Cumans_Onon_7.5kW_Operator_Manual.pdf

Operator Manual

RV Generator Set

HDKAH (Spec A−M) HDKAJ (Spec A−M) HDKAK (Spec A−M) HDKAT (Spec A−M) HDKAU (Spec A−M) HDKAV (Spec A−M)

English − Original Instructions 5−2010 981−0161 (Issue 7)

California

Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

diesel warnings i

Table of Contents

SAFETY PRECAUTIONS 2

INTRODUCTION 4

About This Manual 4 Model Identification 4 Typical Genset 5 Fuel Recommendations 6 Engine Oil Recommendations 6 Starting Batteries 6 Operator’s Console 7 Remote Control Panel 7

OPERATION 8

Conducting the Pre-Start Checks 8 priming the Fuel System 8 Starting the Genset 8 Stopping the Genset 9 Restarting the Genset 9 Loading the Genset 9 Resetting Circuit Breakers 10 Connecting to Utility Power 10 Operating in Cold Weather 11 Operating in Hot Weather 11 Operating at High Altitude 11 Operating in Dusty Environments 11 Breaking in a New Engine 11 Exercising the Genset 11 Storing the Genset 12

PERIODIC MAINTENANCE 13

Conducting General Inspections 14 Checking Engine Oil Level 15 Changing Engine Oil and Oil Filter 16 Maintaining the Battery and Battery Connections 17 Replacing the Air Filter Element 17 Cleaning the Spark Arrestor 18 Replacing the Fuel Filter 19 Changing Coolant 20

TROUBLESHOOTING 22

SPECIFICATIONS 31

INFORMATION FOR CALIFORNIA GENSET USERS 33

HOW TO OBTAIN SERVICE 34

MAINTENANCE RECORD 35

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.

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

alerts you to an immediate hazard that will result in severe personal injury or death.

WARNING alerts you to a hazard or unsafe practice that can result in severe personal injury or death.

CAUTION alerts you to a hazard or unsafe practice that can result in personal injury or equipment damage.

When equipped with an integral or add−on Auto− matic Generator Starting System (AGS) control,ex-haust carbon monoxide (CO), electric shock, and-moving parts hazards are possible due to unex− pected starting. Turn off AGS whenever performing-maintenance or service, when the vehicle is stored-between uses, is awaiting service, or is parked in agarage or other confined area.

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

ENGINE EXHAUST IS DEADLY

• Inspect for exhaust leaks at every startup and after every eight hours of running.

• Learn the symptoms of carbon monoxide poi-soning in the Operator’s Manual.

• Never sleep in the vehicle while the genset is running unless the vehicle is equipped with a working carbon monoxide detector.

• Do not operate the genset when the vehicle is in a confined space, such as a garage.

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

• The exhaust system must be installed in accor-dance with the genset Installation Manual.

• Engine cooling air must not be used for heating working or living spaces or compartments.

GENERATOR VOLTAGE IS DEADLY

• Disable the automatic genset starting fea-ture(AGS) of an inverter−charger or other auto-matic starting device before servicing the gen-set to avoid electric shock from an unexpected start.

• Generator electrical output connections must be made by a trained and experienced electri-cian in accordance with applicable codes.

• The genset must not be connected to the public utility or any other source of electrical power.

Back-feed could lead to electrocution of utility personnel and damage to equipment. An ap-proved switching device must be used to pre-vent interconnections.

• Use caution when working on live electrical equipment. Remove jewelry, make sure cloth-ing and shoes are dry, stand on a dry wooden platform or rubber insulating mat and use tools with insulated handles.

DIESEL FUEL IS COMBUSTIBLE

• Do not smoke or turn electrical switches ON or OFF where fuel fumes are present or in areas sharing ventilation with fuel tanks or equip-ment. Keep flames, sparks, pilot lights, arc-pro-ducing equipment and all other sources of igni-tion well away.

• Fuel lines must be secured, free of leaks and separated or shielded from electrical wiring.

MOVING PARTS CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH

• Disable the automatic genset starting fea-ture(AGS) of an inverter−charger or other auto-matic starting device before servicing the gen-set to avoid unexpected starting.

• Do not wear loose clothing or jewelry near mov-ing parts such as PTO shafts, fans, belts and pulleys.

• Keep hands away from moving parts.

BATTERY GAS IS EXPLOSIVE

• Wear safety glasses.

• Do not smoke.

• To reduce arcing when disconnecting or recon-necting battery cables, always disconnect the negative (−) battery cable first and reconnect it last.

FLAMMABLE VAPOR CAN CAUSE A

DIESEL ENGINE TO OVERSPEED

Flammable vapor can cause a diesel engine to overspeed and become difficult to stop, resulting in possible fire, explosion, severe personal injury and death. Do not operate a diesel-powered genset where a flammable vapor environment can be created by fuel spill, leak, etc. The owners and op-erators of the genset are solely responsible for oper-ating the genset safely.

