Cummins Onan HDKA H, J, K, T, U, V RV generator set Service Manual

Service Manual
RV Generator Set
HDKAH (Spec A−M)
HDKAJ (Spec A−M)
HDKAK (Spec A−M)
HDKAT (Spec A−M)
HDKAU (Spec A−M)
HDKAV (Spec A−M)
English − Original Instructions
6−2010
981−0522 (Issue 9)
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
diesel warnings
Table of Contents
SECTION
PAGE
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
v
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
Engine Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
Starting Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
Operator’s Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
Remote Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
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
i
SECTION
PAGE
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Stator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Rotor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Rotor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
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
ii
SECTION
PAGE
Actuator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Actuator Speed Control Lever Stop (Beginning Spec B) . . . . . . . . . . . . . . . . . . . . 13-4
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
Fault Code Blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
Restoring Fault Code Blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
Bypassable Faults: Prior to Spec F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
AC WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
BATTERY WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
iii
SAFETY PRECAUTIONS
• Engine cooling air must not be used for heating
working or living spaces or compartments.
Thoroughly read the OPERATOR’S MANUAL
before operating the genset. Safe operation and
top performance can only be obtained when
equipment is operated and maintained properly.
GENERATOR VOLTAGE IS DEADLY
• Disable the automatic genset starting feature
of an inverter-charger or other automatic starting device before servicing the genset.
The following symbols in this manual alert you to
potential hazards to the operator, service person
and equipment.
• Generator electrical output connections must
be made by a trained and experienced electrician in accordance with applicable codes.
DANGER alerts you to an immediate hazard
that will result in severe personal injury or
death.
• The genset must not be connected to the public utility or any other source of electrical power.
Back-feed could lead to electrocution of utility
personnel and damage to equipment. An approved switching device must be used to prevent interconnections.
WARNING alerts you to a hazard or unsafe
practice that 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, stand on a dry wooden
platform or rubber insulating mat and use tools
with insulated handles.
alerts you to a hazard or unsafe
practice that can result in personal injury or
equipment damage.
CAUTION
Electricity, fuel, exhaust, moving parts and batteries present hazards which can result in severe personal injury or death.
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 equipment. Keep flames, sparks, pilot lights, arcproducing equipment and all other sources of
ignition well away.
ENGINE EXHAUST IS DEADLY
• Inspect for exhaust leaks at every startup and
after every eight hours of running.
• Learn the symptoms of carbon monoxide poisoning in the Operator’s Manual.
• Fuel lines must be secured, free of leaks and
separated or shielded from electrical wiring.
• Never sleep in the vehicle while the genset is
running unless the vehicle is equipped with a
working carbon monoxide detector.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
• Do not operate the genset when the vehicle is
in a confined space, such as a garage.
• Disable the automatic genset starting feature
of an inverter-charger or other automatic starting device before servicing the genset.
• Disable the automatic genset starting feature
of an inverter-charger or other automatic starting device before storing the vehicle or parking
it in a garage or other confined space.
• Do not wear loose clothing or jewelry near
moving parts such as PTO shafts, fans, belts
and pulleys.
• The exhaust system must be installed in accordance with the genset Installation Manual.
• Keep hands away from moving parts.
iv
BATTERY GAS IS EXPLOSIVE
• 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.
• Wear safety glasses.
• Do not smoke.
• Make sure all fasteners are secure and
torqued properly.
• To reduce arcing when disconnecting or reconnecting battery cables, always disconnect the
negative (−) battery cable first and reconnect
it last.
• Do not work on the genset when mentally or
physically fatigued or after consuming alcohol
or drugs.
FLAMMABLE VAPOR CAN CAUSE A
DIESEL ENGINE TO OVERSPEED
• You must be trained and experienced to make
adjustments while the genset is running—hot,
moving or electrically live parts can cause severe personal injury or death.
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.
• 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 accordance with local environmental regulations.
GENERAL PRECAUTIONS
• Keep multi-class ABC fire extinguishers
handy. Class A fires involve ordinary combustible materials such as wood and cloth; Class B
fires, combustible and flammable liquid fuels
and gaseous fuels; Class C fires, live electrical
equipment. (ref. NFPA No. 10)
• 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 negative (−) battery cable at the battery.
• Genset installation and operation must comply
with all applicable local, state and federal
codes and regulations.
• 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 guards in place over fans, belts, pulleys,
and other moving parts.
Mobile-8
v
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 precautions in this manual.
80HDKAK11454J
F990 123456
Improper service or parts replacement 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.
WARNING
SKB719U6D2RA
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.
CAUTION
719 cc
See the Installation Manual for important recommendations 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 numbers and required quantities. Genuine Onan® replacement 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 nameplate 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.)
FIGURE 1-1. TYPICAL NAMEPLATE
1-1
TYPICAL GENSET
Figure 1-2 illustrates a typical genset.
COOLANT
PRESSURE
CAP
COOLANT
RECOVERY
TANK
GENERATOR
(PMA) STATOR
RADIATOR
GOVERNOR
ACTUATOR
MUFFLER
ASSEMBLY
INNER
BULKHEAD
CONTROLLER/
INVERTER
HOUSING
ENGINE
COOLING
BLOWER
INTAKE AIR
RESONATOR
STARTER
MOTOR
FUEL
FILTER
OIL
FILTER
FIGURE 1-2. TYPICAL GENSET WITH HOUSING PANELS REMOVED
1-2
FUEL
PUMP
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)
Voltage
Frequency
Number of Phases
Current
Line Circuit Breaker(s)
6000 W
120 volts
60 Hz
1
50.0 ampere
2-pole, 30 amp
7500 W
120 volts
60 Hz
1
62.5 ampere
2-pole, 30 or 35 amp
8000 W
120 volts
60 Hz
1
66.7 ampere
2-pole, 30 or 35 amp
ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection, 4-Stroke Cycle Diesel
Bore
Stroke
Displacement
Compression Ratio
2.64 inch (67 mm)
2.68 inch (68 mm)
44 inch3 (719 cc)
23 : 1
3 quart (2.6 l)
4.2 quart (4 l)
0.0065 inch (0.165 mm)
14 to 64 psi over speed range
414 to 469 psi, 327 psi minimum
Oil Capacity (with filter)*
Cooling System Capacity**
Intake and Exhaust Valve Lash (Cold)
Lubricating Oil Pressure
Cylinder Compression Pressure
OPERATING SPEED RANGE:
1600 to 2900 RPM
1600 to 3200 RPM
1600 to 3300 RPM
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)
FUEL CONSUMPTION:
No-load
Half-load (4000 W)
Full-load
DC SYSTEM:
Nominal Battery Voltage
Minimum Battery Capacity
12 volts
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
10 ampere mini-bayonet
10 ampere mini-bayonet
25 ampere
Fuse F1 (control circuit)
Fuse F2 (starter solenoid circuit)
Fuse F3 (glow plug circuit)
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)
2-1
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)
Voltage
Frequency
Number of Phases
Current
Line Circuit Breaker(s)
6000 W
120 volts
60 Hz
1
50.0 ampere
2-pole, 30 amp
7500 W
