOR CALIFORNIA GENSET USERS 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . .

7. HOW TO OBTAIN SERVICE 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. MAINTENANCE RECORD 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii

SAFETY PRECAUTIONS

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

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

DANGER

which will result in severe personal injury or
death.

WARNING

practice which can result in severe personal in­jury or death.

CAUTION

practice which 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.

alerts you to an immediate hazard

alerts you to a hazard or unsafe

alerts you to a hazard or unsafe

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 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

state and federal agencies as causing cancer
or reproductive toxicity. Do not ingest, inhale, or
contact used oil or its vapors.

S Benzene and lead in some gasolines have

been identified by some state and federal
agencies as causing cancer or reproductive
toxicity. Do not to ingest, inhale or contact gaso­line or its vapors.

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.

S The genset must not be connected to shore

power or to any other source of electrical pow­er. Back-feed to shore power can cause electric
shock resulting in severe personal injury or
death and damage to equipment. An approved
switching device must be used 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.

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 this manual.

S Never sleep in the vehicle while the genset is

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

S Leaks can lead to explosive accumulations of

gas. Natural gas rises when released and can
accumulate under hoods and inside housings
and buildings. LPG sinks when released and
can accumulate inside housings and base­ments and other below-grade spaces. Prevent
leaks and the accumulation of gas.

BATTERY GAS IS EXPLOSIVE

S Make sure there is ample fresh air when operat-

ing the genset in a confined area.

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

the working or living space or compartment.

FUEL IS FLAMMABLE AND EXPLOSIVE

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 flame, sparks, pilot lights, arc-pro­ducing equipment and switches and all other
sources of ignition well away.

S Fuel lines must be secured, free of leaks and

separated or shielded from electrical wiring.

S Wear safety glasses.

S Do not smoke.

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.

S Do not wear loose clothing or jewelry near mov-

ing 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.

MOBILE 7

iv

1. Introduction

ABOUT THIS MANUAL

This manual covers operation and maintenance of
the KY Series of generator sets (gensets). Each op­erator should study this manual carefully and ob­serve all of its instructions and safety precautions.
Keep this manual and the Installation Manual with
the other vehicle manuals.

Operation, Periodic Maintenance and Trouble­shooting provide the instructions necessary for op-

erating the genset and maintaining top perfor­mance. The owner is responsible for maintenance
in accordance with the PERIODIC MAINTENANCE
SCHEDULE (Page 3-1). This manual also includes
genset specifications, information on how to obtain
service, and information for California users.

WARNING

This genset is not a life support sys­tem. It can stop without warning. Children, per­sons with physical or mental limitations, and
pets could suffer severe personal injury or
death. A personal attendant, redundant power
or an alarm system must be used if genset op­eration is critical.

NAMEPLATE

Model and Serial Numbers: Refer to Figure 1-1 for
the location of the genset nameplate. Record the
model and serial numbers in the designated boxes
in Figure 1-1 so that they are handy when calling for
parts, service or product information. Each charac­ter, including the last letter in the model number, is
important for obtaining the right parts.

Genuine Onan replacement parts are recom­mended for best performance and safety.

Federal Emissions Compliance Period: The
Federal Emissions Compliance Period referred to
on the nameplate indicates the number of operating
hours for which the engine has been shown to meet
Federal emissions requirements. Category
C = 250 hrs, B = 500 hrs, A = 1000 hrs.

The engine family designation, engine displacement, statement of

compliance with the applicable EPA and / or California emissions

regulations, including the compliance period or category, appear in

this block on the actual nameplate on the genset.

RECORD NUMBERS HERE

MODEL NUMBER:

SERIAL NUMBER:

FIGURE 1-1. TYPICAL NAMEPLATE

1-1

TYPICAL GENSET

Figure 1-2 illustrates a typical genset and the fea­tures requiring attention during operation and peri­odic maintenance.

Securing the access cover: Position the bottom of
the cover so that its lip catches the top edge of the
base tray, rotate the top of the cover towards the
genset and turn the two cover latches clockwise to
CLOSED, making sure the latches catch.

Removing the access cover: Turn the two cover
latches counterclockwise to OPEN and pull the top
of the cover outwards.

REMOTE

CONTROL

CONNECTION

(inside)

AIR CLEANER

COVER

ALTITUDE

ADJUST KNOB

WARNING

Operating the genset with the ac­cess cover off can lead to severe burns and en­gine damage due to overheating. Always secure
the cover after starting the genset.

CONTROL

PANEL

(See Figure 1-3)

OIL FILL CAP

& DIPSTICK

SPARK PLUG

(not shown)

MUFFLER WITH

CLEANOUT PLUGS

(accessible from below)

MAINTENANCE

ACCESS COVER

FUEL INLET

& FILTER

AC

OUTPUT

LEADS

POS (+) BATTERY

CONNECTION

(inside)

NEG (−) BATTERY

& GROUND

CONNECTION

OIL DRAIN PLUG

(accessible from below)

FIGURE 1-2. TYPICAL GENSET

1-2

FUEL RECOMMENDATIONS

WARNING

mable and explosive and can cause severe per­sonal injury or death. Do not smoke or turn elec-
trical switches ON or OFF where fuel fumes,
tanks or equipment are present or in areas shar­ing ventilation. Keep flames, sparks, pilot lights,
arc-producing equipment, switches and all oth­er sources of ignition well away. Keep a type
ABC fire extinguisher in the vehicle.