GENERAL PRECAUTIONS

• Keep children away from the genset.

• Do not use evaporative starting fluids. They are highly explosive.

• To prevent accidental or remote starting while working on the genset, disconnect the nega-tive (−) battery cable at the battery.

• Let the engine cool down before removing the coolant pressure cap or opening the coolant drain. Hot coolant under pressure can spray out and cause severe burns.

• Keep the genset and its compartment clean.

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

• Make sure all fasteners are secure and torqued properly.

• Do not work on the genset when mentally or physically fatigued or after consuming alcohol or drugs.

• You must be trained and experienced to make adjustments while the genset is running—hot, moving or electrically live parts can cause se-vere personal injury or death.

• Used engine oil has been identified by some U. S. state and federal agencies as causing cancer or reproductive toxicity. Do not ingest, inhale, or contact used oil or its vapors.

• Ethylene glycol, used as engine antifreeze, is toxic to humans and animals. Clean up spills and dispose of used engine coolant in accor-dance with local environmental regulations.

• Keep multi-class ABC fire extinguishers handy.

Class A fires involve ordinary combustible ma-terials 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)

• Genset installation and operation must comply with all applicable local, state and federal codes and regulations.

• Keep guards in place over fans, belts, pulleys, and other moving parts.

Mobile-8

Introduction

ABOUT THIS MANUAL

This manual covers the operation and maintenance of the generator set (genset) models on the front cover. Study this manual carefully and observe all of its instructions and precautions. Keep this manual and the genset Installation Manual with the other ve-hicle manuals.

Operation, Periodic Maintenance and Trouble-shooting provide the instructions necessary for op-erating the genset and maintaining it at top perfor-mance. The owner is responsible for performing maintenance in accordance with the PERIODIC MAINTENANCE SCHEDULE (Page 12). This manual also includes genset specifications, infor-mation on how to obtain service and information for California users.

WARNING This genset is not a life support sys-tem. It can stop without warning. Children, per-sons with physical or mental limitations, and pets could suffer personal injury or death. A per-sonal attendant, redundant power or an alarm system must be used if genset operation is criti-cal.

MODEL IDENTIFICATION

When contacting an Onan dealer for parts, service or product information, be ready to provide the mod-el and serial numbers on the genset nameplate. Fig-ure 1 illustrates the nameplate and its location. The numbers in the gray boxes are typical model and se-rial numbers. Every character in these numbers is significant. (The last character of the model number is the specification letter, which is important for ob-taining the right parts.) Record the model and serial numbers in the boxes in Figure 1 so that they are easy to find when you need them.

RECORD NUMBERS HERE

MODEL NUMBER:

SERIAL NUMBER:

SKB719U6D2RA 719 cc

80HDKAK11454J

F990 123456

FIGURE 1. TYPICAL NAMEPLATE

TYPICAL GENSET

The operator’s console, the components requiring attention during periodic maintenance and other features of a typical genset are shown in Figure 2.

See the PERIODIC MAINTENANCE SCHEDULE (Page 12).

OPERATOR’S

CONSOLE

AC TERMINAL

BOX COVER

LIFTING EYE

ACCESS COVER

ACCESS TO

AIR FILTER

COOLING

AIR INLET

GRILLE

OIL DRAIN

PLUG

ACCESS DOOR FOR

OIL AND FUEL FILTERS

FUEL

CONNECTIONS

BATTERY

CONNECTIONS

COOLANT

DRAIN CAP

WARM AIR DISCHARGE

OPENING

EXHAUST TAILPIPE

FLANGE

(NOT VISIBLE)

FIGURE 2. TYPICAL GENSET

FUEL RECOMMENDATIONS

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 arcs, switches and arc-producing equipment and all other sources of ignition well away. Keep a type ABC fire extinguisher in the vehicle.

Use clean, fresh No. 2 diesel fuel (ASTM 2-D) when the outdoor ambient temperature is above freezing, and No. 1 diesel fuel (ASTM 1-D) when below freez-ing. The fuel should have a Cetane number of at least 45 for reliable starting.

ENGINE OIL RECOMMENDATIONS

Use API (American Petroleum Institute) perfor-mance Class CH-4, CG-4 or CF-4 engine oil, which may be in combination with performance Class SJ, SH or SG (for example: CH-4/SJ). Also look for the

SAE (Society of Automotive Engineers) viscosity grade. Referring to Chart 1, choose the viscosity grade appropriate for the outdoor ambient tempera-tures expected until the next scheduled oil change.

STARTING BATTERIES

These gensets have a 12 volt, direct current (DC) starting and control system. See Specifications (Page 30) for minimum battery requirements (cold cranking amperes) for genset starting.