120 volts
60 Hz
1
62.5 ampere
2-pole, 30 or 35 amp
8000 W
120 volts
60 Hz
1
66.7 ampere
2-pole, 30 or 35 amp
ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection, 4-Stroke Cycle Diesel
Bore
Stroke
Displacement
Compression Ratio
2.64 inch (67 mm)
2.68 inch (68 mm)
44 inch3 (719 cc)
23 : 1
3 quart (2.6 l)
4.2 quart (4 l)
0.0065 inch (0.165 mm)
14 to 64 psi over speed range
414 to 469 psi, 327 psi minimum
Oil Capacity (with filter)*
Cooling System Capacity**
Intake and Exhaust Valve Lash (Cold)
Lubricating Oil Pressure
Cylinder Compression Pressure
OPERATING SPEED RANGE:
1600 to 2900 RPM
1600 to 3200 RPM
1600 to 3300 RPM
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)
FUEL CONSUMPTION:
No-load
Half-load (4000 W)
Full-load
DC SYSTEM:
Nominal Battery Voltage
Minimum Battery Capacity
12 volts
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
10 ampere mini-bayonet
10 ampere mini-bayonet
25 ampere
Fuse F1 (control circuit)
Fuse F2 (starter solenoid circuit)
Fuse F3 (glow plug circuit)
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
3. Thread Torques
lbf-ft*
N-m *
−
7-9
7-9
7-9
−
10-12
10-12
10-12
75-80 lbf-inch
7-9
−
8.5-9
10-12
−
Exhaust Assembly Flange Bolts
Exhaust Isolator Clamp Screws
16-20
7-9
22-28
10-12
Housing Panel Screws
Component Mounting Screws (threads into skid-base)
11-13
7-9
15-18
10-12
Vibration Isolator Center Bolt
Vibration Isolator Mounting Screws
43-53
7-9
58-72
10-12
Battery Cable Terminal Block Terminal Nuts
Battery Cable Terminal Block Mounting Screws
Starter Solenoid Terminal Nuts
AC Output Terminal Block Terminal Screws
AC Output Terminal Block Mounting Screws
Circuit Breaker Terminal Screws
Circuit Breaker Mounting Screws
6.7-8.3
7-9
4.4-8.7
12-14 lbf-inch
20-22 lbf-inch
12-14 lbf-inch
12-14 lbf-inch
9-11
10-12
5.9-11.8
1.4-1.6
2.2-2.5
1.4-1.6
1.4-1.6
Flywheel Housing Mounting Bolts
Rotor/Flywheel Mounting Bolts
Stator Mounting Bolts
Blower Mounting Bolts
Starter Mounting Bolts
Oil Pan Mounting Bolts
Coolant Temperature Sender (use thread sealant)
Low Oil Pressure Switch (use thread sealant)
Governor Actuator Bearing Carrier Mounting Screws
Oil Fill Hose Support Clip Screw
18-22
40-43
7-9
7-9
18-22
5.8-6.9
26-32
10.8-14.5
21-27 lbf-inch
7-9
24-30
53.9-58.8
10-12
10-12
24-30
7.9-9.3
35-43
14.7-19.6
2.4-3.0
10-12
M6 Engine Bolts Except When Otherwise Specified
M8 Engine Bolts Except When Otherwise Specified
M10 Engine Bolts Except When Otherwise Specified
M12 Engine Bolts Except When Otherwise Specified
5.8-6.9
13.0-15.2
28.9-33.3
46.3-53.5
7.9-9.3
17.7-20.6
39.2-45.1
62.8-72.6
Air Cleaner Cover Bolt—Three to four clicks past seating.
Air Cleaner Housing Mounting Screws
Intake Air Hose Clamp Screws
Air Intake Resonator Mounting Screws
Fuel Pump Mounting Screws
Fuel Fitting At Fuel Pump
Fuel Fittings at Fuel Filter—One flat passed finger tight.
* − Use engine oil as a lubricant for all threads except when otherwise specified.
3-1
4. Operation
FUEL RECOMMENDATIONS
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 temperatures expected until the next scheduled oil change.
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 reliable starting.
STARTING BATTERIES
These gensets have a 12 volt, direct current (DC)
starting and control system. See Specifications for
minimum battery requirements (cold cranking amperes) for genset starting.
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.
WARNING
ENGINE OIL RECOMMENDATIONS
Regular, monthly maintenance of batteries may be
required. See Periodic Maintenance, and any instructions available from the vehicle manufacturer
or battery manufacturer. Either the vehicle or the
genset will be equipped with a battery charger.
Use API (American Petroleum Institute) performance Class CH-4, CG-4 or CF-4D engine oil,
which may be in combination with performance
Reliable genset starting and starter service life depend upon adequate battery system capacity and
proper maintenance.
Anticipated Ambient Temperature
FIGURE 4-1. OIL VISCOSITY VS. TEMPERATURE
4-1
OPERATOR’S CONSOLE
REMOTE CONTROL PANEL
The operator’s console (Figure 4-2) has the following features:
The vehicle may be equipped with a remote control
panel having a Control Switch and Preheat/Diagnostics Light. In addition, it may have an hour meter and the following engine gauges:
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).
Oil Pressure Gauge − The oil pressure gauge indicates the presence of engine oil pressure.
Status Light − This is an LED (light emitting diode)
in the control switch which blinks rapidly during preheat and cranking. (Preheat is the period of time
prior to engine cranking when the glow plugs preheat the combustion chambers. The time is automatically varied by the genset controller on the basis of engine temperature.) After the genset starts
up, this light stays on continuously, indicating that
the genset is running and that the starter has disconnected. Also, if the genset shuts down, this light
blinks in a coded fashion to indicate the nature of the
shutdown. See Troubleshooting.
Water Temperature Gauge − The water temperature gauge indicates engine coolant temperature.
Voltmeter − The voltmeter indicates battery voltage.
ACCESS
PLATE
COOLANT
RECOVERY TANK
FILL CAP (BLUE)
OIL FILL CAP
AND DIP STICK
(YELLOW)
Line Circuit Breaker(s) − The line circuit breaker(s) protect the AC power leads connected to the
genset.
Engine Oil Fill Cap/Dipstick − The oil dipstick is attached 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.
CONTROL
SWITCH AND
STATUS LIGHT
Fuses F1, F2 and F3 − These fuses are accessible
by removing the access plate on the control console. They protect the control circuits of the genset.
HOUR METER
(OPTIONAL)
LINE CIRCUIT
BREAKER
FIGURE 4-2. OPERATOR’S CONSOLE
4-2
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
• Nausea
• Vomiting
• Headache
• Weakness and Sleepiness
• 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 sleep in the vehicle while the genset is running unless the vehicle has a working carbon monoxide detector. The exhaust system must be installed in accordance with the genset Installation Manual.
Make sure there is ample fresh air when operating the genset in a confined area.
PRIMING THE FUEL SYSTEM
Excessive cranking can overheat and damage the starter motor. Do not
crank for more than 30 seconds at a time.
Wait at least 2 minutes before trying again.
CAUTION
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.
4. See Troubleshooting if the genset does not
start after three tries.
STARTING
5. Let the genset warm up a few minutes until it is
running smoothly before connecting the vehicle electrical loads (appliances).
The genset can be started and stopped from the
genset control panel or from a remote control panel
inside the vehicle.
6. Monitor the engine gauges if the remote panel
is so equipped. Normal readings during operation are as follows:
1. Review Powering Equipment, Varying Operating Conditions, Genset Break-In, Exercise and
Storage and the Maintenance Record in the
Operator’s Manual before starting or servicing
the genset.
Oil Pressure: Approximately center of scale
Temperature: 160°-220° F (71°-104° C)
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.
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.
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 disconnected. (Depending on how cold it is, preheat
can take up to 15 seconds, extending the time
that the light blinks.)
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.
4-3
5. Periodic Maintenance
PERIODIC MAINTENANCE SCHEDULE
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
Periodic maintenance is essential for top performance and long genset life. Use Table 5-1 as a
TABLE 5-1. PERIODIC MAINTENANCE SCHEDULE
MAINTENANCE FREQUENCY
MAINTENANCE OPERATION
Every
Day
Every
Month
Every
Every
150 Hours 500 Hours
Every
1000
Hours
P
a
g
e
General Inspection
x
5-2
Check Engine Oil Level
x
5-3
Check Engine Coolant Level
x
5-8
x3
Clean and Check Battery
Change Engine Oil and Filter
Clean Spark Arrestor
5-3
x1, 2,3, 4
5-3
x4
5-5
x2, 4
5-6
Replace Fuel Filter
x4
5-7
Check Coolant Anti-freeze Protection
x4
5-8
Replace Engine Air Filter
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
x7
12-1
Adjust Valve Lash
1.
