Cumans_Onon_7.5kW_Service_Manual.pdf

Service Manual

RV Generator Set

HDKAH (Spec A−N) HDKAJ (Spec A−N) HDKAK (Spec A−N) HDKAT (Spec A−P) HDKAU (Spec A−P) HDKAV (Spec A−P)

English − Original Instructions 2−2013 981−0522 (Issue 16)

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.

i

Table of Contents

SAFETY PRECAUTIONS iv

1. INTRODUCTION 1-1

About this Manual 1-1

Service Parts and Information 1-1

Typical Genset 1-2

2. SPECIFICATIONS 2-1

3. THREAD TORQUES 3-1

4. OPERATION 4-1

Fuel Recommendations 4-1

Bio−diesel Fuels B5 − B20 4-1

Engine Oil Recommendations 4-2

Starting Batteries 4-2

Operator’s Console 4-3

Remote Control Panel 4-3

Priming the Fuel System 4-4

Starting 4-4

Stopping 4-4

5. PERIODIC MAINTENANCE 5-1

Periodic Maintenance Schedule 5-1

General Inspection 5-2

Checking Engine Oil Level 5-3

Changing Engine Oil and Oil Filter 5-3

Spark Arrestor 5-5

Batteries 5-6

Air Filter 5-6

Fuel Filter 5-7

Changing Coolant 5-8

Coolant Temperature Input 5-10

6. PREPARATIONS FOR SERVICE 6-1

Special Tools 6-1

Safety 6-1

Removing Genset From Vehicle 6-2 ii

Test Stand 6-2

Removing Housing Panels 6-3

Installing Housing Panels 6-3

7. ENGINE AIR INTAKE 7-1

Component Layout 7-1

8. MUFFLER 8-1

Removal 8-1

Installation 8-1

9. ENGINE COOLING SYSTEM 9-1

General 9-1

Radiator Removal 9-1

Radiator Installation 9-1

10. CONTROLLER-INVERTER 10-1

General 10-1

Removal 10-1

Installation 10-1

Controller-Inverter Functions 10-3

11. PMA (GENERATOR) 11-1

General 11-1

Stator Tests 11-1

Stator Removal 11-4

Stator Installation 11-4

Rotor Removal 11-4

Rotor Installation 11-4

12. ENGINE 12-1

Engine Service 12-1

Replacing Coolant Pump Belt 12-1

Engine Sensors 12-1

Engine Removal 12-2

Engine Installation 12-2

Replacing Low Oil Pressure Cutoff Switch 12-2

13. GOVERNOR ACTUATOR 13-1

General 13-1

Actuator Removal 13-1

Actuator Installation 13-1

Actuator Speed Control Lever Stop (Beginning Spec B) 13-4 iii

High-Idle Speed 13-5

High-Idle Stop Screw 13-6

14. FUEL SYSTEM 14-1

General 14-1

Fuel Pump 14-1

Fuel Filter 14-1

Fuel Injection System 14-1

15. BATTERY CHARGER 15-1

Removal 15-1

Installation 15-1

16. STARTER MOTOR 16-1

Removal 16-1

Installation 16-1

Starter Solenoid Replacement 16-2

17. SERVICE CHECKLIST 17-1

18. TROUBLESHOOTING 18-1

Troubleshooting With Table 18-1 18-1

Restoring Fault Code Blinking 18-2

Bypassable Faults: Prior to Spec F 18-2

ENGINE WIRING HARNESS A-1

AC WIRING HARNESS A-2

BATTERY WIRING HARNESS A-3

WIRING DIAGRAM A-4

WIRING DIAGRAM FOR FC32 TROUBLESHOOTING A-5

iv

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 proper-ly.

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

DANGER 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 inju-ry or death.

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

Electricity, fuel, exhaust, moving parts and batter-ies present hazards which can result in severe per-sonal injury or death.

ENGINE EXHAUST IS DEADLY

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

Prior to every startup and after every eight hours of running, all carbon monoxide detec-tors must be tested and confirmed to e working in accordance with the manufacture’s instruc-tions or owners manual.

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

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

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

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

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

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

GENERATOR VOLTAGE IS DEADLY

Disable the automatic genset starting feature of an inverter-charger or other automatic start-ing device before servicing the genset.

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

The genset must not be connected to the pub-lic 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-producing equipment and all other sources of ignition 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 feature of an inverter-charger or other automatic start-ing device before servicing the genset.

Do not wear loose clothing or jewelry near moving parts such as PTO shafts, fans, belts and pulleys.

Keep hands away from moving parts.

v

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 operators of the genset are solely responsible for operating 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 combus-tible 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)

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.

vi

THIS PAGE IS INTENDED TO BE BLANK

1-1

1. Introduction

ABOUT THIS MANUAL

This is the Service Manual for the generator set (genset) models listed on the front cover. Read and carefully observe all of the instructions and precau-tions in this manual.

