Onan GRCA Generator Set Operator's Manual

Onan Operator’s Manual
GRCA
184-0168
May, 2004
Redistribution or publication of this document,
by any means, is strictly prohibited.
Redistribution or publication of this document,
by any means, is strictly prohibited.
Redistribution or publication of this document,
by any means, is strictly prohibited.
Table of Contents
TITLE
PAGE
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Engine Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Starting Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Fuel Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Fuel Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Genset Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Starting and Stopping the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Powering Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Varying Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Genset Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Genset Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Genset Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
3. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Changing Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
i
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4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Status/Diagnostics Light on the Genset Control Switch . . . . . . . . . . . . . . . . . . 4-1
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
5. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
6. INFORMATION FOR CALIFORNIA GENSET USERS . . . . . . . . . . . . . . . . . . . . . . 6-1
7. HOW TO OBTAIN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
ii
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IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS - This manual contains important instructions that
should be followed during installation and maintenance of the generator and battery.
• Used engine oil has been identified by some
state and federal agencies as causing cancer
or reproductive toxicity. Do not ingest, inhale,
or contact used oil or its vapors.
Thoroughly read the OPERATOR'S MANUAL
before operating the genset. Safe operation
and top performance can be obtained only
when equipment is operated and maintained
properly.
• Do not work on the genset when mentally or
physically fatigued or after consuming alcohol or drugs.
The following symbols in this manual alert you to
potential hazards to the operator, service person
and equipment.
• Carefully follow all applicable local, state and
federal codes.
! DANGER alerts you to an immediate hazard
▲
which will result in severe personal injury or
death.
GENERATOR VOLTAGE IS DEADLY!
• Generator output connections must be made
by a qualified electrician in accordance with
applicable codes.
! WARNING
▲
alerts you to a hazard or unsafe
practice which can result in severe personal
injury or death.
• The genset must not be connected to the
public utility or any other source of electrical
power. Connection could lead to electrocution of utility workers and damage to equipment. An approved switching device must be
used to prevent interconnections.
! CAUTION alerts you to a hazard or unsafe
▲
practice which can result in personal injury or
equipment damage.
Electricity, fuel, exhaust, batteries and moving
parts present hazards which can result in severe
personal injury or death.
• Use caution when working on live electrical
equipment. Remove jewelry, make sure
clothing and shoes are dry and stand on a
dry wooden platform. FUEL IS FLAMMABLE
AND EXPLOSIVE
GENERAL PRECAUTIONS
• Keep ABC fire extinguishers handy.
• Keep flames, cigarettes, sparks, pilot lights,
electrical arc–producing equipment and
switches and all other sources of ignition well
away from areas where fuel fumes are present and areas sharing ventilation.
• Make sure all fasteners are secure and
torqued properly.
• 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.
• Fuel lines must be secured, free of leaks and
separated or shielded from electrical wiring.
• Leaks can lead to explosive accumulations of
gas. Natural gas can accumulate under
hoods and inside housings and buildings.
LPG sinks when released and can accumulate inside housings and basements and
other below-grade spaces. Prevent leaks and
the accumulation of gas.
• Before working on the genset, disconnect the
negative (-) battery cable at the battery to
prevent starting.
• Use caution when making adjustments while
the genset is running—hot, moving or electrically live parts can cause severe personal
injury or death.
iii
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wash it off immediately with water and
seek medical attention, and
(3) Where electrolyte contacts the eyes,
flush thoroughly and immediately with
water and seek medical attention, and
(4) Spilled electrolyte is to be washed down
with an acid neutralizing agent. A com
mon practice is to use a solution of one
pound (500 grams) bicarbonate of soda
to one gallon (4 liters) of water. The
bicarbonate of sods solution is to be
added until the evidence of reaction
(foaming) has ceased. The resulting
liquid is to be flushed with water and the
area dried.
ENGINE EXHAUST IS DEADLY!
• Learn the symptoms of carbon monoxide poi-
soning in this manual.
• The exhaust system must be installed in
accordance with the genset Installation
Manual.
• Do not use engine cooling air to heat a room
or compartment.
• Make sure there is ample fresh air when
operating the genset in a confined area.
BATTERY PRECAUTIONS
Battery Gas Is Explosive!
! CAUTION Lead acid batteries present a
• ▲
• When replacing batteries use the same num-
risk of fire because they generate hydrogen
gas. The following procedures are to followed:
(1) DO NOT SMOKE when near batteries.
(2) DO NOT cause flame or spark in battery
area, and
(3) Discharge static electricity from body
before touching batteries by first touch
ing a grounded metal surface.
ber and the following type batteries: Group 26
! CAUTION Do not dispose of battery or bat• ▲
teries in a fire. The battery is capable of
exploding.
! CAUTION Do not open or mutilate the bat• ▲
tery or batteries. Released electrolyte has
ben known to be harmful to the skin and eyes
and to be toxic.
• When disconnecting the battery cables,
! CAUTION A battery presents a risk of
• ▲
always check for a battery charger and disconnect it first then disconnect the negative
(-) battery cable.
electrical shock and high short circuit current. The following precautions are to be
observed when working on batteries.
(1) Remove watches, rings, or other metal
objects.
(2) Use tools with insulated handles.