2.
3.
4.
5.
6.
7.
As a part of engine break-in, change the engine oil and oil filter after the first 50 hours of operation.
Perform more often when operating in dusty conditions.
Perform more often when operating in hot weather.
Perform at least once a year.
Perform at least once every two years.
Perform at least once every five years.
Must be performed by a qualified mechanic (authorized Onan dealer).
5-1
GENERAL INSPECTION
Do not operate power ventilators or exhaust fans
while the vehicle is standing with the genset running. The ventilator or fan can draw exhaust gases
into the vehicle.
Inspect the genset before the first start of the day.
Oil Level
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.
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.
Do not park the vehicle in high grass
or brush. Contact with the exhaust system can
cause a fire.
WARNING
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.
CAUTION
Operating the genset when the
coolant level is low can cause serious engine
damage.
Diesel fuel leaks can lead to fire. Do
not operate the genset if operation causes fuel
to leak.
WARNING
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.
Mechanical
Look for mechanical damage. Start the genset and
look, listen and feel for any unusual noises and
vibrations.
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 prevent exhaust gases from entering the vehicle.
Check the genset mounting bolts to make sure they
are secure.
Replace dented, bent or severely rusted sections of
the tailpipe and make sure the tailpipe extends at
least 1 inch (25.4 mm) beyond the perimeter of the
vehicle.
Check 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).
Park the vehicle so that the genset exhaust gases
can disperse away from the vehicle. Barriers such
as walls, snow banks, high grass and brush and other vehicles can cause exhaust gases to accumulate
in and around the vehicle.
Battery Connections
Check the battery terminals for clean, tight connections. See BATTERIES (p. 5-6).
5-2
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 RECOMMENDATIONS (p. 4-1). DO NOT FILL TO A LEVEL
ABOVE THE FULL MARK ON THE DIPSTICK.
Drain the excess oil if too much has been added.
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.
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 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.
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 allow all of the oil to drain from the engine.
4. Reinstall the oil drain plug and tighten it securely to prevent oil leakage.
FIGURE 5-1. OIL DIPSTICK
5-3
a larger diameter than the original filter cannister, but will fit.)
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.
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 overtighten. Close the access door, making sure it
latches securely.
6. Thoroughly wipe off the filter mounting surface.
Remove the old gasket if it does not come off
with the filter canister.
9. Refill and check the oil level. See Specifications
for oil capacity.
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
10. Dispose of the used oil properly.
ACCESS
DOOR
OIL
FILTER
OIL DRAIN
PLUG
FIGURE 5-2. OIL DRAIN PLUG AND OIL FILTER
5-4
SPARK ARRESTOR
fler, accessible through the air outlet opening in the
bottom of the genset. Clean out the spark arrestor
muffler as follows:
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.
1. Remove the cleanout plug from the muffler
(Figure 5-3).
A hot muffler can cause severe
burns. Let the muffler cool down before removing or installing the cleanout plug.
2. Restart the genset and load it nearly to full power. Let the genset run for about five minutes to
expel the soot in the muffler.
The muffler is mounted inside the genset housing.
The cleanout plug is located on the side of the muf-
3. Stop the genset, allow the muffler to cool down
and then reinstall the plug.
WARNING
CLEANOUT
PLUG
FIGURE 5-3. SPARK ARRESTOR CLEANOUT PLUG
5-5
BATTERIES
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.
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 battery—Stop genset and disconnect charger before disconnecting battery cables—Disconnect
negative (−) cable first and reconnect last.
AIR FILTER
Refer to Table 5-1 for scheduled air filter replacement. 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 inner cover wingnut three to four clicks past seating.
Make sure the outer cover is seated before tightening its wingnut. Check for noise when the genset
is running, and retighten if necessary.
Refer to Table 5-1 for scheduled battery maintenance, and follow the battery manufacturer’s instructions. Have the battery charging system serviced if DC system voltage is consistently low or
high. Always:
1. Keep the battery case and terminals clean and
dry and the terminals tight.
OUTER COVER
INNER COVER
FILTER ELEMENT
SPACER SEAL
FIGURE 5-4. AIR FILTER ELEMENT
5-6
HOUSING
FUEL FILTER
Removing the Fuel Filter: To remove the filter, disconnect the two fittings at the filter and remove the
mounting nut. Apply a wrench on the filter fitting as
well as on the flare nut so as not to stress the fitting.
Flare nut wrenches should be used on the flare nuts
so as not to round the corners on the nuts. Dispose
of the fuel filter according to local regulations.
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 accessible through the maintenance access door in
the skid-base. Squeeze the latches together to
open the door.
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.
CAUTION Wipe the dirt off the fuel fittings before disconnecting them to keep dirt from entering the fuel system.
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.
WARNING Diesel fuel is combustible and can
cause severe personal injury or death. Do not
smoke. Keep flames, sparks, pilot lights, electrical arcs and arc-producing equipment and all
other sources of ignition well away. Keep a type
ABC fire extinguisher handy.
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 displace the air in the new filter with fuel.
FUEL
FILTER
FUEL HOSE
TO ENGINE
FILTER
MOUNTING
NUT
TUBING FROM
FUEL PUMP
FIGURE 5-5. FUEL FILTER
5-7
CHANGING COOLANT
down and turning it until it can be withdrawn. Then
get a suitable container and drain the coolant by removing the system drain cap (Figure 5-6).
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 temperatures down to -34° F (-37° C).
Ethylene glycol antifreeze is considered toxic. Dispose of it according to local
regulations for hazardous substances.
WARNING
Replace the coolant every two years. Use ethylene
or propylene glycol anti-freeze solution that contains a rust and corrosion inhibitor. The anti-freeze
must not contain a stop-leak additive.
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.
The water used for engine coolant must be clean,
low in minerals, and free of corrosive chemicals.
Use distilled water if available.
Refilling the Cooling System
Fill the recovery tank with coolant mixture to the
COLD mark.
See Specifications for cooling system capacity.
Pressure Cap
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 genset for a few minutes and shut it down. (It is recommended 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 secure the 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 engine cooling and minimal coolant loss.
Draining the Cooling System
Hot coolant spray can cause severe
burns. Let the engine cool before releasing the
pressure cap or removing the drain cap.
WARNING
Coolant Level Check
Allow the engine to cool before removing the pressure 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
Check coolant level in the recovery tank before the
first startup of each day and fill to the COLD mark if
necessary.
5-8
PRESSURE CAP
AND SYSTEM FILL
OPENING
COOLANT RECOVERY
TANK FILL CAP (BLUE)
COOLING
SYSTEM
DRAIN CAP
FIGURE 5-6. ENGINE COOLING SYSTEM FILL AND DRAIN CAPS
5-9
COOLANT TEMPERATURE INPUT
TABLE 5-2. COOLANT TEMPERATURE INPUT
Resistance measurements should be taken between the sensor lead and the battery ground post
(rather than the engine chassis) for most accurate
reading with the harness disconnected at the sensor.
DIG _C
DEG _F Sensor V to A/D Genset
(OHMS)
A/D
Count
−20
−4
2100
4.27
218
−10
14
1700
4.13
211
This sensor is not a precise temperature measurement. Differences between the table values and values 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% resistence for a given temperature.)
−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
5-10
6. Preparations for Service
SPECIAL TOOLS
equipment. Do not work alone if possible and
take no risks.
The following tools are necessary for servicing the
genset:
• Be prepared for an accident: Keep fire extinguishers and safety equipment nearby. Agencies 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 procedures part of the work routine.