Regular, monthly maintenance of batteries may be required. See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS (Page 16) and any in-structions available from the vehicle manufacturer or battery manufacturer. Either the vehicle or the genset will be equipped with a battery charger.

Reliable genset starting and starter service life de-pend upon adequate battery system capacity and proper maintenance.

CHART 1. OIL VISCOSITY VS. TEMPERATURE

Anticipated Ambient Temperature

OPERATOR’S CONSOLE

The operator’s console (Figure 3) has the following features:

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 Light − This is an LED (light emitting diode) in the control switch which blinks rapidly during pre-heat and cranking. (Preheat is the period of time prior to engine cranking when the glow plugs pre-heat the combustion chambers. The time is auto-matically varied by the genset controller on the ba-sis of engine temperature.) After the genset starts up, this light stays on continuously, indicating that the genset is running and that the starter has dis-connected. Also, if the genset shuts down, this light blinks in a coded fashion to indicate the nature of the shutdown (see Troubleshooting, Page 21).

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

Engine Oil Fill Cap/Dipstick − The oil dipstick is at-tached to the fill cap and is marked ADD and FULL.

Coolant Recovery Tank Fill Cap − The recovery tank provides for coolant expansion. Replenish the normal loss of coolant by filling here.

Coolant Pressure Cap − The coolant pressure cap is accessible by removing the access plate on the control console. It provides for a pressurized engine cooling system. Fill coolant here when refilling the system.

Fuses F1, F2 and F3 − These fuses are accessible by removing the access plate on the control con-sole. They protect the control circuits of the genset.

Hour Meter (Optional)− The hour meter records the total running time of the genset. It cannot be re-set.

REMOTE CONTROL PANEL

The vehicle may be equipped with a remote control panel having a Control Switch and Preheat/Diag-nostics Light. In addition, it may have an hour me-ter and the following engine gauges:

Oil Pressure Gauge − The oil pressure gauge indi-cates the presence of engine oil pressure.

Water Temperature Gauge − The water tempera-ture gauge indicates engine coolant temperature.

Voltmeter − The voltmeter indicates battery volt-age.

ACCESS

PLATE

COOLANT

RECOVERY TANK

FILL CAP (BLUE)

OIL FILL CAP

AND DIP STICK

(YELLOW)

LINE CIRCUIT

BREAKER

HOUR METER

(OPTIONAL)

CONTROL

SWITCH AND

STATUS LIGHT

FIGURE 3. OPERATOR’S CONSOLE

Operation

WARNING EXHAUST GAS IS DEADLY!

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 op-erate 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 car-bon monoxide detector. Primary protection against poisoning due to inhaling carbon monoxide, how-ever, consists of proper installation of the exhaust system and inspections every day (every eight hours of operation) 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 13). Keep a log of maintenance and the hours run and perform any maintenance that may be due.

See Returning the Genset to Service (Page 11) if the vehicle has been in storage.

Before each start:

1. Make sure all vehicle CO detectors are work-ing.

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 ap-pliances.

PRIMING THE FUEL SYSTEM

The fuel system should be primed after replacing the fuel filter or running the genset out of fuel. To prime the fuel system hold the control switch down in its Stop position for at least 1 minute.

STARTING THE GENSET

Start the genset from the genset control panel or re-mote control panel inside the vehicle.

1. Push and hold the switch at START until the genset starts. The status indicator light on the switch flashes during preheat and cranking. It will come on solid when the starter disconnects, indicating that the genset is running. (Depend-ing on how cold it is, preheat can take up to 15 seconds, extending the time that the light blinks.)

CAUTION Excessive cranking can over-heat and damage the starter motor. Do not crank for more than 20 seconds at a time.

Wait at least 2 minutes before trying again.

2. See Troubleshooting (Page 21) if the genset does not start after three tries.

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

4. Monitor the engine gauges if the remote panel is so equipped. Normal readings during opera-tion are as follows:

Oil Pressure: Approximate center of scale

Temperature: 160°-220° F (71°-104° C)

DC Voltage: 14-15 volts.

5. Check for fuel, exhaust and coolant leaks. Stop the genset immediately if there is a fuel, ex-haust or coolant leak and have it repaired.

STOPPING THE GENSET

Turn off the air conditioner and other large ap-pliances and let the genset run for two minutes to cool down. Then press the switch to STOP to stop the genset.

RESTARTING THE GENSET

See Troubleshooting (Page 21) if the genset shuts down abnormally.

LOADING THE GENSET

The genset can power AC motors, air conditioners, AC/DC converters, battery chargers and other ap-pliances. How much appliance load* can be pow-ered depends upon the genset power rating. The genset will shut down or its circuit breakers will trip if the sum of the loads exceeds genset power. (If the genset shuts down, the status light will probably dis-play Fault Code No. 11, 13, 22 or 38. See Trouble-shooting, Page 21.)