• When reconnecting battery cables, always
reconnect the negative (-) battery cable after
the positive (+) cable, then reconnect the battery charger to reduce arcing.
! CAUTION The electrolyte is a dilute sulfu• ▲
ric acid that is harmful to the skin and eyes.
It is electrically conductive and corrosive.
The following procedures are to be
observed:
(1) Wear full eye protection and protective
clothing,
(2) Where electrolyte contacts the skin,
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
• Do not wear loose clothing or jewelry near
moving parts such as fans.
• Keep hands away from moving parts.
• Keep guards in place over fans.
iv
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Safety Informational Data
1. Where can I find field wiring data on this unit? It it covered by Section 7 of
the Installation Manual.
2. Where can I find explanations of all symbols used in this manual? Refer to
Page iii.
3. Where can I find the circuit breaker used with this unit? A 2-Pole 50 Amp circuit breaker is an intergral part of the Genset located in the main control
panel.
4. At what temperature range can the unit run at? The Genset is designed to
run from 0 to 110 F.
0
0
5. What are the electrical ratings for this unit? Refer to Installation Section 6-1.
6. What is the electrical Phase Configuration of the unit? Single Phase - 3 Wire
120/240v, refer to Installation Section 6-1.
7. What is the fuel connection type, pressure and flow of the unit? See
Installation Sections 6-1, and 3-2 to 3-5.
8. Where can I find exhaust connection and muffler part numbers for the unit?
Refer to Installation Section 3-2.
9. Where are the ground connection instructions? See Installation Section 4-3.
10. Where can I find instructions on the fuses the unit uses? See Installation
Section 4-1.
11. What voltage is the battery rated at? See Installation Section 4-6 and 6-1.
12. What is the minimum cold cranking amperage rating of the batteries? See
Installation Section 6-1.
13. How do I remove and replace the battery? See Installation Section 4-8 and
Operator’s Section 3-7.
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1. Introduction
! WARNING Improper service or replacement of
▲
parts can lead to severe personal injury or
death and to damage to equipment and property. Service personnel must be qualified to
perform electrical and mechanical service.
ABOUT THIS MANUAL
This manual covers operation and maintenance
of the Series GRCA generator sets (gensets).
Study this manual carefully and observe all of its
instructions and precautions.
Unauthorized modifications or replacement of
fuel, exhaust, air intake, or speed control system components that affect engine emissions
are prohibited by law in the State of California.
This manual covers the convertable fuel GRCA
genset:
• (Natural Gas or LP Vapor)
Operation (Section 2) covers basic operation of
the genset under various conditions and includes
recommendations regarding fuel and engine oil
and procedures for break-in, exercise, and storage.
Periodic Maintenance (Section 3) covers the
maintenance and care necessary for peak performance. The owner is responsible for maintaining the genset according to the Maintenance
Schedule (See Table 3–1).
Troubleshooting (Section 4) provides basic troubleshooting guidance for a genset that fails to
start or that shuts down.
This manual also contains useful genset specifications and important information for California
genset users.
Each operator of the genset should become thoroughly familiar with the information in this manual.
Keep this and the Installation Manual at the site.
1-1
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MODEL IDENTIFICATION
When contacting a Cummins/Onan dealer or distributor for parts, service, or product information,
be ready to provide the model and serial numbers
on the genset nameplate (See Figure 1–1). (The
serial number is in the row marked S/N, just
below the model number. The last character of
the model number is the specification letter, which
is important for obtaining the right parts.) Space is
provided in Figure 1–1 for you to record the model
and serial numbers of your genset so that you
have them at hand when you need them.
1-2
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2. Operation
Engine Oil Recommendations
equipment. Keep flames, sparks, pilot lights,
arc-producing equipment, switches, and all
other sources of ignition well away. Keep a
type ABC fire extinguisher handy.
Oil is a major factor affecting performance and
service life. Use 4-stroke automotive detergent oil
that is designed for engines operating on LPG or
NATURAL GAS.
NFPA Standard No. 58 requires all persons
handling and operating LP to be trained in
proper handling and operating procedures.
(The table below are examples of oils that meet
Honda’s requirements for LPG/NATURAL GASfueled engines.) SAE 30 (API service classification SJ) is recommended for general use.
For operation in temperatures below 32 F (0 C),
5W-30 sythetic oil may be used for easier starting. Do not use 5W-30 synthetic oil when the air
temperature is above 32 F (0 C). Units are
shipped with 10W-30 Oil.
0
0
When natural gas is the required fuel, use commercially available natural gas fuel having a
methane content of at least 90 percent (by
volume).
0
When LP (liquified petroleum) is the required fuel,
use grade HD-5 or equivalent consisting of at
least 90 percent propane. Commercial LP may
contain more than 2.5 percent butane, which can
result in poor fuel vaporization and poor engine
starting in ambient temperatures below 32° F
(0° C).
0
Satisfactory performance requires that fuel be
supplied at a pressure within the range indicated
in Specifications.
! WARNING High gas supply pressure can
▲
cause gas leaks which can lead to fire and
severe personal injury or death. Gas supply
pressure must be adjusted to Specifications
in Section 5 by qualified personnel.
FUEL SELECTION
The natural gas/LP vapor genset leaves the factory set up for natural gas. If the genset is to be
run on LP vapor it must be converted for use with
LP vapor. See the Installation Manual for the conversion procedure.