• 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
TABLE 6-1. HAZARDS AND THEIR SOURCES
• Leaking or spilled fuel
There are hazards in servicing gensets. Study Safety Precautions and become familiar with the hazards listed in Table 6-1. Note the following safeguards and ways of avoiding hazards:
Fire and
Explosion
• Hydrogen gas from battery
• Oily rags improperly stored
• Flammable liquids improperly
stored
• 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.
• Hot exhaust pipes
Burns
• Hot engine and generator surfaces
• Electrical shorts
• 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 liquids in approved containers; away from fire,
flame, spark, pilot light, switches, arc-producing equipment and other ignition sources. Keep
the workshop clean and well-lighted and provide adequate ventilation.
Poisonous
Gas
• Operating genset where exhaust gases can accumulate
• Improper generator connections
Electrical
Shock (AC)
• Faulty wiring
• Working in damp conditions
• Jewelry touching
components
• 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
Rotating
Machinery
6-1
electrical
• Fan guards not in place
Slippery
Surfaces
• Leaking or spilled oil
Heavy
Objects
• Removing genset from vehicle
REMOVING GENSET FROM VEHICLE
Removal from the Vehicle
WARNING Gensets are heavy and can cause
severe personal injury if dropped during removal. Use adequate lifting devices. Keep hands
and feet clear while lifting.
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 manufacturer or installer if the best way to remove the genset
is not obvious.
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).
Disconnections
1. Disconnect the negative (-) battery cable from
the battery and then disconnect the battery
cables from the genset.
TEST STAND
WARNING EXHAUST GAS IS DEADLY! Engine
exhaust must be vented outside if the genset is
operated inside a building.
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.
WARNING
Restricting the air inlet and outlet
openings could lead to damage to the genset
due to overheating.
CAUTION
When testing and servicing the genset on a workbench 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.
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 muffler flange.
ACCESS
DOOR
5. Disconnect the supply and return fuel lines from
the genset.
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.
Á
Á
WARNING
AIR
IN
AIR
OUT
FIGURE 6-1. BOTTOM VIEW OF SKID-BASE
6-2
REMOVING HOUSING PANELS
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.
WARNING Do not operate the genset without
the housing panels secure in place. The panels
guard against rotating parts and bare live electrical parts that can cause severe personal injury or death. The housing is also required for
proper genset cooling.
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.
See Figure 6-2. The housing consists of five removable panels. The front (service) panel may also include 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 between panels. Keep the screws separated to make
reassembly easier.
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.
Removing the Front and Top Panels
3. Remove the line circuit breaker mounting
screws (on the operator’s console).
It may be necessary to remove only the front (service) 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.
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 control switch and hour meter (if so equipped) and
cut the wire ties which secure the wiring harness to the panel.
CAUTION Screws that are too long will damage the coolant recovery tank and may cause it
to break away. Make sure the shorter panel
screws are used for the recovery tank.
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.
Removing the Back Panel
Remove the top panel, all the screws around the perimeter of the back panel and the two screws into the
6-3
ACCESS COVER
FUSES AND COOLANT
PRESSURE CAP
LEFT END
PANEL
ACCESS COVER
AC TERMINALS
ACCESS COVER
LIFTING EYE
BACK
PANEL
OPERATOR‘S
CONSOLE
SCREW HOLES FOR
SCREWS WHICH ALSO
SECURE THE COOLANT
RECOVERY TANK
FRONT (SERVICE) PANEL
(MAY INCLUDE A SERVICE DOOR)
TOP
PANEL
FIGURE 6-2. THE GENSET HOUSING PANELS
6-4
RIGHT END
PANEL
7. Engine Air Intake
COMPONENT LAYOUT
Figure 7-1 illustrates the series of parts connected
to the engine air intake manifold. The arrows indicate the flow of air.
SECURE THE END OF THE AIR
INLET HOSE TO THE INLET
GRILLE WITH A WIRE TIE
INLET BAFFLE
ASSEMBLY
MAKE SURE THESE HOSE
CLAMP SCREWS ARE ON TOP
AND ORIENTED AS SHOWN TO
MAKE DISASSEMBLY EASIER
AIR FILTER
ELEMENT
HOUSING
RESONATOR
CLAMP AT ENGINE
INTAKE MANIFOLD
BAFFLE SCREWS TO
SKID-BASE
FIGURE 7-1. ENGINE AIR INTAKE ASSEMBLY
7-1
8. Muffler
REMOVAL
nector when installing the muffler. Tighten all bolts
and screws according to Thread Torques.
The muffler assembly is mounted inside the genset
housing. See Figure 8-1. To remove the muffler:
CAUTION
The flexible connector is fragile
when removed from the assembly and must not
be bent or twisted. Make sure the muffler is securely in place and properly aligned before connecting the flexible connector.
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).
Important safety warnings and instructions regarding the routing and termination of the tailpipe (not
supplied by Onan) are included in the Installation
Manual. Always use a new flange gasket when connecting the tail pipe.
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 genset from the back) until the pins in the two inboard bearings are free.
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 installing the unapproved muffler or performing the
modifications. Use Onan approved exhaust
system parts.
INSTALLATION
Installation is the reverse of removal. Always use
new flange gaskets on both ends of the flexible con-
8-1
ELBOW AND
FLEXIBLE
CONNECTOR
MUFFLER
ASSEMBLY
FLANGE
GASKETS
OUTBOARD
MOUNTING
BEARING
MUFFLER
OUTLET
FLANGE
ENGINE EXHAUST
MANIFOLD FLANGE
INBOARD
MOUNTING
BEARING
(TWO)
FIGURE 8-1. MUFFLER ASSEMBLY
8-2
9. Engine Cooling System
GENERAL
4. Remove the two screws which secure the radiator to the inner bulkhead and pull it away.
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 radiator from the top side into the muffler compartment and then out the bottom. See Figures 9-1 and
9-2.
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).
See Periodic Maintenance for cooling system maintenance.
See Page 12-1 for instructions on how to replace
the coolant pump drive belt.
5. Remove the two screws in the horizontal portion of the bulkhead that projects under the radiator.
See the engine service manual for thermostat and
pump service.
6. Pull the radiator, coolant recovery tank and inner bulkhead away as an assembly with all the
hoses connected.
RADIATOR REMOVAL
RADIATOR INSTALLATION
Removal Procedure
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 (Figure 9-1).
1. Remove the top and back housing panels of the
genset (p. 6-3).
2. Drain the system.
Hot coolant spray can cause severe burns. Let the engine cool before releasing the pressure cap or removing the
drain cap.
WARNING
Make sure to reinstall the hose bracket at the front of
the engine to keep the belt from rubbing on the
hose. (The bracket squeezes the hose slightly.)
Tighten all screws according to Thread Torques.
3. Disconnect all four hoses.
9-1
PRESSURE
CAP
RADIATOR
INNER
BULKHEAD
COOLANT
RECOVERY
TANK
UPPER RADIATOR
HOSE
THERMOSTAT
HOUSING
COOLANT
PUMP
PULLEY
HOSE
BRACKET
CRANKCASE BREATHER
HOSE EXIT
FIGURE 9-1. ENGINE COOLING SYSTEM (I OF 2)
9-2
LOWER ENGINE
HOSE
UPPER
RADIATOR
HOSE
COOLANT
RECOVERY
TANK
PRESSURE
CAP
SYSTEM
FILL HOSE
SYSTEM
VENT HOSE
CRANKCASE
BREATHER
HOSE
HOSE
BRACKET
RADIATOR
LOWER
RADIATOR
HOSE
LOWER
ENGINE
HOSE
SYSTEM
DRAIN “T”
AND CAP
INNER
BULKHEAD
FIGURE 9-2. ENGINE COOLING SYSTEM (2 OF 2)
9-3
10. Controller-Inverter
GENERAL
and remove the genset housing panels
(p. 6-3).