Gasoline and LPG are highly flam-

Gasoline Models

Use clean, fresh unleaded gasoline having a mini­mum octane rating (Anti-Knock Index) of 87.

Satisfactory performance requires that the LPG va-
por be supplied at a pressure within the range indi­cated in Specifications (Page 5-1).

WARNING

High LPG supply pressure can
cause gas leaks which can lead to fire and se­vere personal injury or death. LPG supply pres­sure must be adjusted to Specifications by qual­ified personnel.

ENGINE OIL RECOMMENDATIONS

Use API (American Petroleum Institute) perfor­mance Class SJ engine oil or better. Also look for
the SAE (Society of Automotive Engineers) viscos­ity grade. Referring to Table 1-1, choose the viscos­ity grade appropriate for the ambient temperatures
expected until the next scheduled oil change.

Leaded gasoline may be used but will result in the
extra maintenance required for removing combus­tion chamber and spark plug deposits. Do not use
gasoline or gasoline additives (de-icers) containing
methanol because methanol can be corrosive to
fuel system components.

CAUTION

Do not use gasoline or gasoline ad­ditives containing methanol because methanol
can be corrosive to fuel system components.

Avoid using highly leaded gasolines and lead
additives because of the extra engine mainte­nance that will be required.

LPG Models

Use clean, fresh HD-5 grade liquified petroleum gas
(LPG) or equivalent product consisting of at least
90 percent propane. Commercial liquified petro­leum gas fuels may contain more than 2.5 percent
butane, which can result in poor fuel vaporization
and poor engine starting in ambient temperatures
below 32° F (0° C).

Single-grade SAE 30 oil is preferable when temper­atures are consistently above freezing. Multigrade
oils are better when wide temperature variations are
expected.

TABLE 1-1. OIL VISCOSITY VS. TEMPERATURE

EXPECTED AMBIENT

TEMPERATURES

32° F (0° C) and higher 30

10° F to 100° F (−12° C to 38° C) 15W-40

0° F to 80° F (−18° C to 27° C)

−20° F to 50° F (−28° C to 10° C) 5W-30

SAE VISCOSITY

GRADE

10W-30
10W-40

STARTING BATTERIES

See Specifications (Page 5-1) regarding minimum
battery ratings for reliable genset cranking, espe­cially in cold weather. Also see PERIODIC MAINTE­NANCE SCHEDULE (Page 3-1) and the battery
manufacturer’s instructions regarding battery main­tenance. Reliable genset starting and starter ser­vice life depend upon adequate battery capacity
and proper maintenance.

1-3

GENSET CONTROL PANEL

The genset control panel (Figure 1-3) is located be­hind the maintenance access cover (Figure 2) and
has the following features:

Control Switch − This switch is used to prime the
fuel system, start and stop the genset and display
the fault code. Hold the switch in its START position
to crank and start the genset. Press the switch to its
STOP position to stop the genset. Hold the switch in
its STOP/PRIME position to prime the fuel system
(gasoline models only). See Troubleshooting
(Page 4-1) about displaying fault codes.

Status Indicator Light − This light is an LED (light
emitting diode) in the control switch that blinks rap­idly during cranking and stays on continuously when
the genset is running. If the genset shuts down ab­normally, the light will blink a numerical code to indi­cate the cause of the shutdown. See Troubleshoot-
ing (Page 4-1).

Line Circuit Breaker − The line circuit breaker pro-
tects the AC power leads connected to the genset
from overloads and equipment short circuits.

CONTROL SWITCH &

STATUS INDICATOR LIGHT

FIGURE 1-3. GENSET CONTROL PANEL

LINE CIRCUIT

BREAKER

REMOTE CONTROL PANEL

The vehicle probably has a control panel inside the
vehicle for remote control of the genset. Onan offers
three remote control kits:

S Remote switch with status indicator light only

(Figure 1-4).

S Remote switch with status indicator light and

hour meter (Figure 1-5).

S Remote switch with status indicator light and

DC voltmeter (Figure 1-6).

The hour meter records genset operating time in
hours. It cannot be reset. See the PERIODIC MAIN­TENANCE SCHEDULE (Page 3-1).

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 (Page 3-5).

FIGURE 1-4. REMOTE SWITCH

FIGURE 1-5. REMOTE SWITCH / HOUR METER

FIGURE 1-6. REMOTE SWITCH / DC VOLTMETER

1-4

2. Operation

WARNING

Exhaust gases contain carbon monoxide, an odorless, colorless gas. Carbon monoxide is poisonous
and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning include:

• Dizziness • Throbbing in Temples • Nausea

• Muscular Twitching • Headache • Vomiting

• Weakness and Sleepiness • Inability to Think Clearly

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

Never sleep in the vehicle with the genset running unless the vehicle is equipped with a working car­bon monoxide detector. Primary protection against inhaling carbon monoxide, however, is proper
installation of the exhaust system, daily (every eight hour) inspection for visible and audible exhaust
system leaks.

CONDUCTING THE PRE-START CHECKS

Before the first start of the day and after every eight
hours of operation, inspect the genset as instructed
under CONDUCTING GENERAL INSPECTIONS
(Page 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 (Page 2-6) if the vehicle has been in storage.

EXHAUST GAS IS DEADLY!

switch flashes while cranking. It will stay on
continuously when the genset is running.