To avoid overloading the genset and causing shut-downs, compare the sum of the loads of the ap-pliances that are likely to be used at the same time to the power rating of the genset. Use Table 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 condition-ers are cycling on and off.

Maximum power decreases as altitude increases because air density decreases. For every 1000-foot (305 m) increase in elevation you can expect power to decrease approximately 3 percent. Table 2 shows the results of typical calculations. It may be necessary to run fewer appliances at higher alti-tudes.

TABLE 1. TYPICAL APPLIANCE LOADS

Appliance Load (watts)

Air Conditioner 1400-2000

Battery Charger Up to 2000

DC Converter 300-1200

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. POWER VS. ALTITUDE

Elevation above Mean Sea Level

Max Genset Power*

Max Genset Power* up to 500 ft (152 m)

7500 watts (rated)

8000 watts (rated)

2500 ft (762 m) 7050 watts 7520 watts

5500 ft (1676 m) 6375watts 6800watts above 5500 ft

(1676 m)

6375watts minus 225 watts ev-ery1000 ft (305 m)

6800watts minus 240 watts ev-ery1000 ft (305 m)

* This table does not take into account the effect cir-cuit breakers may have in limiting maximum power.

Commercial Genset Applications

Maximum genset power (nameplate rating) is 7500 watts in an ambient of 85° F (29° C), but only 6000 watts in an ambient of 120° F (50° C)—the maximum operating temperature. Also, continuous operation at up to 80 percent of maximum power (6000 watts) is acceptable.

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

RESETTING CIRCUIT BREAKERS

If a circuit breaker in the main power distribution panel of the vehicle or on the genset (Figure 4) trips, either a circuit shorted or too many appliances were running. Note that the genset will continue to run af-ter a circuit breaker trips.

If a circuit breaker trips, disconnect or turn off as many loads as possible and reset the circuit break-

er. (Push the circuit breaker to OFF to reset it and then to ON to reconnect the circuit.) If the circuit breaker trips right away, either the electrical dis-tribution system has a short or the circuit breaker is faulty. Call a qualified electrician.

If the circuit breaker does not trip, reconnect the ap-pliances, one by one, up to a total load that does not overload the genset or cause the circuit breaker to trip. If a circuit breaker trips right away when an ap-pliance is connected, the appliance probably has a short.

Electrical appliances and tools must be used and maintained properly and be properly grounded to cause the line circuit breakers to trip when short cir-cuits occur.

WARNING Short circuits in electrical ap-pliances and tools can cause fire and electrical shock leading to severe personal injury or death. Read and follow the equipment and tool manufacturer’s instructions and warnings re-garding use, maintenance and proper ground-ing.

CONNECTING TO UTILITY POWER

When the vehicle has provisions for connecting to utility power, such as a cord for plugging into a pow-er outlet receptacle, it must also have an approved device to keep the genset and utility from being in-terconnected. See the genset Installation Manual for more information.

WARNING Interconnecting the genset and the 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.

LINE CIRCUIT

BREAKER

FIGURE 4. LINE CIRCUIT BREAKER

OPERATING IN COLD WEATHER

Make sure the engine oil viscosity is appropriate for the cold weather temperatures. See ENGINE OIL RECOMMENDATIONS (Page 5). Be sure to change the oil if a sudden drop in temperature oc-curs.

OPERATING IN HOT WEATHER

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

1. Make sure nothing blocks airflow to and from the genset.

2. Make sure engine oil viscosity is appropriate for the ambient temperatures. See ENGINE OIL RECOMMENDATIONS (Page 5).

3. Keep the genset clean.

4. Perform maintenance due. See PERIODIC MAINTENANCE SCHEDULE (Page 12).

OPERATING AT HIGH ALTITUDE

For the effect of altitude on maximum power, see LOADING THE GENSET (Page 8).

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 12).

3. Change engine oil more often. See PERIODIC MAINTENANCE SCHEDULE (Page 12).

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

BREAKING IN A NEW ENGINE

Proper engine break-in on a new genset or on one with a rebuilt engine is essential for top engine per-formance and acceptable oil consumption. Run the genset at approximately 1/2 rated power for the first 2 hours and then at 3/4 rated power for 2 more hours. See LOADING THE GENSET (Page 8).

Proper engine oil and oil level are especially critical during break-in because of the higher engine tem-peratures that can be expected. Change the oil if not appropriate for the ambient temperatures during break-in. See ENGINE OIL RECOMMENDATIONS (Page 5). 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 8). A single two hour exercise period is bet-ter than several shorter periods.

Exercising a genset drives off moisture, re-lubri-cates the engine, replaces stale fuel and removes oxides from electrical contacts. The result is better starting, more reliable operation and longer engine life.