STARTING BATTERY
This genset has a 12 VDC starting battery and
control system. See Specifications in Section 6 of
installation manual for minimum battery requirements for genset cranking.
This genset is designed to use natural gas or
LP vapor & can not be converted to use LP liquid.
FUEL RECOMMENDATIONS
! WARNING Fuels are flammable and explosive
▲
and can cause severe personal injury or
death. Do not smoke if you smell gas or are
near fuel tanks or fuel-burning equipment or
are in an area sharing ventilation with such
! CAUTION Wrong fuel selection can result in
▲
hard starting, poor genset performance, and
fault shutdown.
2-1
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Status/Diagnostics Light – This is an LED (light
emitting diode) in the control switch. It blinks rapidly during cranking. It blinks in a coded fashion to
indicate the nature of a genset shut down or of
maintenance required to keep the genset running.
See Troubleshooting in Section 4.
GENSET CONTROL
Figure 2–1 shows the GRCA genset control
panel. The control features are as follows:
Control Switch – This is a three-position RunOff-Auto switch with a status/diagnostics light.
The Run and Off positions are for manual starting and stopping of the genset. The Off position is
also used for resetting the controller following a
fault shutdown. The Auto position is for remote
start or transfer switch control.
Hour Meter – The hour meter records the total
running time of the genset. It cannot be reset.
FIGURE 2–1. GENSET CONTROL
2-2
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FIGURE 2–2. GRCA GENSET
2-3
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! WARNING EXHAUST GAS IS DEADLY!
▲
All engine exhaust contains carbon monoxide, an odorless, colorless, poisonous gas that can
cause unconsciousness and death. Symptoms of carbon monoxide poisoning include
• Dizziness
• Headache
• Weakness and Sleepiness
• Nausea
• 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.
The exhaust system is an integral part of the genset. Do not modify the exhaust system. Make
sure there is ample fresh air when operating the genset in a confined area.
Manual Stopping
STARTING AND STOPPING THE GENSET
Push the control switch to Off. Whenever possible, allow the engine to cool down with the electrical loads disconnected for a few minutes before
stopping the genset.
Pre-start Checks
Perform the maintenance checks instructed in
General Inspection (See page 3–2). Service the
genset and make repairs as required if a fault
shutdown code displays (see Troubleshooting in
Section 4). Also, see Genset Break-In and
Genset Storage in this section before placing in
service a new or rebuilt genset or one that has
been in storage.
! CAUTION Failure to push the control switch
▲
to AUTO before leaving the genset renders the
genset unavailable for automatic standby
service.
Automatic Starting and Stopping
Manual Starting
Push the control switch to Auto for remote, automatic starting and stopping (transfer switch).
Push the control switch to Run. The engine
should crank, start, and run up to governed speed
within 15 seconds. The starter disconnects automatically as the status light stops blinking.
! WARNING Automatic startup of the genset
▲
while performing maintenance or service can
cause severe personal injury or death. Push
the control switch to Off and disconnect the
negative (–) battery cable from the battery to
keep the genset from cranking and starting
while working on it.
If the engine does not start (after 20 seconds of
cranking), the starter disengages. See Troubleshooting in Section 4 if the engine does not start.
Check for fuel and exhaust leaks. Stop the genset
immediately if there is a fuel or exhaust leak and
have it repaired before continuing operation.
Whenever possible, allow the engine to warm up
for a few minutes before connecting the electrical
loads.
2-4
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an air conditioner) “cycles on,” an undervoltage or
under frequency fault shutdown (Code Nos. 13
and 15) could occur. The reason is that for a brief
moment, at startup, motors can draw up to three
or more times their rated power consumption. You
may, therefore, have to consider shutting off
some loads at times when large motor loads are
“On.” When powering large motor loads (such as
an air conditioner) it is recommended that the
total load should not exceed 80% of the genset
kW rating.
POWERING EQUIPMENT
Genset Loading
How much electrical equipment (system load) can
be connected at one time depends upon how
much power is available from the genset (See
Specifications, Section 5) and the type of load
being supplied. If the genset is “overloaded,” its
circuit breaker trips or its controller shuts it down
or both.
Determine how much equipment can be operated
at one time by adding the power consumption ratings of the individual system loads that are likely
to be used at the same time. Compare the sum of
the loads to the kW (kilowatt) rating of the genset
data plate. Note that 1 kW = 1000 watts. See
Table 2–2 for power consumption of typical
residential appliances.
Operating at High Altitude or High
Temperature
Air density is less at higher altitudes, resulting in
less available engine power. Power decreases
approximately 3.5 percent of rated power each
1000 feet (305 meters) of increase in elevation
above sea level. Power also decreases approximately 1.5 percent each 10°F (5.5°C) increase in
ambient temperature above 77°F (25°C).
Note that when a genset is loaded nearly to full
power and one of the large motor loads (such as
2-5
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TABLE 2–2. TYPICAL APPLIANCE POWER CONSUMPTION
Basic Needs
Typical Discretionary Loads
Basic Loads column. Add the power consumption
of all Basic Loads and place it in the Total Basic
Loads box at the bottom of the table.