2. The genset will shut down in 15 to 20 seconds
if it does not start and the status indicator light
will blink Fault Code No. 4. See Troubleshoot-
ing (Page 4-1). Wait 5 seconds for the control
to reset before trying again. After five tries let
the starter motor cool down for 30 seconds be­fore trying again.

Before each start:

1. Make sure all vehicle CO detectors are work­ing.

2. Check for signs of fuel and exhaust leaks and
for damage to the exhaust system.

3. Turn off the air conditioner and other large ap­pliances.

PRIMING THE FUEL SYSTEM

If the genset ran out of fuel (gasoline models only)
prime the fuel system by holding the control switch
at STOP/PRIME for 30 seconds. (The status indica-
tor light will stay on while the pump is on.)

STARTING THE GENSET

Start the genset from the genset control panel or re­mote control panel inside the vehicle (Page 1-4).

1. Push and hold the switch at START until the
genset starts. The status indicator light on the

CAUTION

aged by overheating if not allowed to cool
down for at least 30 seconds after every fifth
crank.

3. For top performance and engine life, especially
in colder weather, let the engine warm up for
two minutes before connecting appliances.

4. Check for fuel and exhaust leaks. Stop the gen­set immediately if there is a fuel or exhaust leak
and have it repaired.

5. See Troubleshooting (Page 4-1) if the engine
shuts down and the status indicator light blinks.

6. Always secure the access cover after starting
the genset at the genset control panel.

WARNING

access cover off can lead to severe burns
and engine damage due to overheating. Al­ways secure the cover after starting the
genset.

The starter motor can be dam-

Operating the genset with the

2-1

STOPPING THE GENSET

Turn off the air conditioner and other large ap­pliances and let the genset run for two minutes to
cool down. This reduces backfiring and run-on.
Then press the switch to STOP to stop the genset.

RESTARTING THE GENSET

See Troubleshooting (Page 4-1) if the genset shuts
down abnormally.

LOADING THE GENSET

The genset can power AC motors, air conditioners,
AC/DC converters 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.

TABLE 2-1. TYPICAL APPLIANCE LOADS

Appliance
Air Conditioner 1400-2000
Battery Charger Up to 800
DC Converter 300-500
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

Load (watts)

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.

Note that the genset may shut down due to over­load—even though the sum of the loads is less than
genset rating—when a large motor or air conditioner
is started last or cycles off and then on again. 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 appliances when large motors and air
conditioners are cycling on and off.

Note also that air density decreases as altitude in­creases, causing genset engine power to de­crease.** Power decreases approximately 3.5 per­cent of rated power each 1000 feet (305 m) of in­crease in elevation. See Table 2-2 for typical cal­culations. It may be necessary to run fewer ap-

pliances at higher altitudes.

TABLE 2-2. POWER VS. ALTITUDE

Elevation above Mean

Sea Level

up to 500 ft (152 m) 4000 watts (rated)
2500 ft (762 m) 3720 watts
5500 ft (1676 m) 3300 watts
above 5500 ft

(1676 m)

* This table does not take into account the effect cir-

cuit breakers may have in limiting maximum power.

Maximum Genset

Power*

3300 watts minus 140 watts

each 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).

** Power decreases even though the altitude adjust knob is set correctly (Page 2-4).

2-2

RESETTING CIRCUIT BREAKERS

If a circuit breaker in the main power distribution
panel of the vehicle or on the genset (Figure 2-1)
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. (It may be necessary to push the circuit breaker
OFF to reset it and then 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.

LINE CIRCUIT

BREAKER

FIGURE 2-1. LINE CIRCUIT BREAKER

WARNING

Short circuits in electrical ap­pliances 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.

CONNECTING TO UTILITY POWER

When the vehicle has provisions for connecting to
utility power, such as a cord for plugging into a pow­er outlet receptacle, it must also 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 the electrocution of personnel working
on the utility lines, damage to equipment and
fire. An approved switching device must be
used to prevent interconnections.

Interconnecting the genset and the

2-3

OPERATING IN COLD WEATHER

Pay particular attention to the following when oper­ating the genset in cold weather:

1. Make sure engine oil viscosity is appropriate for
the ambient temperatures. Change oil if there
is a sudden drop in temperature. See ENGINE
OIL RECOMMENDATIONS (Page 1-3).

2. Check the altitude setting (Figure 2-2).

3. Perform spark plug maintenance (Page 3-6).

4. Perform battery maintenance (Page 3-5).

OPERATING IN HOT WEATHER

Pay particular attention to the following 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 1-3).

3. Keep the genset clean.

4. Perform maintenance due. See PERIODIC
MAINTENANCE SCHEDULE (Page 3-1).

5. Check the altitude setting (Figure 2-2).

ALTITUDE ADJUSTMENT

Gasoline Models − For best fuel economy and gen-

set operation reset the carburetor for the current alti­tude (Figure 2-2). Look at road maps and road
signs. For the effect of altitude on maximum power,
see LOADING THE GENSET (Page 2-2).

CAUTION

Operating the genset at low altitude
with a high altitude setting can cause power
loss, overheating and engine damage. Always
reset when returning to lower altitudes.

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.