STORING THE GENSET

Proper storage is essential for preserving top gen-set performance and reliability when the genset cannot be exercised regularly and will be idle for more than 120 days.

Storing the Genset

1. Push the genset line circuit breaker OFF (Page 9).

2. Change the engine oil and attach a tag indicat-ing oil viscosity. See ENGINE OIL REC- OMMENDATIONS (Page 5).

3. Disconnect the battery cables (negative [−] cable first) from the starting battery and store the battery according to the battery manufac-turer’s recommendations. See MAINTAINING

THE BATTERY AND BATTERY CONNEC-

TIONS (Page 16).

4. Plug the exhaust tail pipe to keep out dirt, mois-ture, bugs, etc.

5. 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 5).

2. Reconnect the starting battery (negative [−] cable last). See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS (Page 16).

3. Remove the plug from the exhaust tailpipe.

4. Change the air filter element if it is dirty (Page 16).

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

6. Inspect the genset. See CONDUCTING GEN- ERAL INSPECTIONS (Page 13).

7. Push the genset line circuit breaker ON (Page 9) when the genset is ready to power appliances.

Periodic Maintenance Periodic maintenance is essential for top perfor-mance and long genset life. Use Table 3 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 main-tenance performed and hours run (Page 34) will help you keep genset maintenance regular and pro-vide a basis for supporting warranty claims.

Maintenance, replacement or repair of emission control devices and systems may be performed by any engine repair establishment or individual. How-ever, warranty work must be completed by an au-thorized Onan dealer.

TABLE 3. PERIODIC MAINTENANCE SCHEDULE

MAINTENANCE PROCEDURE

MAINTENANCE FREQUENCY

Every Day

After First 50 Hours

Every Month

Every

Hours

Every

Hours

Every Hours

P a g e

General Inspection X 13

Check Engine Oil Level X 14

Check Engine Coolant Level X 19

Clean and Check Battery X3 16

Change Engine Oil and Filter X1 X2, 3, 4 15

Clean Spark Arrestor X4 17

Replace Engine Air Filter X2, 4 16

Replace Fuel Filter X 18

Check Coolant Anti-freeze Protection X 19

Flush Coolant System X5 19

Replace Coolant Pressure Cap X5 19

Replace Engine V-belt X6,7 −

Clean Crankcase Breather X6,7 −

Replace Coolant Hoses and Thermostat X6, 7 −

1 − As a part of engine break-in, change the engine oil after the first 50 hours of operation.

2 − Perform more often when operating in dusty conditions.

3 − Perform more often when operating in hot weather.

4 − Perform at least once a year.

5 − Perform at least once every two years.

6 − Perform at least once every five years.

7 − Must be performed by a qualified mechanic (authorized Onan dealer).

CONDUCTING GENERAL INSPECTIONS

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

Oil Level

Check engine oil level (Page 14).

Engine Coolant System

CAUTION Operating the genset when coolant level is low can cause serious engine damage.

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

Exhaust System

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.

Look and listen for exhaust system leaks while the genset is running. Shut down the genset if a leak is found and have it repaired before operating the gen-set again.

Look for openings or holes between the genset compartment and vehicle cab or living space if the genset engine sounds louder than usual. Have all such openings or holes closed off or sealed to pre-vent exhaust gases from entering the vehicle.

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

Park the vehicle so that the genset exhaust gases can disperse away from the vehicle. Barriers such as walls, snow banks, high grass and brush and oth-er vehicles can cause exhaust gases to accumulate in and around the vehicle.

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

Fuel System

Check for leaks at hose, tube and pipe fittings in the fuel supply system while the genset is running and while it is stopped. Check flexible fuel hose sections for cuts, cracks, and abrasions. Make sure the fuel line is not rubbing against other parts. Replace worn or damaged fuel line parts before leaks occur.

WARNING Diesel fuel leaks can lead to fire. Do not operate the genset if operation causes fuel to leak.

Battery Connections

Check the battery terminals for clean, tight connec-tions. Loose or corroded connections have high electrical resistance which makes starting harder.

See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS (Page 16).

WARNING Arcing at battery terminals or in 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 trouble light ON or OFF away from bat-tery—Stop genset and disconnect charger be-fore disconnecting battery cables—Disconnect negative (−) cable first and reconnect last.

Mechanical

Look for mechanical damage. Start the genset and look and listen for any unusual noises and vibra-tions.

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.

Check the engine gauges from time to time while the genset is running (if so equipped).

CHECKING ENGINE OIL LEVEL

WARNING State and federal agencies have de-termined 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.

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

1. Unscrew the oil fill cap, pull out the dipstick and wipe off the oil (Figure 5). Reinsert the dipstick, screw the cap back on, remove the dipstick again and check the oil level on the dip stick.