How To Use the Table
Table 2–2 lists the typical power consumption of
some common household appliances. The value
in the table is a typical value, check the value on
the nameplate of your appliance for the most
accurate value. Also, you may want to use appliances that are not listed in the table. In that case,
use the value on the nameplate of the appliance
for its power consumption. For the most accurate
genset loading, substitute the values from the
nameplates on the appliances for all calculations.
Compare the Basic Loads Total with the rated
output of the genset. If the genset still has additional capacity (that is the Basic Loads Total is
less than 80% of the genset capacity), you can
select additional loads from the list. Write the
power consumption of these additional loads in
the Loads Chosen column. Add the power consumption of all Chosen Loads and place it in the
Total Chosen Loads box at the bottom of the
table. You can add loads to the Basic Loads until
you reach 80% of the genset capacity.
Select the appliances that satisfy your basic
needs and write the power consumption in the
2-6
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Example
If a circuit breaker trips, disconnect or turn off as
many loads (appliances) as possible and reset
the circuit breaker. If the circuit breaker trips right
away, either the main distribution system has a
short or the circuit breaker is faulty.
Using the chart on the previous page for a genset
rated at 10 kW. Select a total load less than 8kW
(8000 watts) in order to operate within the 80%
limit.
Well Pump (1/2 HP)
Refrigerator
If the circuit breaker does not trip, reconnect the
loads, one by one, up to 80% of the genset rating.
If a circuit breaker trips right away when a load is
connected, the load probably has a short.
1000
800
Air Conditioner (2 ton)
2000
Connecting The System To Utility Power
10 100 watt Bulbs
1000
An approved device such as a manual or automatic
transfer switch must be provided to keep the genset
and utility from being interconnected. The automatic transfer switch automatically reconnects the utility
when service is restored and also must provide a
constant trickle charge to maintain battery voltage.
Sump Pump (1/3 HP)
Microwave Oven (1000 W)
Coffee Maker
Total
500
1500
900
7700
! WARNING Interconnecting the genset and the
▲
public utility (or any other power source) can
lead to the electrocution of utility workers and
damage to equipment and fire. An approved
switching device must be used to prevent
interconnections.
This example uses 7700 watts. You could still
safely use a TV, a small appliance, or even your
computer before you exceed the 80% limit.
Remember that some loads are intermittent. For
example your refrigerator does not run constantly. However, as it starts it requires considerably
more current than when it is running. For the sake
of the calculation from the table assume that all
loads are constant. If total power consumption
exceeds genset power output, the genset may
shut down. In this case, you may have to operate
some loads in sequence, one after another, rather
than all at the same time.
VARYING OPERATING CONDITIONS
Cold Weather
Perform maintenance due according to Periodic
Maintenance in Section 3. See Engine Oil Recommendations 2.1.
An optional thermostatically controlled heater for
the battery is recommended for more reliable starting in ambient temperatures down to 0°F. The
genset may require longer cranking time than
warmer conditions; this is normal.
If the load on the genset exceeds the rated
capacity of the genset, the genset shuts
down. If the genset shuts down under load,
remove loads by turning off appliances, press
the switch on the control to OFF and back to
AUTO to allow automatic remote restarting.
Hot Weather
Perform maintenance according to Table 3–1 of
Periodic Maintenance. See engine oil section 2.1.
Make sure nothing blocks airflow to and from the
genset. Keep the cooling fins clean.
Restarting The Genset
If the genset shuts down because it is overloaded, disconnect or turn off as many loads
(appliances) as possible and try to restart the
genset as instructed in Starting and Stopping in
this section. Reconnect the loads one by one up
to 80% of the genset rating.
High Altitude
See Powering Equipment in this section for information on how altitude affects the maximum
power output of the genset.
Resetting Circuit Breakers
Dusty Conditions
If a circuit breaker in the main power distribution
panel or on the genset (See Figure 2–1) trips,
there is either a short circuit or too many loads
operating at the same time. Note that the genset
continues to run after a circuit breaker trips.
Keep the cooling fins clean. Perform air cleaner
maintenance and change engine oil and oil filter
more often than usual. See Periodic Maintenance
in Section 3.
2-7
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2. Remove the air filter and start the genset.
While the genset is running, spray an engine
fogger (OnaGardTM)1 into the carburetor, following the instructions on the container
label, and then stop the genset. (A fogger
coats the intake, cylinder and exhaust systems with a protective coat of oil.)
GENSET BREAK-IN
Proper engine break-in on a new genset or on
one with a rebuilt engine is essential for top
engine performance and acceptable oil consumption. For proper break-in, run the genset at
1/2 rated power for the first 2 hours and then at
3/4 rated power for 2 more hours. Avoid light load
or no load operation during break in. See
Powering Equipment in this section.
3. Change the engine oil and oil filter. Also,
change the air filter if it is dirty.
4. Disconnect the battery cables (negative [–]
cable first) from the starting battery and
store the battery according to the battery
manufacturer's recommendations.
Proper engine oil and oil level are especially critical during break-in because of the higher engine
temperatures that can be expected. See Engine
Oil Recommendations in this section. Check the
oil level twice a day or every 4 hours during the
first 24 hours of operation and change the oil after
the first 25 hours of operation.