ALTITUDE

ADJUST

KNOB

FIGURE 2-2. ALTITUDE ADJUST KNOB

(GASOLINE MODELS ONLY)

2. Perform air cleaner maintenance more often
(Page 3-5).

3. Change engine oil every 50 hours.

4. Keep containers of engine oil that have been
opened tightly closed to keep out dust.

2-4

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 2-2).

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 1-3). Check oil level twice a day or every
4 hours during the first 20 hours of operation and
change the oil after the first 20 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 2-2). 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 in fuel lines and
carburetor and removes oxides from electrical con­tacts and generator slip rings. The result is better
starting, more reliable operation and longer engine
life.

run the genset for about 10 minutes at approxi­mately 1/2 rated power to fill the fuel lines with
the fresh fuel and preservative.

WARNING

Gasoline preservatives (stabil­izers) are toxic. Follow the instructions on
the container label. Avoid skin contact.
Wash your hands with soap and water after
dispensing the fluid.

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

3. Remove the air filter and restart the genset.
While the genset is running, spray an engine

TM

fogger (OnaGard

) into the carburetor, follow­ing the instructions on the container label, and
then stop the genset. The fogger leaves a pro­tective coat of oil on the internal surfaces of the
engine.

4. Disconnect all appliances, push the genset line
circuit breaker to OFF (Page 2-3) and stop the
genset.

5. 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 3-5).

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

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.

1. Gasoline Models Only − Fill the fuel tank with
fresh fuel and add a fuel preservative (Ona-

TM

Fresh
tainer label. Unless a preservative (stabilizer) is
added, the gasoline in the fuel system will dete­riorate causing fuel system corrosion, gum
formation and varnish-like deposits which can
lead to hard starting and rough operation. Then

OnaFresh and OnaGard are trademarks of Onan Corporation.

), following the instructions on the con-

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

8. LPG Models − Check the local ordinances if
the vehicle is to be garaged. Generally, ordi­nances require that the LPG system be leak­free, that the LPG container not be filled beyond
specified limits, that the container shutoff valve
be closed and that the vehicle not be parked
near sources of heat or ignition.

WARNING

LPG leaks can lead to explosive
accumulations in pits, sumps or other be­low-grade locations. Comply with all local
ordinances regarding the garaging of ve­hicles with LPG engine fuel systems.

2-5

9. Gasoline Models − Drain the carburetor float
bowl to prevent deposits of gum from clogging
the tiny passages in the carburetor as the gaso­line in the bowl evaporates during storage (Fig­ure 2-3). Drain it as follows:

A. Let the engine cool down thoroughly.
B. Place paper towels under the drain to ab-

sorb all of the drainage (less than 1/2 cup).

C. Open the drain valve by turning it counter-

clockwise with a screwdriver.

D. Close the drain valve after draining the car-

buretor by turning it clockwise with a
screwdriver until just snug.

WARNING

Do not open the carburetor
drain when the engine is hot. Close the
drain immediately after draining. Failure to
heed this warning can lead to fire resulting
in severe personal injury or death.

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 1-3).

2. Reconnect the starting battery (negative [−]
cable last). See MAINTAINING THE BATTERY
AND BATTERY CONNECTIONS (Page 3-5).

3. Remove the plug from the exhaust tailpipe.

4. Change the air filter element if it is dirty
(Page 3-5).

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

6. Inspect the genset. See CONDUCTING GEN­ERAL INSPECTIONS (Page 3-2).

7. Start the genset. There may be smoke and
rough operation for a few minutes until the oil
from the fogger burns off. If the engine does not
start, clean or replace the spark plug, which
may have been fouled by the fogger.

8. Push the genset line circuit breaker ON
(Page 2-3) when the genset is ready to power
appliances.

FLOAT BOWL
DRAIN VALVE

FIGURE 2-3. CARBURETOR DRAIN VALVE

(GASOLINE MODELS ONLY)

2-6

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
dusty environments some maintenance procedures
should be performed more frequently, as indicated
by the footnotes in the table. Keeping a log of main­tenance performed and hours run will help you keep

TABLE 3-1. PERIODIC MAINTENANCE SCHEDULE

MAINTENANCE

PROCEDURE

General Inspections X 3-2

Check Engine Oil Level X 3-3

Clean and Check Battery X

Clean Spark Arrestor X 3-6

Every

Day or

Every 8

Hours

After First

20 Hours

genset maintenance regular and provide a basis for
supporting warranty claims (Page 8-1).

Maintenance, replacement or repair of emission
control devices and systems may be performed by
any engine repair establishment or individual. How­ever, warranty work must be completed by an au­thorized Onan dealer.

MAINTENANCE FREQUENCY

Every

Month

3

Every 50

Hours

Every

150

Hours

Every

250

Hours

Every

450

Hours

P
a
g
e

3-5

Change Engine Oil X

Replace Air Filter Element X

Clean Engine Cooling Fins X

Replace Spark Plug X

Replace Fuel Filter X

Adjust Valve Lash X

Clean/Replace Cylinder Head X

1 − As a part of engine break-in, change the engine oil after the first 20 hours of operation.
2 − Perform more often when operating in dusty environments.
3 − Perform more often when operating in hot weather.
4 − Perform at least once a year.
5 − Perform sooner if engine performance deteriorates.
6 − Must be performed by a qualified mechanic (authorized Onan dealer).

1

2, 3, 4

X

2

2

5

5, 6

6

6

3-4

3-5

−

3-6

−

−

−

3-1

CONDUCTING GENERAL INSPECTIONS

Fuel System

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

Oil Level

Check engine oil level (Figure 3-1).