2. Add or drain oil as necessary. See ENGINE OIL RECOMMENDATIONS (Page 5). 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. Reinsert the dipstick and screw the oil fill cap back on securely. FIGURE 5. CHECKING ENGINE OIL LEVEL

CHANGING ENGINE OIL AND OIL FILTER

WARNING State and federal agencies have de-termined that contact with used engine oil can cause cancer or reproductive toxicity. Avoid skin contact and breathing of vapors. Use rub-ber gloves and wash exposed skin.

Refer to Table 3 for scheduled engine oil change.

Change oil more often in hot and dusty environ-ments.

1. Run the engine until warm, stop it and remove the oil fill cap and dipstick (Figure 5).

2. Place a pan underneath the genset and un-screw the oil drain plug (Figure 6). Let all oil drain from the engine.

3. Reinstall the oil drain plug and tighten it secure-ly to prevent oil leakage.

4. Squeeze the access door latches together and let the door swing down (Figure 6).

5. Spin off the oil filter canister. Thoroughly wipe off the filter mounting surface and remove the old gasket if it does not come off with the filter canister.

6. Make sure the new gasket is in place on the new filter canister and apply a thin film of oil to the gasket. (The replacement filter canister has a larger diameter than the original filter cannis-ter, but will fit.)

7. Spin on the new filter canister by hand until the gasket just touches the mounting pad and then turn it an additional 1/2 to 3/4 turn. Do not over-tighten. Close the access door, making sure it latches securely.

8. Refill with 3 quarts (2.6 l) of oil. See ENGINE OIL RECOMMENDATIONS (Page 5). Check the oil level and add or drain oil as necessary.

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.

9. Reinsert the dipstick and screw the oil fill cap back on securely.

10. Dispose of the used oil and oil filter in accor-dance with local environmental regulations.

OIL DRAIN PLUG

OIL FILTERACCESS DOOR

FIGURE 6. OIL DRAIN PLUG AND OIL FILTER

MAINTAINING THE BATTERY AND

BATTERY CONNECTIONS

WARNING Arcing at battery terminals or in 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 trouble light ON or OFF away from bat-tery—Stop genset and disconnect charger be-fore disconnecting battery cables—Disconnect negative (−) cable first and reconnect last.

Refer to Table 3 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.

REPLACING THE AIR FILTER ELEMENT

Refer to Table 3 for scheduled air filter element re-placement. In dusty environments the filter element should be inspected and changed more frequently.

To change the filter element (Figure 7), remove the outer and inner cover and reassemble with a new air filter element. Turn the inner cover wingnut three to four clicks past seating. Make sure the outer cover is seated before tightening its wingnut. Check for noise when the genset is running, and retighten if necessary.

OUTER COVER INNER COVER FILTER ELEMENT SPACER SEAL HOUSING

FIGURE 7. REPLACING THE AIR FILTER ELEMENT

CLEANING THE SPARK ARRESTOR

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

WARNING A hot muffler can cause severe burns. Let the muffler cool down before remov-ing or installing the cleanout plug.

The muffler is mounted inside the genset housing.

The cleanout plug is located on the side of the muf-fler, accessible through the air outlet opening in the bottom of the genset. Clean out the spark arrestor muffler as follows:

1. Remove the cleanout plug from the muffler (Figure 8).

2. Restart the genset and load it nearly to full pow-

er. See LOADING THE GENSET (Page 8).

Let the genset run for about five minutes to ex-pel the soot in the muffler.

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

CLEANOUT PLUG

FIGURE 8. SPARK ARRESTOR CLEANOUT PLUG

REPLACING THE FUEL FILTER

Refer to Table 3 for scheduled replacement of the fuel filter (Figure 9). A dirty fuel filter may be the cause if the engine fails to start. The fuel filter is ac-cessible through the maintenance access door in the skid-base. Squeeze the latches together to open the door.

CAUTION Wipe dirt off the fuel hose connec-tions at the fuel filter before disconnecting the hoses so as to keep dirt out of the fuel system.

WARNING Diesel fuel is combustible and can cause severe personal injury or death. Do not smoke. Keep flames, sparks, pilot lights, electri-cal arcs, switches and arc-producing equip-ment and all other sources of ignition well away.

Keep a type ABC fire extinguisher handy.

Removing the Fuel Filter: To remove the filter, dis-connect 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.

Installing the Fuel Filter: Rotate the filter half a turn around its mounting stud if the fittings interfere with the bracket. It only fits properly 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.

Close the access door and prime the fuel system by holding the control switch down in its Stop position for at least 1 minute. Priming is necessary to dis-place the air in the new filter with fuel.

FILTER

MOUNTING

NUT

TUBING FROM

FUEL PUMP

FUEL HOSE

TO ENGINE

FUEL

FILTER

FIGURE 9. FUEL FILTER

CHANGING COOLANT

Refer to Table 3 for scheduled maintenance. The engine cooling system is filled with a 50/50 mixture of ethylene glycol anti-freeze and water when the genset leaves the factory, which is suitable for tem-peratures down to -34° F (-37° C).