5. Close the fuel supply valve. If the genset is
being removed from the premises, cap or
plug any unused fuel line to prevent gas
leakage if a fuel shutoff valve is opened
inadvertently.
GENSET EXERCISE
If genset use is infrequent, it is recommended that
the genset be exercised at least 1/2 hour, once a
month, without load. Exercising the genset drives
off moisture, re-lubricates the engine, and removes
oxide from electrical contacts and generator slip
rings, thereby promoting better starting, more reliable operation, and longer engine life.
! WARNING Leaks can lead to explosive accu▲
mulations of gas. Natural gas rises when
released and can accumulate under hoods
and inside housings and buildings. LP vapor
sinks when released and can accumulate
inside housings and basements and other
below-grade spaces. Prevent leaks and the
accumulation of gas.
An operator can exercise the genset by placing
the control switch in the ON position. The genset
would start and run at no load for a time determined by the operator. When the exercise period
is finished, return the control switch to the AUTO
position.
Returning The Genset To Service
1. Inspect the genset. See General Inspection.
2. Reconnect the starting battery (negative [–]
cable last). See Battery Care in Section 3.
! CAUTION Failure to push the control switch
▲
to AUTO before leaving the genset renders the
genset unavailable for automatic standby
service.
3. Open the fuel supply valve.
4. Start the genset at the genset control panel.
The initial startup may be slow and there
may be smoke and rough operation for a few
minutes until the oil in the cylinders from the
fogger burns off. If the engine does not start,
clean or replace the spark plugs as they may
have been fouled by the fogger.
When a transfer switch with an exerciser clock is
available, set the clock to exercise the genset
once a month for 1/2 hour at no load.
See the transfer switch operator's manual for
instructions on how to adjust and activate the
genset exerciser clock.
5. Push the genset line circuit breaker to Run
(Figure 2–1) and the control switch to Auto
for remote, automatic starting and stopping
(transfer switch).
GENSET STORAGE
If the genset is to be stored for 120 days or
longer, proper storage is essential for preserving
top genset performance and reliability.
! CAUTION Failure to push the control switch
▲
to AUTO before leaving the genset renders the
genset unavailable for automatic standby
service.
Storing the Genset
1. Push the genset line circuit breaker OFF
(Figure 2–1).
1 OnaGard is a trademark of the Onan Corporation.
2-8
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3. Periodic Maintenance
! WARNING Automatic startup of the genset
▲
operations should be performed more frequently,
as indicated by the footnotes in the table. Keep a
log of maintenance performed and the hours run.
Recording maintenance helps you keep it regular
and provide a basis for supporting warranty
claims.
while performing maintenance or service can
cause severe personal injury or death. Push
the control switch to Off and disconnect the
negative (–) battery cable from the battery to
keep the genset from starting while working
on it.
Maintenance, replacement, or repair of emission
control devices and systems may be performed by
any engine repair establishment or individual.
However, warranty work must be completed by an
authorized Cummins/Onan dealer or distributor.
Periodic maintenance is essential for top performance and long genset life. Use Table 3–1 as a
guide for normal periodic maintenance. Under hot
or dusty operating conditions some maintenance
* Emission-related items.
(*) Replace the paper element type only.
(1) Service more frequently when used in dusty areas.
(2) These items should be serviced by your service dealer, unless you have the proper tools and are
mechanically proficient. Refer to Honda shop manual for service procedures.
3-1
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roded or loose battery cables (negative [–] cable
first) and clean and reconnect them as instructed
under Battery Care in this section.
GENERAL INSPECTION
Inspect the genset according to the genset
Periodic Maintenance Schedule.
! WARNING Batteries give off explosive gases
▲
that can cause severe personal injury. Do not
smoke near batteries. Keep flames, sparks,
pilot lights, electrical arcs and arc-producing
equipment and all other ignition sources well
away.
Oil Level
Check the engine oil level as explained under
Checking Engine Oil Level in this section.
Exhaust System
Look and listen for exhaust system leaks while
the genset is running. Shut down the genset if a
leak is found and have it repaired before operating the genset.
Do not disconnect the battery charger or battery cables while the genset is cranking or
running: the arcing can ignite the explosive
battery gases.
Fuel System
Mechanical
Check the fuel supply line and fittings for leaks
while the genset is running. 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.
Look for mechanical damage. Start the genset
and look, listen, and feel for any unusual noises
and vibrations.
Check to see that the genset air inlet and outlet
openings are not blocked or clogged with debris.
! WARNING Gaseous fuels are highly flamma▲
Clean accumulated dust and dirt from the genset.
Do not clean the genset while it is running or still
hot. Protect the generator, air cleaner, control
panel, and electrical connections from water,
soap and cleaning solvents. Always wear safety
glasses when using compressed air.
ble and explosive and can cause severe personal injury or death. Shut down and repair
leaks immediately.
Battery Connections
Check the battery terminals for clean, tight connections. Loose or corroded connections have
high electrical resistance which makes starting
harder. Shut the genset off and disconnect cor-
! WARNING Always wear safety glasses when
▲
using compressed air to avoid severe eye
injury.
3-2
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in Section 2. Do Not Fill to a Level Above
the Upper Limit on the Dipstick. Drain the
excess oil if too much has been added.
CHECKING ENGINE OIL LEVEL
Set the genset control to the Off position before
checking the engine oil level.