Exhaust System

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.

Check for leaks at the hose, tube and pipe fittings in
the fuel supply system while the genset is running
and while it is stopped. Do not use a flame to check
for LPG leaks. 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.

If you smell gas, close the LPG container shutoff
valve and have the genset serviced before using it
again.

WARNING

Gasoline and LPG are highly flam­mable and explosive and can cause severe per­sonal injury or death. Shut down the genset and
repair leaks immediately.

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 (Page 3-5).

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.

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.

WARNING

EXHAUST GAS IS DEADLY! Do not
operate the genset if there is an exhaust leak or
any danger of exhaust gases entering or being
drawn into the vehicle.

WARNING

Do not park the vehicle in high grass
or brush. Contact with the exhaust system can
cause a fire.

Mechanical

Look for mechanical damage. Start the genset and
check for unusual noises and vibrations.

Check the genset mounting bolts to make sure they
are secure.

Check to see that the genset air inlet and outlet
openings are not clogged with debris or blocked.

Clean accumulated dust and dirt from the genset.
Do not clean the genset while it is running or still hot.
Protect the generator, air cleaner, control panel, and
electrical connections from water, soap and clean­ing solvents.

WARNING

Always wear safety glasses when
using compressed air, a pressure washer or a
steam cleaner to avoid severe eye injury.

3-2

CHECKING ENGINE OIL LEVEL

Park the vehicle on level ground and shut off the
genset before checking the engine oil level.

WARNING

Crankcase pressure can blow hot
engine oil out the fill opening causing severe
burns. Always stop the genset before removing
the oil fill cap.

1. Unscrew the oil fill cap and wipe oil off the dip­stick (Figure 3-1). Screw the cap back on, re­move it again and check the oil level on the dip
stick.

2. Add or drain oil as necessary. See ENGINE OIL
RECOMMENDATIONS (Page 1-3). 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.

3. Screw the oil fill cap back on securely.

FILL TO THIS

MARK

DO NOT RUN IF

BELOW THIS MARK

FIGURE 3-1. CHECKING ENGINE OIL LEVEL

3-3

CHANGING ENGINE OIL

WARNING

State and federal agencies have de­termined that contact with used engine oil can
cause cancer or reproductive toxicity. Try to
avoid skin contact and breathing of vapors. Use
rubber gloves and wash exposed skin.

Refer to Table 3-1 for scheduled engine oil change.
Change oil more often in hot and dusty environ­ments.

WARNING

Crankcase pressure can blow hot
engine oil out the fill opening causing severe
burns. Always stop the genset before removing
the oil fill cap.

1. Run the engine until warm, stop it and remove
the oil fill cap (Figure 3-1).

2. Remove the oil drain hole cover in the base,
place a pan underneath and unscrew the drain
plug (Figure 3-2). Let all oil drain from the en­gine and then secure the drain plug. Torque the
plug to 21 lbs-ft (27 N-m) and secure the cover.

OIL DRAIN HOLE

COVER

FIGURE 3-2. OIL DRAIN PLUG

OIL DRAIN PLUG

3. Refill with 1.6 quarts (1.5 liters) of oil. See EN­GINE OIL RECOMMENDATIONS (Page 1-3).
Check the oil level and add or drain oil as nec­essary.

4. Screw the oil fill cap back on securely.

5. Dispose of the used oil in accordance with local
environmental regulations.

3-4

MAINTAINING THE BATTERY AND

BATTERY CONNECTIONS

WARNING

switch or other equipment or flames and sparks
can ignite battery gas causing severe personal
injury—Ventilate battery area before working on
or near battery—Wear safety glasses—Do not
smoke—Switch trouble light ON / OFF away
from battery—Do not disconnect battery cables
while genset is running or vehicle battery charg­ing system is on—Always disconnect nega­tive (−) cable first and reconnect it 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.

Arcing at battery terminals or light

3. Make sure which terminal is positive (+) and
which is negative (−) before making battery
connections, always removing the negative (−)
cable first and reconnecting it last to reduce
arcing.

REPLACING THE AIR FILTER ELEMENT

Refer to Table 3-1 for scheduled air filter element re­placement. In dusty environments the filter element
should be inspected and changed more frequently.
To change the filter element (Figure 3-3):

1. Remove the air filter housing cover and filter
element cover plate, which are secured by sep­arate wing nuts, and remove the filter element.

2. Reassemble the air filter with a new filter ele­ment. Make sure the filter element is centered
over the carburetor air inlet. Do not tighten the
wing nuts too tightly. Excessive tightening can
distort the filter element and cause air leaks
around the element.

WING

NUT

AIR FILTER

HOUSING COVER

FIGURE 3-3. REPLACING THE AIR FILTER ELEMENT

WING

NUT

3-5

FILTER COV-

ER PLATE

AIR FILTER

ELEMENT

REPLACING THE SPARK PLUG

Refer to Table 3-1 for scheduled spark plug replace­ment. (The genset has one spark plug, Figure 3-4.)
The spark plug must be in good condition for proper
engine starting and performance. A spark plug that
fouls frequently or has heavy soot deposits indi­cates the need for engine service. See Trouble-
shooting (Page 4-1).