Replace the coolant every two years. Use ethylene or propylene glycol anti-freeze solution that con-tains a rust and corrosion inhibitor. The anti-freeze should not contain a stop-leak additive.

The water used for engine coolant should be clean, low in minerals, and free of corrosive chemicals.

Use distilled water if available. The cooling system has a 4.2 quart (4 l) capacity.

Pressure Cap

Replace the pressure cap (Figure 10) every two years because its seals can deteriorate and begin to leak. Proper cooling system pressure is essential for optimal engine cooling and minimal coolant loss.

Draining the Cooling System

WARNING Hot coolant spray can cause severe burns. Let the engine cool before releasing the pressure cap or removing the drain cap.

Allow the engine to cool before removing the pres-sure cap. Then relieve any remaining pressure by turning the pressure cap slowly, without pushing down on it, until it catches. When the pressure has been relieved, remove the pressure cap by pushing down and turning it until it can be withdrawn. Then get a suitable container and drain the coolant by re-moving the system drain cap (Figure 10).

WARNING Ethylene glycol antifreeze is con-sidered toxic. Dispose of it according to local regulations for hazardous substances.

It is recommended that the system be cleaned and flushed 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.

Refilling the Cooling System

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

Secure the system drain cap. Fill the cooling system with coolant mixture through the pressure cap/fill opening. Pull the hose connected to the pressure cap assembly out as far as it will go. When coolant fills up to the fill opening, start and operate the gen-set for a few minutes and shut it down. (It is recom-mended that the air conditioners or other large loads be turned on so that the genset will operate under load, causing the engine to run faster and expel trapped air.) Add more coolant if necessary and se-cure the pressure cap.

Coolant Level Check

Check coolant level in the recovery tank (Figure 10) before the first startup of each day and fill to the COLD mark if necessary.

PRESSURE CAP AND

SYSTEM FILL OPENING

COOLING SYSTEM

DRAIN CAP

COOLANT RECOVERY

TANK FILL CAP (BLUE)

FIGURE 10. ENGINE COOLING SYSTEM FILL AND DRAIN CAPS

Troubleshooting WARNING Hot engine parts can cause severe burns. Always allow the engine time to cool be-fore performing any maintenance or service.

TABLE 4. TROUBLESHOOTING lists the Fault Codes in numerical order along with step-by-step instructions for corrective action. If you fail to re-solve the problem after taking the corrective actions suggested, contact an authorized Onan dealer. See How to Obtain Service (Page 33).

First note the following:

• Maintaining engine oil level, keeping battery connections clean and tight, watching the fuel gauge, not overloading the genset, etc. will prevent most shutdowns.

• When the genset and vehicle engine share a common fuel tank the fuel dip tubes are usual-ly 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.

First-Level Fault Codes: The genset controller provides extensive diagnostics by causing the sta-tus indicator light on the Control Switch to blink in a coded fashion. Following a fault shutdown, the indi-cator light will repeatedly blink 1, 2 or 3 blinks at a time.

• One blink indicates shut down due to high tem-perature

• Two blinks indicates shutdown due to a loss of engine oil pressure

• Three blinks indicates shutdown due to some other abnormal condition.

Second-Level Fault Codes: For a 1-blink or 3-blink first-level fault code, one touch to Stop brings up a second-level fault code. This 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. 23 would ap-pear as:

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

NOTE: Fault Code Nos. 1, 2 and 3 are first-level faults.

Avoid interpreting them as second-level Fault Codes 11, 22 and 33. The pauses between repetitions of the fault code are longer than the pauses between the tens and units digits of the the code. For example, Fault Code 33 would appear as:

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

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 cor-rected.

TABLE 4. TROUBLESHOOTING

Some genset service procedures present hazards that can result in severe per-sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.

WARNING

GENSET WON’T STOP RUNNING—STATUS INDICATOR LIGHT ON

(Faulty Stop Switch or grounded wiring)

Removing genset panels or disconnecting fuel lines to stop a genset that won’t stop can lead to severe personal injury or death from electrocution, contact with moving parts or fire.

Try the genset Stop Switch if the remote Stop Switch does not work, and vice versa. Otherwise, let the genset run out of fuel.

WARNING

GENSET WON’T STOP RUNNING—STATUS INDICATOR LIGHT OFF

(Binding governor mechanism, misadjusted speed stop)

Removing genset panels or disconnecting fuel lines to stop a genset that won’t stop can lead to severe personal injury or death from electrocution, contact with moving parts or fire.

Let the genset run out of fuel.

WARNING

STATUS INDICATOR LIGHT STAYS ON

(Reversed battery connections)

Corrective Action: Reconnect the battery correctly (Page 16).