Figure 10-1 shows two views of the controller-inverter housing. Also shown are all of the wiring
leads, connectors and terminals on the housing,
and the heat sink for the electronic components inside.
2. Disconnect all external wiring connections and
the grounding strap from the housing.
3. Remove the screw securing the housing to the
radiator frame and inner bulkhead.
There are no field replaceable parts inside the controller/inverter housing. See Troubleshooting to determine when it may be necessary to replace the assembly.
4. Remove the 6 screws securing the housing to
the inlet baffle assembly (Figure 7-1).
5. Remove the 5 screws along the lower back of
the housing and lift out the housing.
Note: Tests with an ohmmeter or diode checker
across the leads, terminals and connector pins on
the controller/inverter housing itself have not been
prescribed, as they would not lead to useful service
information.
INSTALLATION
Note also that attempting to operate the genset with
any of the wiring disconnected from the controller/
inverter assembly results only in shutdown and a
Fault Code being displayed.
Installation is the reverse of removal.
1. Make sure to reconnect the grounding eyelet in
the AC harness (p. A-2) and the grounding
strap from the skid-base.
REMOVAL
2. Tighten all screws according to Thread
Torques.
1. Disconnect the negative (-) battery cable from
the battery to prevent the genset from starting
10-1
SECURE ENGINE AND
AC HARNESS SUPPORT
CLIPS HERE
J1 AND J2
FOR ENGINE
HARNESS
6 LEADS WITH QUICK CONNECTORS
2 TO CT (CURRENT TRANSFORMER) IN AC HARNESS
AND 4 TO GLOW PLUGS AND STARTER SOLENOID IN
ENGINE HARNESS
TB3
FOR AC
HARNESS
CONNECT GROUND STRAP FROM
SKID-BASE AND GROUNDING
EYELET IN AC HARNESS HERE
6 LEADS WITH QUICK
CONNECTORS TO PMA LEADS
FIGURE 10-1. CONTROLLER-INVERTER HOUSING
10-2
HEAT
SINK
CONTROLLER-INVERTER FUNCTIONS
Stopping
The controller-inverter is an integrated microprocessor-based engine and generator control. See
the block diagram in Figure 10-2. It provides all the
control, monitoring and diagnostics functions required to operate the genset. Major functions include:
When the control switch is touched to the Stop position, the Controller disables output voltage, deenergizes the fuel pump and governor actuator, turns off
the status indicator, writes session data (number of
cranks, minutes of operation, last fault, etc.) to nonvolatile memory (NVM) and removes processor
power when idle 5 minutes (battery saver function).
Initialization
Note: Stop takes precedence over Start if both present due to a faulty switch or other cause.
Control initialization consists of checking memory
(RAM, ROM, EEPROM) and genset configuration.
Priming
Starting
When the control switch is pressed and held in the
Stop position for more than 2 seconds, the Controller energizes the fuel pump and turns on the status
indicator for as long as Stop is held.
When the control switch is pressed and held in the
Start position until start disconnect, the startup sequence of the Controller:
1. Energizes the fuel pump.
2. Flashes the status indicator to indicate preheat
and crank.
Note: Beginning Spec F, Stop must be released if
stopping the genset and reapplied to prime.
3. Energizes the glow plugs for temperature-dependent durations (Tables 10-1 and 10-2).
Speed Control
4. Energizes the governor actuator (moves toward full rack).
The Controller maintains the speed range for which
the genset is configured (Specifications). For RV
configurations (HDKAH, HDKAJ and HDKAK) a
speed of approximately 2300 rpm is commanded
during the first minute, 1950 rpm during the second
minute and 1600 rpm (idle) thereafter. Speed will be
increased at any time as loading requires (variable
speed control).
5. Energizes the starter when preheat has been
completed.
6. Deenergizes the starter at 800 rpm.
7. Turns on the status indicator to indicate start
disconnect.
8. Turns on Switched B+ (remote connector
pin J8-F).
Voltage Control
9. Enables the inverter (output voltage).
The Inverter converts the 3-phase AC output of the
engine-driven PMA (permanent magnet alternator)
into 1-phase AC output at the voltage and frequency
for which the genset is configured (follow the heavy
arrows in Figure 10-2). The Controller maintains
nominal AC voltage output during steady state operation. In response to transient loads the Controller
adjusts the voltage setpoint to allow engine recovery.
TABLE 10-1. PREHEAT TIMINGS
Coolant Temp > 120 °F
0 sec
Coolant Temp 50 °F
Coolant Temp 23 °F
5 sec
10 sec
Coolant Temp < −4 °F
15 sec
TABLE 10-2. POSTHEAT TIMINGS*
Coolant Temp > 70 °F
0 sec
Coolant Temp < 70 °F
5 sec
* − Following start disconnect
Fault Shutdown and Diagnostics
Note: Beginning Spec F, Start must be released and
reapplied for subsequent start attempts.
See Troubleshooting.
10-3
CONTROLLER-INVERTER ASSEMBLY
(FOR ILLUSTRATION ONLY—INTERNAL PARTS NOT FIELD SERVICEABLE)
INVERTER
OVERTEMP
LOCAL CONTROL
REMOTE CONTROL
PMA
SWITCHED B+
DC BUS
PC SERIAL CONNECTION
(FOR FACTORY ONLY)
FUEL PUMP
CONTROLLER
POWER
DEVICES
GLOW PLUGS
STARTER
GOVERNOR ACTUATOR
AC
FILTERS
ENGINE SENSORS
BATTERY
CURRENT
SENSOR
CONTROL & FEEDBACK
OUTPUT POWER
AC OUTPUT
FIGURE 10-2. CONTROLLER-INVERTER BLOCK DIAGRAM
10-4
11. PMA (Generator)
GENERAL
ment, the test should be repeated after the windings
have been dried. The most effective way of drying
the stator windings, if the genset is operable, is to
run it under full load for at least one hour.
The genset has an 8-pole permanent magnet alternator (PMA) type of generator with a 3-phase stator
(Figure 11-1). The magnets are bonded to the rotor
with adhesive. The rotor is a one piece casting with
the flywheel. A bearing is not used to support the
end of the rotor and there are no slip rings, brushes
or exciters. See Figure 11-2.
Testing with a Digital Ohmmeter: A digital ohmmeter can be used (highest scale) as a preliminary
check. It should read infinite resistance.
Winding Resistance
STATOR TESTS
Testing with a Digital Ohmmeter: A digital ohmmeter can be used (lowest scale) as a preliminary
check for an open winding. It should read approximately 1 ohm.
Winding Insulation Resistance Test
Disconnect the negative (-) battery cable from the
battery to prevent the genset from starting and remove the top panel of the housing (p. 6-3).
Testing with a Wheatstone Bridge: Use a Wheatstone bridge having at least a 0.001 ohm precision
to measure the resistance across each winding lead
pair: T1-1—T2-1, T3-1—T2-1, T1-1—T3-1,
T1-2—T2-2, T3-2—T2-2, T1-2—T3-2. The resistance should be 0.997-1.219 ohms at 70° F (21° C).
WARNING Do not operate the genset without
the housing panels secured in place. The panels
guard against rotating parts and bare live electrical parts that can cause severe personal injury or death.
Disconnect the six PMA winding leads from the controller/inverter assembly leads (p. 10-2).
T1-1
Testing with a Megger: A 500 VDC megger is recommended for testing winding insulation resistance. Apply the test voltage between a lead from
each winding group (T1-1 and T1-2) and ground
(stator laminations) for 10 minutes and record resistance values at one minute and at 10 minutes.