WARNING Improper service or parts replace-ment can lead to severe personal injury or death and to damage to equipment and property. Ser-vice personnel must be qualified to perform electrical and mechanical service.

CAUTION Unauthorized modifications or re-placement of fuel, exhaust, air intake or speed control system components that affect engine emissions are prohibited by law in the State of California.

See the Installation Manual for important recom-mendations concerning the installation and for a list of the installation codes and standards for safety which may be applicable.

See the Parts Catalog for parts identification num-bers and required quantities. Genuine Onan re-placement parts are recommended for best results.

SERVICE PARTS AND INFORMATION

When contacting Onan for parts, service or product information, be ready to provide the model number and the serial number, both of which appear on the genset nameplate. Figure 1-1 illustrates the name-plate and its location. The numbers in the gray boxes are typical model and serial numbers. Every character in these numbers is significant. (The last character of the model number is the specification letter, which is important for obtaining the right parts.)

SKB719U6D2RA 719 cc

80HDKAK11454J

F990 123456

FIGURE 1-1. TYPICAL NAMEPLATE

1-2

TYPICAL GENSET

Figure 1-2 illustrates a typical genset.

COOLANT

RECOVERY

TANK

RADIATOR

CONTROLLER/

INVERTER

HOUSING

INTAKE AIR

RESONATOR

STARTER

MOTOR

GENERATOR

(PMA) STATOR

INNER

BULKHEAD

ENGINE

COOLING

BLOWER

GOVERNOR

ACTUATOR

COOLANT

PRESSURE

CAP

FUEL

FILTER

OIL

FILTER

FUEL

PUMP

MUFFLER

ASSEMBLY

FIGURE 1-2. TYPICAL GENSET WITH HOUSING PANELS REMOVED

2-1

2. Specifications

HDKAH HDKAJ HDKAK

GENSET CONTROLLER: Integrated Microprocessor Based Engine and Generator Controller

GENERATOR: Brushless, Exciterless, Bearingless, Permanent Magnet Alternator

AC OUTPUT RATINGS:

Power (@1.0 power factor) 6000 W 7500 W 8000 W

Voltage 120 volts 120 volts 120 volts

Frequency 60 Hz 60 Hz 60 Hz

Number of Phases 1 1 1

Current 50.0 ampere 62.5 ampere 66.7 ampere

Line Circuit Breaker(s) 2-pole, 30 amp 2-pole, 30 or 35 amp 2-pole, 30 or 35 amp

ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection, 4-Stroke Cycle Diesel Bore 2.64 inch (67 mm)

Stroke 2.68 inch (68 mm)

Displacement 44 inch3 (719 cc)

Compression Ratio 23 : 1

Oil Capacity (with filter)* 3 quart (2.6 l) Cooling System Capacity** 4.2 quart (4 l) Intake and Exhaust Valve Lash (Cold) 0.0065 inch (0.165 mm) Lubricating Oil Pressure 14 to 64 psi over speed range Cylinder Compression Pressure 414 to 469 psi, 327 psi minimum

OPERATING SPEED RANGE: 1600 to 2900 RPM 1600 to 3200 RPM 1600 to 3300 RPM

FUEL CONSUMPTION:

No-load Half-load (4000 W) Full-load

0.13 gph (.49 l/h)

0.49 gph (1.85 l/h)

0.80 gph (3.03 l/h)

0.13 gph (.49 l/h)

0.49 gph (1.85 l/h)

0.96 gph (3.63 l/h)

0.13 gph (.49 l/h)

0.49 gph (1.85 l/h)

1.02 gph (3.86 l/h)

DC SYSTEM:

Nominal Battery Voltage 12 volts

Minimum Battery Capacity 450 CCA*** down to 0 F (−17 C)

650 CCA*** down to −20 F (−29 C) Maximum Regulated-Voltage Battery Charging Current (Optional) 10 ampere

Fuse F1 (control circuit) 10 ampere mini-bayonet Fuse F2 (starter solenoid circuit) 10 ampere mini-bayonet Fuse F3 (glow plug circuit) 25 ampere

WEIGHT AND SIZE:

Weight (wet) Length x Width x Height

420 lbs (191 kg)

36.3 x 23.6 x 22.3 inch (922 x 599 x 566 mm)

* See oil filling instructions.