ENGINE CRANKS WHEN BATTERY CONNECTED

(Faulty Start Switch or grounded wiring)

Corrective Action: See an authorized Onan dealer.

ENGINE WON’T CRANK—FUEL PUMP WON’T STOP

(Faulty Stop Switch or grounded wiring)

Corrective Action: See an authorized Onan dealer.

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. Replace Fuse F1 (B+) if blown (Page 6).

3. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery, vehicle frame and genset (Page 16).

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

TABLE 4. TROUBLESHOOTING (CONT.)

Some genset service procedures present hazards that can result in severe per-sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.

WARNING

STARTING BATTERIES RUN DOWN

(Marginal battery, battery 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 (Page 16).

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

ENGINE CRANKS BUT DOES NOT START

(Fuel delivery, glow plugs or engine are marginal)

Corrective Action:

1. Check fuel level. (Note: The genset fuel pickup is probably higher than the vehicle engine pickup.)

2. Prime the engine fuel system by holding the control switch down in its Stop position for at least 1 min-ute.

3. Check the engine air filter and remove any blockage (Page 16).

4. Replace Fuse F3 (glow plugs) if blown (Page 6).

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 (Page 16).

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

4. Increase battery cable size or run parallel cables.

NO POWER—GENSET RUNNING, RUN LIGHT ON

(Line circuit breaker OFF or tripped or faulty wiring)

Corrective Action: Reset or turn “On” the line circuit breaker on the genset operator’s console.

GENSET HUNTS UNDER FULL LOAD

(Fuel delivery marginal, governor misadjusted)

Corrective Action: Prime the engine fuel system by holding the control switch down in its Stop posi-tion for at least 1 minute.

Some genset service procedures present hazards that can result in severe per-sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.

WARNING

HIGH TEMPERATURE—FAULT CODE NO. 1

(Engine coolant or inverter heat sink temperature exceeded design limit)

Corrective Action: Check the second-level fault code by touching Stop. The second-level fault will be either No. 33 or No. 34.

LOW OIL PRESSURE—FAULT CODE NO. 2

(Low oil pressure cutoff switch did not open)

Corrective Action:

1. Check engine oil level and add oil as necessary (Page 14).

2. Drain excess oil (above dipstick Full mark).

SERVICE CHECK FAULT—CODE NO. 3

(A second-level fault occurred)

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

OVERLOAD—CODE NO. 8

(Models HDKAH & HDKAV only: Load exceeded110 percent of genset rating for 2 minutes)

Corrective Action: Reduce load and restart

OVERCURRENT FAULT—CODE NO. 11

(AC output short)

Corrective Action:

1. Turn off the genset line circuit breaker. If the genset no longer shuts down, the genset is probably okay—check for and repair a short circuit in the vehicle appliances, wiring or shorted battery charger transformer.

2. Check whether the vehicle engine and genset share the same starting battery. If so, and this fault occurs when cranking the vehicle engine, low battery voltage may be causing this shutdown. In-crease battery capacity or install a separate battery and battery charging system for the genset.

Some genset service procedures present hazards that can result in severe per-sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.

WARNING

INVERTER OVERVOLTAGE FAULT—CODE NO. 12

(Controller not able to regulate to rated voltage)

Corrective Action: Check whether the vehicle engine and genset share the same starting battery. If so, and this fault occurs when cranking the vehicle engine, low battery voltage may be causing this shutdown. Increase battery capacity or install a separate battery and battery charging system for the genset.

INVERTER UNDERVOLTAGE FAULT—CODE NO. 13

(Controller not able to regulate to rated voltage)

Corrective Action: Check whether the vehicle engine and genset share the same starting battery. If so, and this fault occurs when cranking the vehicle engine, low battery voltage may be causing this shutdown. Increase battery capacity or install a separate battery and battery charging system for the genset.

INVERTER OVERFREQUENCY FAULT—CODE NO. 14

(Controller not able to regulate to rated frequency)

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

INVERTER UNDERFREQUENCY FAULT—CODE NO. 15

(Controller not able to regulate to rated frequency)

Corrective Action:

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

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

GOVERNOR ACTUATOR FAULT—CODE NO. 19

(Controller sensed open or short circuit)

Corrective Action: See an authorized Onan dealer.

GOVERNOR ACTUATOR OVERLOAD FAULT—CODE NO. 22

(Duration of operation at or near full-duty cycle beyond design limit)

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

Some genset service procedures present hazards that can result in severe per-sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.

WARNING

LOW OIL PRESSURE CUTOFF SWITCH FAULT—CODE NO. 23

(Controller sensed switch still open during start—not a running fault)

Corrective Action: See an authorized Onan dealer.

COOLANT TEMPERATURE SENDER FAULT—CODE NO. 24

(Controller did not sense temperature change during first 5 minutes of operation)

Corrective…