Always thread the spark plug in by hand until it
seats, to prevent cross threading, and torque to
13 lbs-ft (17 N-m). If you don’t have a torque
wrench, turn the spark plug an additional 1/4 turn, if
being reused, or 3/8 to 1/2 turns if new.

CLEANING THE SPARK ARRESTOR

Refer to Table 3-1 for scheduled cleaning of the
spark arrestor muffler (which meets U.S. Forest
Service requirements). Cleaning is required for
maximum genset performance.

GAP

FIGURE 3-4. SPARK PLUG

WARNING

A hot muffler can cause severe
burns. Let the muffler cool down before remov­ing or installing the cleanout plugs.

The muffler is mounted inside the genset housing.
The cleanout plugs are located on the bottom side of
the muffler, accessible through the air outlet open­ing in the bottom of the genset. Clean out the spark
arrestor muffler as follows:

1. Remove the cleanout plugs from the bottom of
the muffler (Figure 3-5).

2. Restart the genset and load it nearly to full pow­er. Let the genset run for about five minutes to
expel the soot in the muffler.

3. Stop the genset, allow the muffler to cool down
and then reinstall the plugs.

CLEANOUT PLUGS

FIGURE 3-5. SPARK ARRESTOR CLEANOUT

PLUGS

3-6

4. Troubleshooting

WARNING

burns. Always allow the engine time to cool be­fore performing any maintenance or service.

TABLE 1. TROUBLESHOOTING lists the Fault
Codes in numerical order along with step-by-step
instructions for corrective action. If you fail to re­solve the problem after taking the corrective actions
suggested, contact an authorized Onan dealer. See
How to Obtain Service (Page 7-1).

First note the following:

S Maintaining engine oil level, keeping battery

connections clean and tight, watching the fuel
gauge, not overloading the genset, etc. will
prevent most shutdowns.

S When the genset and vehicle engine share a

common fuel tank the fuel dip tubes are usual­ly arranged so that the genset will run out of
fuel first. Marking the genset empty point on
the fuel gauge will make it easier to tell when
to stop the genset before running it out of fuel.

Hot engine parts can cause severe

FAULT CODES

The genset controller provides extensive diagnos­tics by causing the status indicator light on the Con­trol Switch to blink a numeric code. Following a fault

shutdown, the indicator light will repeatedly blink 3
blinks or 4 blinks at a time.

S Three blinks indicates a service fault. Press

Stop once to cause the two-digit, second-lev-

el fault code to blink. (Pressing Stop again will
stop the blinking.)The two-digit code consists
of 1, 2, 3 or 4 blinks, a brief pause, and then
1 to 9 blinks. The first set of blinks represents
the tens digit and the second set of blinks the
units digit of the fault code number. For exam­ple, Fault Code No. 36 appears as:

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

S Four blinks indicates that cranking exceed-

ed 15 to 20 seconds without the engine start­ing.

S

Note: Fault Code Nos. 3 and 4 are first level
faults. Avoid interpreting them as second-level
Fault Code Nos. 33 and 44, which have not
been assigned as fault codes.

Restoring Fault Code Blinking − The fault code

stops blinking after five minutes. Press Stop three
times within five seconds to restore blinking. Note

that the last fault logged will blink, even after the
condition that caused the shutdown has been
corrected.

TABLE 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-

STATUS INDICATOR LIGHT DEAD

(Faulty connections, no battery voltage)

Corrective Action:

1. Try the genset Start Switch if the remote Start Switch does not work, and vice versa.

2. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery, vehicle
frame and genset.

3. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.

4-1

TABLE 1. TROUBLESHOOTING (CONT.)

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 BATTERIES RUN DOWN

(Marginal batteries, connections, or charging system or, parasitic loads)

Corrective Action:

1. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery, vehicle
frame and genset.

2. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.

3. Have a battery charging system installed or serviced in the vehicle.

STARTER ENGAGES-DISENGAGES

(Cranking voltage dips below 6 volts—low battery charge, poor connections, long cables)

Corrective Action:

1. Have the vehicle propulsion engine running while trying to start the genset—the battery charging alter­nator may be able to maintain starting voltage high enough to get the genset started.

2. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery, vehicle
frame and genset.

3. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.

4. Increase battery cable size or run parallel cables.

STATUS INDICATOR LIGHT GOES OUT WHILE CRANKING—NO START

(Internal short circuit caused automatic-reset circuit protective device to trip)

Corrective Action: Try starting again. See an authorized Onan dealer if the status indicator light
flashes and then goes out again without the engine starting.

NO POWER—GENSET RUNNING, STATUS LIGHT ON

(Line circuit breaker OFF, or tripped due to short circuit or overload)

Corrective Action:

1. Turn on or reset the line circuit breaker on the genset (Page 2-3).

2. Turn on or reset the line circuit breakers on the main distribution panel in the vehicle.

SERVICE CHECK FAULT—CODE NO. 3

(First-level fault code—Indicates fault with second-level fault code)

Corrective Action: Check the second-level fault code by pressing STOP once. The second-level fault
code will have two-digits. The faults are listed in numerical order in this table.

4-2

TABLE 1. TROUBLESHOOTING (CONT.)

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-

OVERCRANK FAULT—CODE NO. 4

(First-level fault code—Cranking exceeded 20 seconds without engine starting)

Corrective Action:

1. Gasoline Models − Check and fill the fuel tank, as necessary. (Note: The genset fuel pickup tube is
probably higher up in the fuel tank than the vehicle engine pickup.)