** Includes coolant recovery tank.

*** Cold Cranking Amps @ 0 F (−17 C)

2-2

HDKAV HDKAT HDKAU

GENSET CONTROLLER: Integrated Microprocessor Based Engine and Generator Controller

GENERATOR: Brushless, Exciterless, Bearingless, Permanent Magnet Alternator

AC OUTPUT RATINGS:

Power (@1.0 power factor) 6000 W 7500 W 8000 W

Voltage 120 volts 120 volts 120 volts

Frequency 60 Hz 60 Hz 60 Hz

Number of Phases 1 1 1

Current 50.0 ampere 62.5 ampere 66.7 ampere

Line Circuit Breaker(s) 2-pole, 30 amp 2-pole, 30 or 35 amp 2-pole, 30 or 35 amp

ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection, 4-Stroke Cycle Diesel Bore 2.64 inch (67 mm)

Stroke 2.68 inch (68 mm)

Displacement 44 inch3 (719 cc)

Compression Ratio 23 : 1

Oil Capacity (with filter)* 3 quart (2.6 l) Cooling System Capacity** 4.2 quart (4 l) Intake and Exhaust Valve Lash (Cold) 0.0065 inch (0.165 mm) Lubricating Oil Pressure 14 to 64 psi over speed range Cylinder Compression Pressure 414 to 469 psi, 327 psi minimum

OPERATING SPEED RANGE: 1600 to 2900 RPM 1600 to 3200 RPM 1600 to 3300 RPM

FUEL CONSUMPTION:

No-load Half-load (4000 W) Full-load

0.13 gph (.49 l/h)

0.49 gph (1.85 l/h)

0.80 gph (3.03 l/h)

0.13 gph (.49 l/h)

0.49 gph (1.85 l/h)

0.96 gph (3.63 l/h)

0.13 gph (.49 l/h)

0.49 gph (1.85 l/h)

1.02 gph (3.86 l/h)

DC SYSTEM:

Nominal Battery Voltage 12 volts

Minimum Battery Capacity 450 CCA*** down to 0 F (−17 C)

650 CCA*** down to −20 F (−29 C) Maximum Regulated-Voltage Battery Charging Current (Optional) 10 ampere

Fuse F1 (control circuit) 10 ampere mini-bayonet Fuse F2 (starter solenoid circuit) 10 ampere mini-bayonet Fuse F3 (glow plug circuit) 25 ampere

WEIGHT AND SIZE:

Weight (wet) Length x Width x Height

420 lbs (191 kg)

36.3 x 23.6 x 22.3 inch (922 x 599 x 566 mm)

* See oil filling instructions.

** Includes coolant recovery tank.

*** Cold Cranking Amps @ 0 F (−17 C)

3-1

3. Thread Torques lbf-ft* N-m *

Air Cleaner Cover Bolt—Three to four clicks past seating. − −

Air Cleaner Housing Mounting Screws 7-9 10-12

Intake Air Hose Clamp Screws 7-9 10-12

Air Intake Resonator Mounting Screws 7-9 10-12

Fuel Pump Mounting Screws 75-80 lbf-inch 8.5-9

Fuel Fitting At Fuel Pump 7-9 10-12

Fuel Fittings at Fuel Filter—One flat passed finger tight. − −

Exhaust Assembly Flange Bolts 16-20 22-28

Exhaust Isolator Clamp Screws 7-9 10-12

Housing Panel Screws 11-13 15-18

Component Mounting Screws (threads into skid-base) 7-9 10-12

Vibration Isolator Center Bolt 43-53 58-72

Vibration Isolator Mounting Screws 7-9 10-12

Battery Cable Terminal Block Terminal Nuts 6.7-8.3 9-11

Battery Cable Terminal Block Mounting Screws 7-9 10-12

Starter Solenoid Terminal Nuts 4.4-8.7 5.9-11.8

AC Output Terminal Block Terminal Screws 12-14 lbf-inch 1.4-1.6

AC Output Terminal Block Mounting Screws 20-22 lbf-inch 2.2-2.5

Circuit Breaker Terminal Screws 12-14 lbf-inch 1.4-1.6

Circuit Breaker Mounting Screws 12-14 lbf-inch 1.4-1.6

Flywheel Housing Mounting Bolts 18-22 24-30

Rotor/Flywheel Mounting Bolts 40-43 53.9-58.8

Stator Mounting Bolts 7-9 10-12

Blower Mounting Bolts 7-9 10-12

Starter Mounting Bolts 18-22 24-30

Oil Pan Mounting Bolts 5.8-6.9 7.9-9.3

Coolant Temperature Sender (use thread sealant) 26-32 35-43

Low Oil Pressure Switch (use thread sealant) 10.8-14.5 14.7-19.6

Governor Actuator Bearing Carrier Mounting Screws 21-27 lbf-inch 2.4-3.0

Oil Fill Hose Support Clip Screw 7-9 10-12

M6 Engine Bolts Except When Otherwise Specified 5.8-6.9 7.9-9.3

M8 Engine Bolts Except When Otherwise Specified 13.0-15.2 17.7-20.6

M10 Engine Bolts Except When Otherwise Specified 28.9-33.3 39.2-45.1

M12 Engine Bolts Except When Otherwise Specified 46.3-53.5 62.8-72.6

* − Use engine oil as a lubricant for all threads except when otherwise specified.