T2-1
T1-2
Resistance values of at least 5 megohms should be
obtained for a new stator with dry windings. The polarization index (the ratio of the resistance reading
at 10 minutes to the reading at one minute) should
also be at least 2. For a genset that has been in service, the resistance reading should not be less than
1 megohm nor the polarization index less than 2.
T2-2
T3-1
T3-2
If the readings are low, or the genset has been in
storage for a long time in a high-humidity environ-
FIGURE 11-1. STATOR WINDING GROUPS
11-1
PMA ROTOR, FLYWHEEL
AND STARTER RING GEAR
PMA STATOR AND
WINDING LEADS
ENGINE COOLING
BLOWER
ENGINE
FLYWHEEL
HOUSING
FIGURE 11-2. PMA ASSEMBLY
11-2
STATOR REMOVAL
ROTOR REMOVAL
The rotor can be unbolted from the engine after the
stator has been removed.
See Page 12-2 if the stator and engine are to be removed as an assembly. If the engine and rotor are to
remain in place, remove the stator as follows:
ROTOR INSTALLATION
Note when installing the rotor that the five rotor-tocrankshaft bolts are not equally spaced, though
they look as if they are. To register the rotor and
crankshaft bolt holes properly before bolting:
1. Disconnect the negative (-) battery cable from
the battery to prevent the genset from starting
and remove the housing (p. 6-3).
2. Disconnect the stator winding leads.
3. Remove the
(p. 10-1).
controller/inverter
1. Bar the engine until the counterweight on the
front engine pulley is straight down.
assembly
2. Mate the rotor to the crankshaft such that the
middle line on the back of the flywheel lines up
with the pointer in the window in the flywheel
housing. See Figure 11-3.
4. Remove the blower (Figure 11-2).
5. Remove the air filter cover and element.
3. Tighten all bolts according to Thread Torques.
6. Remove the three screws which secure the inlet baffle assembly (Figure 7-1) to the base and
the two screws which secure it to the inner bulkhead and tilt it out.
MIDDLE LINE ON FLYWHEEL
MUST LINE UP WITH
POINTER IN HOUSING
7. Remove the 4 stator mounting bolts and pull the
stator straight back. (The rotor magnets will resist the motion.)
STATOR INSTALLATION
Installation is the reverse of removal. The stator
leads must be oriented as shown (Figure 11-2). The
stator must sit square within the four guide ears in
the flywheel housing. Tighten all bolts and screws
according to Thread Torques.
CAUTION The rotor magnets can be chipped
by rough handling, especially along the edges.
Guide the stator on and off carefully to avoid
chipping the edges of the magnets.
PULLEY COUNTERWEIGHT
MUST BE DOWN
To prevent loss of magnetism due to shock, protect the rotor from being dropped or struck
while the stator is off, and keep metal chips
away from the rotor.
FIGURE 11-3. ROTOR-CRANKSHAFT ALIGNMENT
11-3
12. Engine
ENGINE SERVICE
ENGINE SENSORS
See Engine Workshop Manual 981−0514 for servicing the engine proper and for adjusting valve clearance (lash), replacing the glow plugs, cleaning the
crankcase breather assembly, replacing the coolant
thermostat and pump and servicing the fuel injection system. See Page 16-1 for starter motor removal. See Periodic Maintenance regarding regular
maintenance.
The engine is equipped with a coolant temperature
sensor and low oil pressure cutout switch (Figure 12-2). The associated fault codes are as follows:
• No. 2—Low Oil Pressure
• No. 23—Oil Pressure Switch Fault
• No. 24—Temperature Sender Fault
• No. 33—High Engine Temperature Fault
Use the flywheel timing mark shown in Figure 12-1
when adjusting valve lash and fuel injector pump
timing. The center line is 20° BTDC. The reference
marks on either side are 4° degrees from the timing
mark.
See Troubleshooting.
TIMING MARK
REPLACING COOLANT PUMP BELT
See Periodic Maintenance for the belt replacement
interval. Since there is no means to adjust belt tension, it is critical that the correct replacement belt be
used. (Belt tension increases slightly as the engine
runs and is sufficient for the relatively light pump
load.)
Using the wrong coolant pump
drive belt can lead to engine overheating.
CAUTION
To remove the belt, remove the negative (−) battery
cable from the battery to prevent accidental starting
of the set during replacement. Remove the 4 bolts
which secure the pump pulley to its hub and pull the
pulley and belt off.
To install a new belt, run the belt over both pulleys
and pull the pump pulley up to its hub and push it on.
Secure the pulley with the 4 bolts and tighten the
bolts according to Thread Torques.
Re-attach negative (−) battery cable to the battery.
FIGURE 12-1. ENGINE TIMING MARKS
12-1
ENGINE REMOVAL
ENGINE INSTALLATION
The engine is mounted on 3 vibration isolator
mounts secured to the skid-base (Figure 12-2). To
remove the engine:
Installation is the reverse of removal.
1. Make sure the air seal ring is in place around
the oil drain hole in the skid-base to seal against
leakage of cooling air and noise.
1. Disconnect the negative (-) battery cable from
the battery to prevent the genset from starting.
Remove the front, top, back and right end housing panels (p. 6-3).
2. Tighten all screws and bolts according to
Thread Torques.
2. Remove the muffler (p. 8-1).
3. Make sure the engine crankcase breather hose
is pushed back through the hole in the inner
bulkhead (p. 9-3).
3. Remove the oil dipstick and disconnect the oil
fill tube from the coolant recovery tank. (If the
oil fill tube is to be removed from the oil pan,
drain the oil first to avoid spillage.)
REPLACING LOW OIL PRESSURE
CUTOFF SWITCH
4. Drain the coolant system, disconnect the hoses
at the engine and remove the radiator and inner
bulkhead (p. 9-1).
1. Disconnect the negative (-) battery cable from
the battery to prevent the genset from starting
and remove the front, top, back and right end
housing panels (p. 6-3).
5. Disconnect the air inlet hose at the resonator
(Figure 7-1).
6. Disconnect the PMA stator leads (Figure 11-2).
2. Remove the muffler (p. 8-1).
7. Disconnect the engine harness from the controller/inverter assembly and fuel pump.
3. Disconnect the the PMA stator leads (Figure
11-2) to prevent strain when the inner bulkhead
is tilted.
8. Disconnect the skid-base ground strap from
the flywheel housing.
4. Remove the screw that secures the coolant
drain “T” (p. 9-3), the two screws in the horizontal portion of the bulkhead that projects under
the radiator and the screw that secures the radiator to the controller/inverter assembly.
9. Disconnect the battery harness from the engine.
CAUTION Using only one lifting eye will
cause the unit to rotate and drop, causing
severe equipment damage and possible
personal injury.
5. Lift and tilt the inner bulkhead until the switch is
accessible.
10. Attach a hoist at both the flywheel housing lifting eye and the front engine lifting eye.
6. Disconnect the lead and remove the switch.
11. Remove the three isolator-mount center bolts
and lift the engine/PMA assembly away.
Reassembly is the reverse of removal. Use thread
sealant and tighten according to Thread Torques.
Make sure the engine crankcase breather hose is
pushed back through the hole in the inner bulkhead
(p. 9-3).
12. Remove the cooling blower, PMA stator, rotor
and flywheel housing from the engine (Figure
11-2).
12-2
HOT COOLANT OUTLET AND
THERMOSTAT HOUSING
COOLANT PUMP
DRIVE PULLEY
AND BELT
GOVERNOR
ACTUATOR
CRANKCASE BREATHER
FILTER HOUSING AND
DISCHARGE TUBE
STARTER
MOTOR AND
SOLENOID
OIL FILL
TUBE
OIL
FILTER
COOLANT
TEMPERATURE
SENDER
COOLANT PUMP
INLET
LOW OIL PRESSURE
CUTOFF SWITCH
AIR SEAL
AROUND OIL
DRAIN PLUG
OIL PAN
FIGURE 12-2. ENGINE AND ACCESSORIES
12-3
1 OF 3 ENGINE
MOUNTS
13. Governor Actuator
GENERAL
Installation is the reverse of removal. Note the following:
The governor actuator (Figure 13-1) is powered by
the genset controller to position the fuel rack (Figure
13-2) according to load demand.