2. Prime the engine fuel system by holding the control switch at Stop/Prime for 30 seconds.

3. LPG Models − Check and fill the LPG container, as necessary. On cold days the LPG container may

have to be kept at least half full to provide the rate of vaporization necessary to keep up with the genset
fuel demand.

4. Open any closed fuel valves.

5. Secure the spark plug lead on the spark plug (Page 3-6).

6. Replace the spark plug (Page 3-6).

7. Service the air cleaner (Page 3-5).

OVERVOLTAGE FAULT—CODE NO. 12

(Controller unable to maintain rated voltage)

Corrective Action: See an authorized Onan dealer.

UNDERVOLTAGE FAULT—CODE NO. 13

(Controller unable to maintain rated voltage)

Corrective Action: Reduce the number of connected appliances, especially when air conditioners and
battery chargers are running.

OVERFREQUENCY FAULT—CODE NO. 14

(Engine governor unable to maintain rated frequency)

Corrective Action: See an authorized Onan dealer.

UNDERFREQUENCY FAULT—CODE NO. 15

(Engine governor unable to maintain rated frequency)

Corrective Action: Reduce the number of connected appliances, especially when air conditioners and
battery chargers are running.

VOLTAGE SENSE FAULT—CODE NO. 27

(Controller unable to sense output voltage)

Corrective Action: See an authorized Onan dealer.

4-3

TABLE 1. TROUBLESHOOTING (CONT.)

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-

HIGH BATTERY VOLTAGE FAULT—CODE NO. 29

(Voltage across battery system greater than 19 volts)

Corrective Action:

1. Check battery bank connections and reconnect if necessary so that the 12 volt batteries serving the
genset are connected in parallel (12 volt) rather than in series (24 volt).

2. Select a lower battery boost charge rate.

LOW CRANKING SPEED FAULT—CODE NO. 32

(Cranking speed less than 180 rpm for more than 2 seconds)

Corrective Action:

1. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery and at the
genset.

2. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.

3. Replace engine oil with oil of proper viscosity for ambient temperatures (Page 1-3). (High oil viscosity
can slow down cranking speed.)

CONTROL CARD FAILURE FAULT—CODE NO. 35

(Microprocessor EEPROM error during self-test)

Corrective Action: See an authorized Onan dealer.

ENGINE STOPPED FAULT—CODE NO. 36

(Engine stopped without command by controller)

Corrective Action:

1. Gasoline Models − Check and fill the fuel tank, as necessary. (Note: The genset fuel pickup tube is
probably higher up in the fuel tank than the vehicle engine pickup.)

2. LPG Models − Check and fill the LPG container, as necessary. On cold days the LPG container may

have to be kept at least half full to provide the rate of vaporization necessary to keep up with the genset
fuel demand.

3. Secure the spark plug lead on the spark plug (Page 3-6).

4. Replace the spark plug (Page 3-6).

5. Service the air cleaner (Page 3-5).

6. Check for mechanical damage.

INVALID GENSET CONFIGURATION FAULT—CODE NO. 37

(Genset configuration is preprogrammed at the factory)

Corrective Action: See an authorized Onan dealer.

4-4

TABLE 1. TROUBLESHOOTING (CONT.)

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-

OVERCURRENT FAULT—CODE NO. 38

(Low power factor loads)

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. Have air conditioners and other appliances checked for proper operation. (A locked compressor rotor
can cause very low power factor.)

GENERATOR ROTOR FAULT—CODE NO. 41

(Controller unable to sense field or output voltage)

Corrective Action: See an authorized Onan dealer.

PROCESSOR FAULT—CODE NO. 42

(Microprocessor ROM error during self-test)

Corrective Action: See an authorized Onan dealer.

PROCESSOR FAULT—CODE NO. 43

(Microprocessor RAM error during self-test)

Corrective Action: See an authorized Onan dealer.

SPEED SENSE FAULT—CODE NO. 45

(Controller unable to sense quadrature frequency)

Corrective Action: See an authorized Onan dealer.

IGNITION FAULT—CODE NO. 47

(Controller unable to sense ignition)

Corrective Action: See an authorized Onan dealer.

GENERATOR FIELD SENSE FAULT—CODE NO. 48

(Controller unable to sense field voltage)

Corrective Action: See an authorized Onan dealer.

4-5

5. Specifications

GASOLINE MODELS LPG MODELS

4KY 3.6KY 3.6KY 3.3KY

GENERATOR: 2-Pole Revolving Field, Self-Excited, 1-Phase, Microprocessor Regulated

Power 4000 watts 3600 watts 3600 watts 3300 watts

Frequency 60 Hertz 50 Hertz 60 Hertz 50 Hertz

Voltage 120 volts

Current 33.3 amperes 15.7 amperes 30 amperes 14.3 amperes

Speed 3600 rpm 3000 rpm 3600 rpm 3000 rpm

FUEL CONSUMPTION:

No load
Half load
Full load

ENGINE: 1-Cylinder, 4-Stroke Cycle, Spark-Ignited, OHV, Air Cooled, Mechanically Governed

Bore 3.11 inch (79 mm) 3.11 inch (79 mm)

Stroke 2.44 inch (62 mm) 2.44 inch (62 mm)

Displacement 18.5 inch3 (304 cc) 18.5 inch3 (304 cc)