3-2

4-1

4. Operation

FUEL RECOMMENDATIONS

Use clean, fresh No. 2 diesel fuel (ASTM 2-D) in ambients above freezing and No. 1 diesel fuel (ASTM 1-D) in ambients below freezing. The fuel should have a Cetane number of at least 45 for reli-able starting.

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

BIO−DIESEL FUELS B5 − B20

B5 bio−diesel fuel that meets industry specifications and quality is suitable for use with this generator set.

Bio−Diesel Above B5 and up to B20 Bio−Diesel Blends

The following must be verified before using bio−die-sel blends up to B20:

The generator set is at Spec M or higher.

The vehicle propulsion engine is capable of us-ing B20 when sharing the same fuel tank.

The OEM has installed B20 compatible fuel line from fuel tank to generator set.

The OEM has installed a water separator in the fuel line just before the generator set.

Approved Bio−Diesel Fuel:

For biodiesel blends above B5 and up to B20, Cummins Onan requires that the fuel meet the specifications outlined in ASTM D7467. The biodiesel component of this fuel blend must meet ASTM D6751 or EN14214 and the petro-leum diesel component must meet ASTM D975.

Blended bio−diesels fuels should be bought pre−blended and not made by customers.

Bio−Diesel Properties:

Bio−diesel has poor oxidation stability which can accelerate fuel oxidation. Fuel oxidation will reduce generator performance. This effect is accelerated at increased ambient tempera-tures.

Bio−diesel properties change at low ambient temperatures (below 23F/−5C). Necessary precautions must be taken when operating the generator with bio−diesel blends in low ambi-ent temperatures, such as a fuel heater, hose insulation, or additional anti−gel fuel additives.

Bio−diesel fuel blends are an excellent medium for microbial growth. Microbes cause fuel sys-tem corrosion and premature filter plugging.

The effectiveness of all commercially available conventional anti−microbial additives, when used in bio−diesel, is not known. Consult your fuel and additive supplier for assistance.

WARNING It is highly recommended that specific market applications are avoided or excercised with extra care due to some of the properties of bio−die-sel fuel blends such as cold weather operation, long term storage, material incompatibilities and other effects on engine operating characteristics. Such applications that should use standard fuels include applications that will experience seasonal usage, storage for periods exceeding 90 days, and extreme temperatures or humidity.

Storage Requirements:

If using bio−diesel for seasonal applications (stored more than 90 days), the generator must be purged before storage by running the en-gine on pure diesel fuel meeting ASTM D975 for a mininmum of 30 minutes.

Warranty Coverage:

Cummins Onan Warranty covers failures that are a direct result of defects in material or factory work-manship. Generator damage, service issues and/or performance issues determined by Cummins Onan to be caused by bio−diesel fuel blends not meeting the specifications outlined in the applicable Installa-

4-2 tion, Operator, and Service Manuals are not consid-ered to be defects in material or workmanship and may affect your generator’s warranty.

ENGINE OIL RECOMMENDATIONS

Use API (American Petroleum Institute) perfor-mance Class CH-4, CG-4 or CF-4D 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 Figure 4-1, choose the viscosity grade appropriate for the ambient temper-atures expected until the next scheduled oil change.

STARTING BATTERIES

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

Regular, monthly maintenance of batteries may be required. See Periodic Maintenance, 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.

Anticipated Ambient Temperature

FIGURE 4-1. OIL VISCOSITY VS. TEMPERATURE

4-3

OPERATOR’S CONSOLE

The operator’s console (Figure 4-2) has the follow-ing 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.

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.

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 4-2. OPERATOR’S CONSOLE

4-4

WARNING EXHAUST GAS IS DEADLY! All engine exhaust contains carbon monoxide, an odor-less, colorless, poisonous gas that can cause unconsciousness and death. Symptoms of carbon monoxide poisoning include:

Dizziness Headache Nausea Weakness and Sleepiness Vomiting Inability to Think Coherently

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

Never occupy the vehicle while the genset is running unless the vehicle has a working carbon monox-ide detector. The exhaust system must be installed in accordance with the genset Installation Manual.

Make sure there is ample fresh air when operating the genset in a confined area.

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 can be started and stopped from the genset control panel or from a remote control panel inside the vehicle.

1. Review Powering Equipment, Varying Operat-ing Conditions, Genset Break-In, Exercise and Storage and the Maintenance Record in the Operator’s Manual before starting or servicing the genset.

2. Check fuel, oil and coolant levels, prime the fuel system if necessary (by pushing the Stop switch), and turn off the air conditioner(s) and other large electrical loads.

3. Push the control switch to its Start position and hold it there while the status light blinks rapidly indicating preheat. Let go when the light comes on continuously, indicating that the genset is running and that the starter has been discon-nected. (Depending 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 30 seconds at a time.

Wait at least 2 minutes before trying again.

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

5. Let the genset warm up a few minutes until it is running smoothly before connecting the ve-hicle electrical loads (appliances).

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

Oil Pressure: Approximately center of scale

Temperature: 160-220 F (71-104 C)

DC Voltage: 14-15 volts.