1. Use a long-nose pliers to rehook the governor
spring to the actuator high-idle speed control
lever.
Note: The engine governor used with these gensets
has 4 steel balls (Figure 13-2) instead of the 8 shown
in the engine Workshop Manual.
2. Apply a liquid-type gasket (Three Bond 1215 or
equivalent) to both sides of the new gasket between the engine gear cover and actuator
base.
ACTUATOR REMOVAL
3. Tighten the four base mounting screws according to Thread Torques.
1. Disconnect the negative (-) battery cable from
the battery to prevent the genset from starting
and remove the front housing panel (p. 6-3).
4. Adjust the actuator speed control lever stop
(beginning Spec B) before installing the rotor
(p. 13-4).
2. Disconnect the two leads from the engine harness and remove the cover.
5. Install the rotor using a new retainer ring. Note
that the ring is concave (dished). Push the
dished side down against the rotor to keep it in
place on the shaft.
Uncontrolled release of spring
tension can cause eye damage. Wear safety
glasses with side shields when removing
spring.
WARNING
6. Install the stator and bearing carrier. Tighten
the four mounting screws according to Thread
Torques.
3. Use a screwdriver to pry the leg of the fuel rack
return spring out of its slot in the bearing carrier.
Be prepared to catch the spring from flying off.
The genset may not stop reliably on command if the fuel rack return
spring is not assembled properly.
CAUTION
4. Remove the four stator screws and lift off the
bearing carrier and stator.
5. Pry the rotor off the shaft.
7. Check the fuel rack return spring for wear and
replace it if worn. This spring returns the fuel
rack to the no-fuel position. Push the spring on
over the flat on the shaft and then pry the leg
into its slot in the bearing carrier (Figure 13-1).
The extension below the knee must catch under the bearing carrier. Finally, push the spring
down as far as it will go on the shaft.
6. Remove the four screws that secure the base
to the top of the engine gear cover. Note that
there are copper washers under the two inboard screw heads. These washers seal
against oil seepage since these screw holes
run through into the gear case.
7. Unhook the governor spring from the actuator
high-idle speed control lever (top lever) while
lifting the actuator assembly away.
8. Readjust high-idle speed (p. 13-5).
9. Snap the cover onto the actuator and then secure a wire tie around the actuator and cover to make sure the cover stays in place.
ACTUATOR INSTALLATION
Note: The actuator base assembly used for gensets
beginning Spec B is the replacement part also for
Spec A gensets.
10. Reconnect the two leads from the engine harness.
13-1
SPRING, SHAFT, BEARING ASSEMBLY
SNAP-ON
COVER
ROTOR
RETAINER
RING
FUEL
RACK
RETURN
SPRING
ROTOR
SHAFT
BEARING
CARRIER
TERMINALS
STATOR
FIGURE 13-1. GOVERNOR ACTUATOR
13-2
ACTUATOR HIGH-IDLE
SPEED CONTROL
LEVER
FUEL INJECTION
PUMP ASSEMBLY
FUEL RACK
CONTROL ROD
ACTUATOR SPEED
CONTROL LEVER
4-BALL
GOVERNOR
HIGH-IDLE
STOP SCREW
FIGURE 13-2. INTERNAL GOVERNOR PARTS
13-3
GOVERNOR
SPRING
ACTUATOR SPEED CONTROL LEVER
STOP (BEGINNING SPEC B)
The actuator speed control lever stop (Figure 13-3)
must be adjusted whenever a different actuator
base assembly is installed. The stop screw, rather
than the fuel rack control lever, must stop the speed
control linkage when the fuel rack is driven to the nofuel position (to the right, as shown in Figure 13-2).
Actuator Rotor Not In Place
1. Assemble the actuator stator and bearing carrier to the base so that the shaft will be supported
in its bearing.
2. Loosen the stop screw locknut and back the
screw out a few turns. (Top one in the group of
three.)
3. Turn the stop screw in until it just makes contact. Turn the screw one more full turn in and set
the locknut.
4. Remove the bearing carrier and stator and
complete reassembly with the rotor in place.
ACTUATOR SPEED
CONTROL LEVER
STOP SCREW
FIGURE 13-3. ACTUATOR SPEED CONTROL LEVER STOP (BEGINNING SPEC B)
Actuator Rotor In Place
1. Loosen the stop screw locknut and back the
screw out a few turns. (Top one in the group of
three.)
2. Turn the stop screw in until it just makes contact
and set the locknut.
13-4
HIGH-IDLE SPEED
B. Adjust high-idle speed by turning the adjusting screw and set its lock nut.
High-idle speed must be readjusted each time the
governor actuator base or the fuel injector pump is
installed.
C. Run the clamping screw back in by hand
until snug, back it out 1-1/2 turns and set its
lock nut.
WARNING This adjustment involves operating
the genset without a housing panel in place. The
panels guard against rotating parts and bare
live electrical parts that can cause severe personal injury or death. Keep your hands, clothing, and jewelry away from the engine pulleys,
blower blades and electrical terminal block TB3
on the controller/inverter housing (Figure 10-1).
8. Let the rotor go. The genset should stop and
display a fault code. Restart the genset and recheck high idle speed. Readjust if necessary.
Note: The genset will only run a few minutes before shutting down because the controller has
shut down the fuel pump.
1. Remove the front housing panel (p. 6-3).
2. Set up a tachometer to indicate engine speed.
(If the tachometer has to be held or adjusted
while taking a reading, it will take two people to
make this adjustment.)
3. Remove the actuator cover and reconnect the
leads.
4. Start the genset and push the actuator rotor
clockwise by hand as far as it will go (about 1/2
inch [12 mm]) and hold it there. (It may be easier to use a wrench on the flat at the top of the
shaft to hold the rotor position.) Make sure the
fuel rack return spring is in place on the rotor
shaft to shut down the genset if you lose hold.
PUSH HERE
TO ROTATE
ROTOR
SPEED ADJUSTING
SCREW ACCESS
(2.5 MM ALLEN HEAD)
FIGURE 13-4. HIGH-IDLE SPEED ADJUSTMENT
(SPEC A)
Do not let engine speed exceed
3600 rpm. PMA voltages caused by higher
speeds can damage the controller/inverter.
CAUTION
5. Adjust high-idle speed to 3500-3600 rpm:
6. Spec A: (Figure 13-4)
A. If the genset hunts under full load, see
HIGH IDLE STOP SCREW ADJUSTMENT (p. 13-6).
PUSH HERE
TO ROTATE
ROTOR
B. Adjust high-idle speed by turning the adjusting screw (2.5 mm allen head).
SPEED
ADJUSTING
SCREW
7. Beginning Spec B: (Figure 13-5).
A. Loosen the lock nuts on the two screws in
the bottom row and remove the clamping
screw.
CLAMPING
SCREW
FIGURE 13-5. HIGH-IDLE SPEED ADJUSTMENT
(BEGINNING SPEC B)
13-5
HIGH-IDLE STOP SCREW
2. Adjust the high-idle stop screw in the front of the
engine to obtain a speed of 3550 to 3590 rpm,
while holding the actuator fully clockwise, and
set the jam nuts.
On Spec A engines prior to 1997 adjust the high-idle
stop screw (Figure 13-6) if the genset hunts under
full load.
1. Back off high-idle speed in accordance with
Steps 4 and 5 of the HIGH-IDLE SPEED adjustment procedure (p. 13-5) to less than
3300 rpm.