Compression Ratio 8.5 : 1 8.5 : 1

Oil Capacity 1.6 quart (1.5 l) 1.6 quart (1.5 l)

Intake Valve Lash (Cold) 0.002 inch (0.05 mm) 0.002 inch (0.05 mm)

Exhaust Valve Lash (Cold) 0.002 inch (0.05 mm) 0.002 inch (0.05 mm)

Spark Plug Tightening Torque 13 lbs-ft (17 N-m) 13 lbs-ft (17 N-m)

Ignition Timing (magneto) 25° BTDC, non-adjustable 25° BTDC, non-adjustable

Magneto Air Gap 0.009-0.015 inch (0.23-0.38 mm) 0.009-0.015 inch (0.23-0.38 mm)

Spark Plug Gap 0.025 inch (0.64 mm) 0.020 inch (0.51 mm)

DC SYSTEM:

Nominal Battery Voltage 12 volts 12 volts

Min. Battery Rating: Cold
Cranking Amps (CCA)
@ 0° F (−18° C)

Battery Charging Current − 10 amp (regulated) − 10 amp (regulated)

INSTALLATION:

Weight (with engine oil) 174 pounds (79 Kg) 184 pounds (84 Kg) 174 pounds (79 Kg) 184 pounds (84 Kg)

Minimum Compartment Size
(H x D x W)

Minimum Free Air Inlet Area 40 inch2 (258 cm2) 40 inch2 (258 cm2)

Muffler Outlet Collar O. D. 1.13 inch 1.13 inch

Fuel Connection 1/4 inch barb fitting for gasoline hose 5/8-18UNC, SAE 45° Flare Fitting

LPG Vapor Supply Pressure −

1. Also available for 100 volts, with grounded or isolated neutral.

2. Reconnectable. See the Installation Manual.

3. See the Installation Manual for additional considerations when sizing the genset compartment.

3

0.29 gph (1.1 l/h)

0.48 gph (1.8 l/h)

0.71 gph (2.7 l/h)

(366 mm x 508 mm x 775 mm)

1

450 450

14.4 inch x 20 inch x 30.5 inch

230 volts

0.21 gph (0.79l/h)

0.37 gph (1.4 l/h)

0.58 gph (2.2 l/h)

1, 2

120 volts 230 volts

1.5 lbs/h (0.7 kg/h)

2.2 lbs/h (1.0 kg/h)

3.3 lbs/h (1.5 kg/h)

14.4 inch x 20 inch x 30.5 inch

(366 mm x 508 mm x 775 mm)

9-13 inch (228-330 mm)

Water Column (WC)

1.1 lbs/h (0.5 kg/h)

2.0 lbs/h (0.9 kg/h)

2.9 lbs/h (1.3 kg/h)

2

5-1

6. Information for California Genset Users

This genset meets the requirements of California’s
Exhaust Emissions Standards as stated on the
nameplate. Figure 1-1 illustrates where this infor­mation appears on the nameplate.

As a California user of these gensets, please be
aware that unauthorized modifications or replace­ment of fuel, exhaust, air intake, or speed control
system components that affect engine emissions
are prohibited. Unauthorized modification, removal
or replacement of the genset label is prohibited.

TABLE 2. EMISSIONS CONTROL INFORMATION

The California emissions control warranty statement is located in

Genset Warranty Information

Engine Valve Lash See Specifications (Page 5-1).

Engine Ignition Timing See Specifications (Page 5-1).

Engine Fuel Requirements

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

Gasoline Models: The engine is certified to operate on un­leaded gasoline. See Fuel Recommendations (Page 1-3).

LPG Models: The engine is certified to operate on LPG vapor.
See Fuel Recommendations (Page 1-3).

You should carefully review Operator (Owner),
Installation and other manuals and information you
receive with your genset. If you are unsure that the
installation, use, maintenance or service of your
genset is authorized, you should seek assistance
from an approved Onan dealer.

California genset users may use Table 2 as an aid in
locating information related to the California Air Re­sources Board requirements for emissions control.

Engine Lubricating Oil Requirements See ENGINE OIL RECOMMENDATIONS (Page 1-3).

Engine Fuel Mixture Settings

Engine Adjustments

Engine Emission Control System

These genset engines have precision-manufactured carburetors
which are not adjustable.

Gasoline Models: See Altitude Adjustment on Page 2-4.

LPG Models: Not applicable.

The engine emission control system consists of internal engine
design.

6-1

7. How to Obtain Service

When you need service, parts, or product literature
(such as the Service Manual) for your genset, con­tact the nearest authorized distributor. Onan has
factory-trained representatives to handle your
needs for genset parts and service. You may go to
Internet site www.onan.com for information for con-
tacting our distributors worldwide.

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 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 Model Identification (Page 4).

2. The date of purchase

3. The nature of the problem. See Troubleshoot-

ing (Page 4-1).

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

WARNING

parts can result in severe personal injury, death,
and/or equipment damage. Service personnel
must be trained and experienced in performing
electrical and/or mechanical service.

Improper service or replacement of

7-1

8. Maintenance Record

Record all periodic and unscheduled maintenance and service. See Periodic Maintenance (Page 3-1).

HOUR

DATE

METER

READING

MAINTENANCE OR SERVICE PERFORMED

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

8-1

Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
763-574-5000
Fax: [phone]

Cummins and Onan are registered trademarks of Cummins Inc.