7. Check for fuel, coolant and exhaust leaks. Stop the genset immediately if there is a fuel, coolant or exhaust leak and repair it before continuing operation.

STOPPING

Run the genset at no load for a few minutes to allow the engine to cool down and then push the control switch briefly to its Stop position.

5-1

5. Periodic Maintenance

PERIODIC MAINTENANCE SCHEDULE

Periodic maintenance is essential for top perfor-mance and long genset life. Use Table 5-1 as a guide for normal periodic maintenance. Under hot or dusty operating conditions some maintenance operations should be performed more frequently, as indicated by the footnotes in the table.x

TABLE 5-1. PERIODIC MAINTENANCE SCHEDULE

MAINTENANCE FREQUENCY

MAINTENANCE OPERATION Every Day

Every Month

Every 150 Hours

Every 500 Hours

Every Hours

P a g e

General Inspection x 5-2

Check Engine Oil Level x 5-3

Check Engine Coolant Level x 5-8

Clean and Check Battery x3 5-3

Change Engine Oil and Filter x1, 2,3, 4 5-3

Clean Spark Arrestor x4 5-5

Replace Engine Air Filter x2, 4 5-6

Replace Fuel Filter x4 5-7

Check Coolant Anti-freeze Protection x4, 8 5-8

Flush Coolant System x5 5-8

Replace Coolant Pressure Cap x5 5-8

Replace Coolant Hoses and Thermostat x6, 7 12-1

Replace Engine V-belt x6, 7 12-1

Clean Crankcase Breather x6, 7 12-1

Adjust Valve Lash x7 12-1

1. As a part of engine break-in, change the engine oil and oil filter 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).

8. Perform every 250 hours when using B20 Bio−diesel fuel.

5-2

GENERAL INSPECTION

Inspect the genset before the first start of the day.

Oil Level

Check engine oil level (p. 5-3).

Engine Coolant System

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.

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

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 gen-set.

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 and 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.

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.

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.

Fuel System

Look for fuel leaks around the bottom of the genset and its fuel supply lines when the genset is running.

Do not operate the genset if there is a fuel leak.

Have the leaks fixed as soon as possible.

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

Mechanical

Look for mechanical damage. Start the genset and look, listen and feel for any 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.

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

Battery Connections

Check the battery terminals for clean, tight connec-tions. See BATTERIES (p. 5-6).

5-3

CHECKING ENGINE OIL LEVEL

Shut off the genset before checking the engine oil level.

1. Remove the oil fill cap (yellow) and wipe the stick clean (Figure 5-1).

2. Screw the oil fill cap back on and remove it to check the oil level on the dipstick.

3. Add oil as necessary until the full mark is reached. See ENGINE OIL RECOMMEN- DATIONS (p. 4-2). DO NOT FILL TO A LEVEL

ABOVE THE FULL MARK ON THE DIPSTICK.

Drain the excess oil if too much has been add-ed.

CAUTION Too much oil can cause high oil consumption, high operating temperatures and oil foaming. Too little oil can cause se-vere engine damage. Keep the oil level be-tween the Full and Add marks on the dip-stick.

4. Screw the oil fill cap on securely to prevent oil leakage.

CHANGING ENGINE OIL AND OIL FILTER

Refer to Table 5-1 for scheduled engine oil change.

In hot weather and dusty conditions the oil should be changed more often.

WARNING State and federal agencies have de-termined that contact with used engine oil can cause cancer or reproductive toxicity. Take care to limit skin contact and breathing of vapors as much as possible. Use rubber gloves and wash exposed skin.

1. Place a pan under the oil drain plug. Run the engine until it is warm and shut it off.

2. Remove the oil fill cap (Figure 5-1).

3. Unscrew the oil drain plug (Figure 5-2) and al-low all of the oil to drain from the engine.

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

FIGURE 5-1. OIL DIPSTICK

5-4

5. Squeeze the access door latches together and let the door swing down (Figure 5-2). Spin off the oil filter canister, drain it of oil and discard it according to local regulations.

6. Thoroughly wipe off the filter mounting surface.

Remove the old gasket if it does not come off with the filter canister.

7. 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.)

8. 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.

9. Refill and check the oil level. See Specifications for oil capacity.

10. Dispose of the used oil properly.

OIL DRAIN

PLUG

OIL

FILTER

ACCESS

DOOR

FIGURE 5-2. OIL DRAIN PLUG AND OIL FILTER

5-5

SPARK ARRESTOR

Refer to Table 5-1 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 5-3).

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

er. 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 plug.

CLEANOUT

PLUG

FIGURE 5-3. SPARK ARRESTOR CLEANOUT PLUG

5-6

BATTERIES

WARNING Arcing at battery terminals, light switch or other equipment, flame, 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 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 5-1 for scheduled battery mainte-nance, and follow the battery manufacturer’s in-structions. Have the battery charging system ser-viced if DC system voltage is consistently 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.