! CAUTION Too much oil can cause high
▲
oil consumption, high operating temperatures and oil foaming. Too little oil can
cause severe engine damage. Keep the
oil level between the Full and Add marks
on the dipstick.
1. Remove the oil fill cap/dipstick (See Figure
3–1), wipe it clean, screw the cap back on
and then remove it again to check the oil
level on the dipstick.
! WARNING Crankcase pressure can blow
▲
hot engine oil out the fill opening causing
severe burns. Always stop the genset
before removing the oil fill cap.
3. Secure the oil fill cap by turning clockwise
until tight to prevent oil leakage.
Return the genset control to Auto when finished
performing maintenance.
2. Add oil as necessary until the upper limit is
reached. See Engine Oil Recommendations
FIGURE 3–1. OIL LEVEL CHECK
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the gasket just touches the mounting pad
and then turn it an additional 1/2 to 3/4 turn.
Do not over-tighten.
CHANGING ENGINE OIL AND OIL FILTER
Refer to Table 3–1 for scheduled engine oil
change. In hot weather and dusty conditions the
oil should be changed more often.
8. Refill with oil (See Engine Oil Recommendations in Section 2 and Specifications in
Section 5) for oil capacity. Check oil level.
Set the genset control to the Off position before
changing engine oil.
9. Secure the oil fill cap with a 1/4 turn to prevent oil leakage.
! WARNING State and federal agencies have
▲
determined 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.
10. Used oil is harmful to the environment if it is
not disposed of properly. Pour used oil into
a sealed container and deliver it to the nearest recycling center or automotive service
station.
1. Place a pan under the oil drain hose. Run the
engine until it is warm and then shut it off.
Return the genset control to Auto when finished
performing maintenance.
2. Remove the oil fill cap (See Figure 2–2),
remove the hose plug, open the oil drain
valve, and allow all of the oil to drain from
the engine.
3. Close the oil drain valve (grasp the hose
near the engine, push in to stop, turn clockwise to stop, and release) and replace the
hose plug.
4. Spin off the oil filter canister (See Figure 2–2)
and catch the oil in the canister. Discard the
oil filter according to local regulations.
5. Thoroughly wipe off the filter mounting surface. Make sure that the mounting surface is
clean and free of filter particles (gasket from
old filter is not stuck to surface).
6. Make sure the gasket is in place on the new
filter canister and apply a thin film of oil to
the gasket.
7. Spin on the new filter canister by hand until
3-4
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To change the air filter element (Figure 3–2).
Reassemble the air filter with a new air filter element and foam element. Do not oil the filter or
foam element.
AIR FILTER
Refer to Table 3–1 for scheduled air filter replacement. In dusty conditions the air filter element and
wrapper should be inspected and changed more
frequently for best operation.
Return the genset control to Auto when finished
performing maintenance.
Set the genset control to the Off position before
checking the air filter.
FIGURE 3–2. AIR FILTER ELEMENT AND WRAPPER
3-5
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SPARK PLUGS
Set the genset control to the Off position before
checking the spark plugs.
Refer to Table 3–1 for scheduled spark plug
replacement. (The genset has two spark plugs:
one on each side of the engine.) The spark plugs
must be in good condition for proper engine starting and performance. A spark plug that fouls frequently or has heavy soot deposits indicates the
need for engine service. See Troubleshooting in
Section 4.
To prevent crossthreading a spark plug, always
thread it in by hand until it seats. If the spark plug
is being reused, turn it with a wrench an additional 1/4 turn. If the spark plug is new, turn it an additional 3/8 to 1/2 turn.
Return the genset control to Auto when finished
performing maintenance.
3-6
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Be sure the vent plugs are tight to prevent cleaning solution from entering the cells.
BATTERY CARE
! WARNING Ignition of explosive battery gases
▲
can cause severe personal injury or death.
Arcing at battery terminals, light switch or
other equipment, flame, pilot lights and
sparks can ignite battery gas. Do not smoke,
or switch trouble light ON or OFF near battery.
Discharge static electricity from body before
touching batteries by first touching a grounded
metal surface.
After cleaning, flush the outside of the battery and
surrounding areas with clean water.
Keep the battery terminals clean and tight. After
making connections, coat the terminals with a
light application of petroleum jelly or non-conductive grease to retard corrosion.
Checking Specific Gravity
Use a battery hydrometer to check the specific
gravity of the electrolyte in each battery cell.
Ventilate battery area before working on or
near battery—Wear goggles—Stop genset
and disconnect charger before disconnecting
battery cables—Disconnect negative (-) cable
first and reconnect last.
Hold the hydrometer vertical and take the reading. Correct the reading by adding four gravity
points (0.004) for every ten degrees the electrolyte temperature is above 80° F (27° C). A fully
charged battery will have a corrected specific
gravity of 1.260. Charge the battery if the reading
is below 1.215.
! CAUTION Disconnect battery charger from
▲
AC source before disconnecting battery
cables. Otherwise, disconnecting cables can
result in voltage spikes damaging to DC control circuits of the set.