AIR FILTER

Refer to Table 5-1 for scheduled air filter replace-ment. In dusty conditions the air filter element should be inspected and changed more frequently for best operation. To change the air filter element, remove the outer and inner covers (Figure 5-4) and reassemble with a new air filter element. Turn the in-ner cover wingnut three to four clicks past seating.

Make sure the outer cover is seated before tighten-ing its wingnut. Check for noise when the genset is running, and retighten if necessary.

OUTER COVER INNER COVER FILTER ELEMENT SPACER SEAL HOUSING

FIGURE 5-4. AIR FILTER ELEMENT

5-7

FUEL FILTER

Refer to Table 5-1 for scheduled replacement of the fuel filter (Figure 5-5). 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 the dirt off the fuel fittings be-fore disconnecting them to keep dirt from enter-ing 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 and arc-producing equipment 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 5-5. FUEL FILTER

5-8

CHANGING COOLANT

Refer to Table 5-1 for scheduled maintenance. The engine cooling system is filled with a 50/50 mixture of ethylene glycol anti-freeze and water when the genset leaves the factory, which is suitable for tem-peratures down to -34 F (-37 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 must not contain a stop-leak additive.

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

Use distilled water if available.

See Specifications for cooling system capacity.

Pressure Cap

Replace the pressure cap every two years because its seals can deteriorate and begin to leak. Proper cooling system pressure is essential for optimal en-gine 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 5-6).

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 before the first startup of each day and fill to the COLD mark if necessary.

5-9

PRESSURE CAP

AND SYSTEM FILL

OPENING

COOLING

SYSTEM

DRAIN CAP

COOLANT RECOVERY

TANK FILL CAP (BLUE)

FIGURE 5-6. ENGINE COOLING SYSTEM FILL AND DRAIN CAPS

5-10

COOLANT TEMPERATURE INPUT

Resistance measurements should be taken be-tween the sensor lead and the battery ground post (rather than the engine chassis) for most accurate reading with the harness disconnected at the sen-sor.

This sensor is not a precise temperature measure-ment. Differences between the table values and val-ues displayed on the LCD or tool are possible. See sensor print for details. For example, if the sensor is placed in an ice bath, the control may read 32�F +/− few degrees, depending on the actual resistance of the sensor being tested (sensor spec is +/−10% resis-tence for a given temperature.)

TABLE 5-2. COOLANT TEMPERATURE INPUT

DIG �C DEG �F Sensor

(OHMS)

V to A/D Genset A/D Count

−20 −4 2100 4.27 218

−10 14 1700 4.13 211

−5 23 1500 4.04 206

0 32 1300 3.92 200

5 41 1150 3.82 195

10 50 1000 3.68 188

20 68 750 3.39 173

30 86 600 3.13 160

40 104 450 2.79 142

50 122 320 2.36 121

60 140 210 1.85 94

65 149 175 1.64 84

70 158 145 1.44 74

75 167 128 1.32 67

80 176 110 1.18 60

85 185 90 1.01 51

90 194 70 0.82 42

100 212 57 0.69 35

110 230 43 0.54 27

120 248 33 0.42 22

130 266 25 0.33 17

140 284 20 0.27 14

150 302 15 0.20 10

6-1

6. Preparations for Service

SPECIAL TOOLS

The following tools are necessary for servicing the genset:

Torque wrench: 0-75 lbs-ft (0-100 N-m)

Tachometer

Digital multi-meter: AC and DC Voltage, Ohms

Load test panel and leads

SAFETY

There are hazards in servicing gensets. Study Safe-ty Precautions and become familiar with the haz-ards listed in Table 6-1. Note the following safe-guards and ways of avoiding hazards:

Use personal protection: Wear appropriate protective safety equipment, such as safety shoes and safety glasses. Do not wear rings or jewelry and do not wear loose or damp clothing that might get caught in equipment or conduct electricity.

Reduce the hazard: A safe, orderly workshop area and well-maintained equipment reduce the hazard potential. Keep guards and shields in place on machinery and maintain equipment in good working condition. Store flammable liq-uids in approved containers; away from fire, flame, spark, pilot light, switches, arc-produc-ing equipment and other ignition sources. Keep the workshop clean and well-lighted and pro-vide adequate ventilation.

Develop safe work habits: Unsafe actions cause accidents with tools and machines. Be familiar with the equipment and know how to use it safely. Use the correct tool for the job and check its condition before starting. Comply with the warnings in this manual and take special precautions when working around electrical equipment. Do not work alone if possible and take no risks.

Be prepared for an accident: Keep fire extin-guishers and safety equipment nearby. Agen-cies such as the Red Cross and public safety departments offer courses in first aid, CPR and fire control. Take advantage of this information to be ready to respond to an accident. Learn to be safety-conscious and make safety proce-dures part of the work routine.

TABLE 6-1. HAZARDS AND THEIR SOURCES

Fire and Explosion

Leaking or spilled fuel

Hydrogen gas from battery

Oily rags improperly stored

Flammable liquids improperly stored

Burns

Hot exhaust pipes

Hot engine and generator sur-faces

Electrical shorts

Poisonous Gas

Operating genset where ex-haust gases can accumulate

Electrical Shock (AC)

Improper generator connec-tions

Faulty wiring

Working in damp conditions

Jewelry touching electrical components

Rotating Machinery

Fan guards not in place

Slippery Surfaces

Leaking or spilled oil

Heavy Objects

Removing genset from vehicle

6-2

REMOVING GENSET FROM VEHICLE

See Troubleshooting to determine the probable cause of the problem before removing the genset for service. The genset is normally mounted in a special compartment on the floor of the vehicle or on a supporting frame. Contact the vehicle manufac-turer or installer if the best way to remove the genset is not obvious.

Disconnections

1. Disconnect the negative (-) battery cable from the battery and then disconnect the battery cables from the genset.

WARNING Sparks and high current could cause fire and other damage to the battery, battery cables and vehicle if the loose ends of cables connected to the battery touch.

Always disconnect the negative (−) battery cable from the battery before disconnecting the battery cables from the genset.

2. Disconnect the remote control wiring harness connector at the genset.

3. Disconnect the AC output leads at the genset terminals.

4. Disconnect the exhaust tailpipe from the muf-fler flange.

5. Disconnect the supply and return fuel lines from the genset.

WARNING Diesel fuel is combustible and can cause severe personal injury or death.

Do not smoke if you are near fuel tanks or fuel-burning equipment or are in an area sharing ventilation with such equipment.

Keep flames, sparks, pilot lights, electrical arcs and arc-producing equipment and all other sources of ignition well away.

Removal from the Vehicle

WARNING Gensets are heavy and can cause severe personal injury if dropped during remov-

al. Use adequate lifting devices. Keep hands and feet clear while lifting.

Make sure that the genset is firmly supported before loosening any mounting bolts. There are four bolt holes in the skid-base for securing the genset to the floor or supporting frame. A lifting eye is accessible through the access opening in the top panel of the genset (Figure 6-2).

TEST STAND

WARNING EXHAUST GAS IS DEADLY! Engine exhaust must be vented outside if the genset is operated inside a building.

CAUTION Restricting the air inlet and outlet openings could lead to damage to the genset due to overheating.

When testing and servicing the genset on a work-bench or test stand make sure the openings in the skid-base shown in Figure 6-1 (shaded areas) are free and clear. Also, make sure there is ample fresh air when operating the genset.

ÁÁÁ

ÁÁÁ

AIR

AIR

ACCESS

OUT

IN

DOOR

FIGURE 6-1. BOTTOM VIEW OF SKID-BASE

6-3

REMOVING HOUSING PANELS

WARNING Do not operate the genset without the housing panels secure in place. The panels guard against rotating parts and bare live elec-trical parts that can cause severe personal inju-ry or death. The housing is also required for proper genset cooling.

See Figure 6-2. The housing consists of five remov-able panels. The front (service) panel may also in-clude a removable service door secured by latches.

Note that the screws which secure the panels to the skid-base are slightly longer than the screws be-tween panels. Keep the screws separated to make reassembly easier.

Removing the Front and Top Panels

It may be necessary to remove only the front (ser-vice) or front and top panels for access to the parts which need service (Figure 1-2). To do so, remove all the screws around the perimeter of each panel and pull the panel away. Note that the three screws in the top panel which are circled also support the coolant recovery tank.

CAUTION Screws that are too long will dam-age the coolant recovery tank and may cause it to break away. Make sure the shorter panel screws are used for the recovery tank.

Removing the Back Panel

Remove the top panel, all the screws around the pe-rimeter of the back panel and the two screws into the radiator frame. Because of overlapping edge flanges, loosen the screws along the bottom edge of the left end panel so that it can be tilted out of the way while lifting out the back panel.

Removing the Right End Panel

Remove the top panel and all the screws around the perimeter of the right end panel and lift it out.

Removing the Left End Panel

1. Remove the front, top and back panels.

2. Remove the AC terminal block mounting screws so that it will be unnecessary to loosen the wire binding screws.

3. Remove the line circuit breaker mounting screws (on the operator’s console).

4. Disconnect the engine harness from the control switch and hour meter (if provided).

5. Remove the screws along the bottom edge, tilt the panel out, disconnect the leads to the con-trol switch and hour meter (if so equipped) and cut the wire ties which secure the wiring har-ness to the panel.

INSTALLING HOUSING PANELS

Installation is the reverse of removal. Use wire ties to secure the engine and AC harnesses (p. A-1 and A-2) to the left end panel when reassembling the genset. Tighten the panel screws according to Thread Torques.