Checking Electrolyte Level
! CAUTION Do not add water in freezing weath▲
Check the condition of the starting batteries at the
interval specified in the Maintenance Table. To
prevent dangerous arcing, always disconnect the
negative ground cable from the battery before
working on any part of the electrical system or the
engine. Disregard the sections On Checking
Specific Gravity and Checking Electrolyte Level if
using a “maintenance–free” battery.
er unless the engine will run long enough (two
to three hours) to assure a thorough mixing of
water and electrolyte.
Check the level of the electrolyte (acid and water
solution) in the batteries at least every 200 hours
of operation.
Fill the battery cells to the bottom of the filler neck.
If cells are low on water, add distilled water and
recharge. If one cell is low, check case for leaks.
Keep the battery case clean and dry. An accumulation of moisture will lead to a more rapid discharge and battery failure.
Cleaning Batteries
! WARNING Electrolyte is a dilute sulfuric acid
▲
that is harmful to the skin and eyes. Do not get
the substance in your eyes or contact with
skin. Wear goggles and protective, rubber
gloves and apron when servicing batteries.
Battery Replacement
In case of contact, immediately wash skin
with soap and water. In case of contact, immediately flood eyes with large amounts of water
for a minimum of 15 minutes. IMMEDIATELY
CALL A PHYSICIAN.
Always replace the starting battery with the same
number and type (vented, lead acid). Properly
dispose of battery in accordance with local environmental agency requirements.
! WARNING Electrolyte or explosion of battery
▲
can cause severe personal injury or death. Do
not mutilate or burn the battery in a fire for
disposal.
Keep the batteries clean by wiping them with a
damp cloth whenever dirt appears excessive.
If corrosion is present around the terminal connections, remove battery cables and wash the
terminals with a solution consisting of 1/4 pound
of baking soda added to 1 quart of water. (This
solution is also used for washing down spilled
electrolyte.)
Damage to case will release electrolyte which
is harmful to the skin and eyes and is also
toxic. Burning of battery may cause an
explosion.
3-7
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4. Troubleshooting
negative (–) battery cable from the battery to
keep the genset from starting up while working on it.
Table 4–1 provides troubleshooting guidance for
a genset that fails to start or that shuts down. The
genset controller has an extensive diagnostic
capability and its fault codes are covered in
numerical sequence in Table 4–1. Gaps in the
code numbers are for codes that do not apply to
this genset.
! WARNING Hot engine parts can cause severe
▲
burns. Always allow the engine time to cool
before performing any maintenance or service.
FAULT CODES
Most shutdowns can be prevented by proper
maintenance and use of the genset—maintaining
oil levels, keeping battery connections clean and
tight, and not overloading the genset.
The genset controller provides extensive diagnostics by causing the status indicator light on the
Control Switch to blink in a coded fashion.
Following a fault shutdown, the indicator light
blinks repeatedly 2, 3, or 4 blinks at a time.
If the load on the genset exceeds the rated
capacity of the genset, the genset shuts
down. In this case, remove loads by turning
off appliances, press the switch on the control
to OFF and back to AUTO to reenable automatic remote restarting.
• Two blinks indicates that the low oil pressure cutoff switch did not open within 10 seconds of starting.
• Three blinks indicates a service fault.
If you fail to resolve the problem after taking the
corrective actions suggested, contact an authorized Cummins/Onan dealer. See How to Obtain
Service in Section 7.
• Four blinks indicates that cranking without
start exceeded 20 seconds.
The fault code stops blinking after five minutes.
STATUS/DIAGNOSTICS LIGHT ON THE
GENSET CONTROL SWITCH
The genset controller blinks the status/diagnostics LED to indicate a fault code if there is a fault
shutdown that requires maintenance or service.
There are distinct pauses between repetitions of
the code blink transmissions.
FUSE REPLACEMENT
• Control Power Fuse 20A:
Push in fuse holder cap - turn counter
clockwise 1/4 turn.Pull cap and fuse from
fuse holder.Replace with Buss MDL20A
or equivalent.
Single–Digit Fault Code - A single–digit fault
code is indicated by a corresponding number of
blinks. For example:
• Battery Charger AC Supply Fuse 10A current limiting:
Unscrew fuse holder cap counterclock
wise.Pull cap and fuse from fuse holder.
Replace with ATMR10 or equivalent.
Code No. 4: blink-blink-blink-blink
Two–Digit Fault Code - Two–digit faults indicate
that a service fault has occurred. These codes
are accessed by an authorized Cummins/Onan
service Technician.
• Battery Charger DC Outlet Fuse 9A:
Locate red wire from battery charger to
battery. Pull apart yellow fuse holder.
Replace with SFE9 or equivalent.
! WARNING Automatic startup of the genset
▲
while performing maintenance or service can
cause severe personal injury or death. Push
the control switch to Off and disconnect the
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TABLE 4–1. TROUBLESHOOTING
! WARNING 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.