6-4

FRONT (SERVICE) PANEL

(MAY INCLUDE A SERVICE DOOR)

RIGHT END

PANEL

LEFT END

PANEL

ACCESS COVER

LIFTING EYE

ACCESS COVER

AC TERMINALS

ACCESS COVER

FUSES AND COOLANT

PRESSURE CAP

BACK

PANEL

TOP

PANEL

SCREW HOLES FOR

SCREWS WHICH ALSO

SECURE THE COOLANT

RECOVERY TANK

OPERATOR‘S

CONSOLE

FIGURE 6-2. THE GENSET HOUSING PANELS

7-1

7. Engine Air Intake

COMPONENT LAYOUT

Figure 7-1 illustrates the series of parts connected to the engine air intake manifold. The arrows indi-cate the flow of air.

SECURE THE END OF THE AIR

INLET HOSE TO THE INLET

GRILLE WITH A WIRE TIE

RESONATOR

INLET BAFFLE

ASSEMBLY

AIR FILTER

ELEMENT

HOUSING

CLAMP AT ENGINE

INTAKE MANIFOLD

MAKE SURE THESE HOSE

CLAMP SCREWS ARE ON TOP

AND ORIENTED AS SHOWN TO

MAKE DISASSEMBLY EASIER

BAFFLE SCREWS TO

SKID-BASE

FIGURE 7-1. ENGINE AIR INTAKE ASSEMBLY

7-2

8-1

8. Muffler

REMOVAL

The muffler assembly is mounted inside the genset housing. See Figure 8-1. To remove the muffler:

1. Disconnect the negative (-) battery cable from the battery to prevent the genset from starting and remove the top and back genset housing panels (p. 6-3).

2. Disconnect the tailpipe.

3. Remove the flange bolts on both ends of the flexible connector and remove it carefully.

4. Remove the outboard bearing clamp and slide the assembly to the right (while facing the gen-set from the back) until the pins in the two in-board bearings are free.

INSTALLATION

Installation is the reverse of removal. Always use new flange gaskets on both ends of the flexible con-nector when installing the muffler. Tighten all bolts and screws according to Thread Torques.

CAUTION The flexible connector is fragile when removed from the assembly and must not be bent or twisted. Make sure the muffler is se-curely in place and properly aligned before con-necting the flexible connector.

Important safety warnings and instructions regard-ing the routing and termination of the tailpipe (not supplied by Onan) are included in the Installation Manual. Always use a new flange gasket when con-necting the tail pipe.

WARNING Exhaust gas is deadly. The exhaust system must not leak. Liability for injury, death, damage and warranty expense due to the use of an unapproved muffler or due to modifications becomes the responsibility of the person instal-ling the unapproved muffler or performing the modifications. Use Onan approved exhaust system parts.

8-2

ENGINE EXHAUST

MANIFOLD FLANGE

MUFFLER

ASSEMBLY

ELBOW AND

FLEXIBLE

CONNECTOR

OUTBOARD

MOUNTING

BEARING

MUFFLER

OUTLET

FLANGE

FLANGE

GASKETS

INBOARD

MOUNTING

BEARING

(TWO)

FIGURE 8-1. MUFFLER ASSEMBLY

9-1

9. Engine Cooling System

GENERAL

The genset has a liquid cooled engine. A centrifugal blower (Figure 11-2) is mounted on the end of the generator (PMA) rotor to move air for cooling the genset and radiator. The blower pulls air in from an opening in the bottom of the genset to pressurize the engine compartment. Air flows through the ra-diator from the top side into the muffler compart-ment and then out the bottom. See Figures 9-1 and 9-2.

See Periodic Maintenance for cooling system main-tenance.

See Page 12-1 for instructions on how to replace the coolant pump drive belt.

See the engine service manual for thermostat and pump service.

RADIATOR REMOVAL

Removal Procedure

1. Remove the top and back housing panels of the genset (p. 6-3).

2. Drain the system.

WARNING Hot coolant spray can cause se-vere burns. Let the engine cool before re-leasing the pressure cap or removing the drain cap.

3. Disconnect all four hoses.

4. Remove the two screws which secure the ra-diator to the inner bulkhead and pull it away.

Alternative Removal Procedure

1. Perform Steps 1 and 2.

2. Remove the muffler (p. 8-1).

3. Disconnect the upper and lower hoses from the engine and loosen the hose bracket at the front of the engine.

4. Remove the screw which secures the system drain “T” (Figure 9-2).

5. Remove the two screws in the horizontal por-tion of the bulkhead that projects under the ra-diator.

6. Pull the radiator, coolant recovery tank and in-ner bulkhead away as an assembly with all the hoses connected.

RADIATOR INSTALLATION

Installation is the reverse of removal. If the inner bulkhead was removed, make sure the end of the crankcase breather hose (Figure 9-2) is pushed back through the exit hole in the bulkhead (Fig-ure…