STARTING BATTERIES RUN DOWN
(Marginal batteries, connections, or charging system or parasitic loads)
Corrective Action:
1. Clean and tighten the positive (+) and negative (–) genset battery cable connections.
2. Recharge or replace the battery. Refer to the battery manufacturer's recommendations.
3. Have a battery charging system installed or serviced.
STARTER ENGAGES–DISENGAGES
(Cranking voltage dips below 6 volts—low battery charge, poor connections, long cables)
Corrective Action:
1. Clean and tighten the positive (+) and negative (-) genset battery cable connections.
2. Recharge or replace the battery. Refer to the battery manufacturer's recommendations.
NO POWER—GENSET RUNNING, RUN LIGHT ON
(Line circuit breaker OFF or tripped or faulty wiring)
Corrective Action:
1. Turn on or reset the line circuit breaker on the genset.
2. Turn on or reset the line circuit breakers on the main distribution panel
3. If the condition still exists, contact Cummins/Onan service.
LOW OIL PRESSURE FAULT—CODE NO. 2
(The controller sensed that the low oil pressure cutoff did not open within 10 seconds of starting)
Corrective Action:
1. Check engine oil level and add oil as necessary. Repair oil leaks.
2. Drain excess oil. (Excess oil leads to foaming and a consequent loss of oil pressure.)
3. If the oil level is OK, contact Cummins/Onan Service.
SERVICE CHECK FAULT—CODE NO. 3
(A service check fault occurred)
Corrective Action:
1. Reduce the number of appliances running at the same time, especially those with high
motor starting loads such as air conditioners.
2. Open any closed fuel valves and check for an adequate fuel supply.
3. Check for fouled spark plugs.
4. Check air cleaner.
5. Clean and tighten the positive (+) and negative (-) genset battery cable connections.
6. If the condition still exists, contact Cummins/Onan Service.
OVERCRANK FAULT—CODE NO. 4
(Cranking exceeded 20 seconds without engine starting)
Corrective Action:
1. Check fuel level.
2. Open any closed fuel valves.
3. Secure the spark plug lead on the spark plug.
4. Check the spark plugs.
5. Service the air cleaner.
4-2
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5. Specifications
in Engine Manual.
in Engine Manual.
See Page 2-1
3-1
5-1
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6. Information for California Genset Users
You should carefully review Operator (Owner),
Installation and other manuals and information
you receive with your genset. If you are unsure
that the installation, use, maintenance or service
of your genset is authorized, you should seek
assistance from an approved Onan engine or
genset dealer.
The Honda GX670 (used in Model GRCA Spec
4229 genset) meets the requirements of
California's Exhaust Emissions Standards for
1995 and later for Utility and Lawn and Garden
Equipment Engines.
As a California user of these gensets, please be
aware that unauthorized modifications or replacement of fuel, exhaust, air intake, or speed
control system components that affect engine
emissions are prohibited. Unauthorized modification, removal or replacement of the genset label is
prohibited.
California genset users may use Table 6–1 as an
aid in locating information related to the California
Air Resources Board requirements for emissions
control.
TABLE 6–1. EMISSIONS CONTROL INFORMATION
Genset Warranty Information
The California emissions control warranty statement is
located in the same packet of information as this manual
when the genset is shipped from the factory.
Engine Valve Clearance
See Specifications, Section 5.
Engine Ignition Timing
See Specifications, Section 5.
Engine Fuel Requirements
LPG Models: The engine is certified to operate on LPG.
See Fuel Recommendations in Operation, Section 2.
Engine Lubricating Oil Requirements
See Engine Oil Recommendations in Operation, Section 2.
Engine Fuel Mixture Settings
These genset engines have precision–manufactured carburetors and gas demand regulators and mixers which are not
adjustable.
Engine Adjustments
See Fuel Selection in Operation, Section 2 for steps necessary to convert from LPG to Natural Gas and vice versa.
Engine Emission Control System
The engine emission control system consists of internal
engine modifications (EM).
6-1
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7. How to Obtain Service
To get service, contact the authorized dealer or
distributor nearest you, explain the problem and
make an appointment. If you have difficulty in
arranging for service or resolving a problem,
please contact the dealer coordinator or service
manager at the nearest Cummins/Onan distributor for assistance.
When you need parts or service for your genset
contact the nearest authorized dealer or distributor. Onan has factory-trained representatives to
handle your needs for genset parts and service.
To locate the nearest authorized distributor:
1. Check the North American Sales and
Service Directory (F–118) supplied with your
Onan genset. These directories list authorized distributors who will assist you in locating the nearest authorized dealer.
Before calling for service, have the following information available:
1. The complete genset model number, spec
number, and serial number (see Model
Identification on page 1–2)
2. Consult the Yellow Pages. Typically, our distributors are listed under:
2. The date of purchase
GENERATORS - ELECTRIC,
ENGINES - GASOLINE OR DIESEL, or
RECREATIONAL VEHICLES - EQUIPMENT,
PARTS AND SERVICE.
3. The nature of the problem (See Troubleshooting, Section 4)
! WARNING Improper service or replacement of
▲
3. Call 1-800-888-ONAN for the name and
telephone number of the nearest Cummins/
Onan or Onan-only distributor in the United
States or Canada. (This automated service
utilizes touch-tone phones only).
parts can result in severe personal injury,
death, and/or equipment damage. Service personnel must be qualified to perform electrical
and/or mechanical service.
7-1
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Maintenance Record
Use the following table to keep a record of all periodic and unscheduled maintenance and service. See
Periodic Maintenance.
DATE
HOUR
METER
READING
MAINTENANCE OR SERVICE PERFORMED
Record the name, address, and phone number of your authorized Onan service center.
7-2
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Redistribution or publication of this document,
by any means, is strictly prohibited.
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