3. Readjust high-idle speed according to Step 5
of the HIGH-IDLE SPEED adjustment procedure (p. 13-5).
HIGH-IDLE
STOP SCREW
FIGURE 13-6. HIGH-IDLE STOP SCREW (SPEC A PRIOR TO 1997)
13-6
14. Fuel System
GENERAL
Removal and Installation
Figure 14-1 shows two views of the fuel filter, pump
and hoses for delivering fuel to and from the fuel injection system.
The fuel pump mounting screws are accessible
from below the skid-base and the fuel pump is removeable through the maintenance access door.
Unless provision has been made to provide access
to these screws, the genset will have to be tilted up
or removed from the vehicle.
Diesel fuel is combustible and can
cause severe personal injury or death. Do not
smoke near fuel tanks or fuel-burning equipment or are in an area sharing ventilation with
such equipment. Keep flames, sparks, pilot
flames, electrical arcs and switches and other
sources of ignition well away. Keep a type ABC
fire extinguisher handy.
WARNING
When installing a fuel pump make sure the air seal is
placed around the fuel inlet fitting to seal against
leakage of cooling air and noise. Tighten all screws
according to Thread Torques.
Thread Sealant and Fuel Line Fittings
Always wipe dirt off fuel fittings before disconnecting them to keep dirt from entering the fuel system.
CAUTION
The fuel line between the fuel pump and fuel filter
has flare fittings. Do not use any type of thread
sealant on flare fittings.
FUEL PUMP
The connections for fuel supply and return that extend through the side of the base are pipe thread fittings. For these fittings use liquid-type pipe thread
sealant Listed as suitable for diesel fuel. Apply the
sealant sparingly to the male threads only.
Fuel Flow Test
1. Disconnect the fuel return hose from the line to
the supply tank and point the end into a quart
(1 liter) or larger container that has volume
graduations.
CAUTION
Excess liquid-type pipe thread
sealant or pieces of teflon-type pipe thread sealant can plug the engine fuel system. Apply liquid-type pipe thread sealant sparingly to the
male threads only. Do not use teflon tape.
2. Prime the genset by pushing the Start/Stop
switch to STOP and holding it there for the
duration of the test. Flow should not be less
than 200 ml (0.4 pints) per minute.
3. If flow is less than specified:
FUEL FILTER
A. Replace the fuel filter.
The fuel filter is mounted on a bracket just above the
maintenance access door in the skid-base. See Periodic Maintenance for the filter replacement interval.
B. Check for other restrictions in the fuel
lines.
C. Check for air bubbles in the fuel. Tighten
fittings and replace fuel lines as necessary.
Replace a cracked fuel filter body.
FUEL INJECTION SYSTEM
See the Engine Workshop Manual for fuel injection
system service.
D. Replace the fuel pump.
14-1
INJECTOR
RETURN
LINE
INJECTOR
PUMP
SUPPLY
FUEL SUPPLY
FITTING
FUEL PUMP
SHIELD
FUEL
FILTER
FUEL PUMP
FUEL FILTER
BRACKET
MOUNTING
SCREWS
PUMP TO
FILTER LINE
FUEL RETURN
FITTING
AIR SEAL
PUMP
MOUNTING
SCREWS
FIGURE 14-1. FUEL DELIVERY SYSTEM
14-2
15. Battery Charger
REMOVAL
and remove the front, top and left end housing
panels (p. 6-3).
The battery charger is optional. The charger and its
transformer are mounted on the skid-base as
shown in Figure 15-1.
2. Remove the battery charger.
3. Remove the controller/inverter assembly (Figure 10-1), the cooling blower (Figure 11-2) and
the air intake hoses from the back of the air filter
housing (Figure 7-1).
Battery Charger Removal
1. Disconnect the negative (-) battery cable from
the battery to prevent the genset from starting
and remove the front housing panel (p. 6-3).
4. Disconnect the quick connectors in the two remaining leads (four leads altogether).
2. Disconnect the quick-connectors in the two
leads to the transformer and disconnect the
third lead at the starter solenoid.
5. Remove the two mounting screws.
INSTALLATION
3. Remove the mounting screw.
Transformer Removal
Installation of the battery charger and transformer is
the reverse of removal. Tighten all screws according to Thread Torques.
1. Disconnect the negative (-) battery cable from
the battery to prevent the genset from starting
TRANSFORMER
BATTERY CHARGER
FIGURE 15-1. BATTERY CHARGER AND TRANSFORMER
15-1
16. Starter Motor
REMOVAL
See Figure 16-1. To remove the starter motor assembly from the genset:
1. Disconnect the negative (-) battery cable from
the battery to prevent the genset from starting.
2. If the genset is installed in the vehicle and does
not have an access door in the front panel,
open the maintenance access door in the skidbase and remove the fuel filter and its mounting
bracket (Figure 14-1).
WARNING Diesel fuel is combustible and
can cause severe personal injury or death.
Do not smoke. Keep flames, sparks, pilot
lights, electrical arcs and arc-producing
equipment and all other sources of ignition
well away. Keep a type ABC fire extinguisher handy.
3. If the genset has been removed from the vehicle, remove the front housing panel (p. 6-3).
(If the genset has an access door in the front
panel, remove the access door instead.)
4. Disconnect all wires and cables from the motor
terminals.
5. Remove the two starter mounting bolts and remove the starter.
INSTALLATION
Installation is the reverse of removal. Tighten bolts
and terminals according to Thread Torques.
FIGURE 16-1. STARTER MOTOR AND SOLENOID
16-1
STARTER SOLENOID REPLACEMENT
3. Using a heavy cable from the negative (−) terminal on the battery, briefly touch the mounting
flange on the motor.
WARNING This test involves high electrical
currents, strong arcing and moving parts that
can cause severe personal injury. Do not conduct this test near fuel tanks or when flammable
vapors are present. Wear safety glasses. Keep
fingers away from the pinion gear.
A. If the motor does not spin up quickly and
smoothly, replace the motor/solenoid assembly.
The starter solenoid is separately replaceable. To
determine whether the problem is in the solenoid or
in the motor:
B. If the motor does spin up quickly and
smoothly, the motor is probably okay: replace the solenoid.
1. Secure the motor assembly in a vice after it has
been removed from the genset.
C. The solenoid is removeable by disconnecting the motor lead from the solenoid
terminal and removing the two solenoid
mounting nuts. When installing a new solenoid, make sure the solenoid plunger engages the shift fork.
2. Using a heavy jumper cable, because of the
large currents involved, connect the motor terminal on the solenoid (the one closest to the
motor) to the positive (+) terminal on a 12 volt
battery.
16-2
17. Service Checklist
GENERAL
EXHAUST SYSTEM
After servicing, inspect and test the installation to
confirm that the genset will operate as intended.
Check each of the areas described below before
putting the genset into service.
While the genset is running inspect the entire exhaust system. Look and listen for leaks at all connections, welds, gaskets and joints. Also make sure
the exhaust pipe is not overheating adjacent materials or equipment. Do not run the genset until all exhaust leaks have been repaired.
HOUSING
WARNING Exhaust gas is deadly. The exhaust
system must not leak and must discharge all exhaust away from the vehicle. Do not run the genset until the exhaust leaks have been repaired.
Check to see that all housing panels and access
covers are in place and secure (p. 6-3).
MOUNTING
Examine all mounting bolts and supporting members to verify that the genset is properly mounted.
All fasteners should be tightened securely to prevent them from working loose when subjected to
vibration.
The exhaust tailpipe must be supported by a
hanger near the vehicle perimeter and terminate
at least 1 inch outside the perimeter and at least
1 foot from doors and windows.
FUEL SYSTEM
LUBRICATION
While the genset is running, inspect the fuel supply
and return lines, filter and fittings for leaks. Check
flexible sections for cuts, cracks and abrasions and
make sure they are not rubbing against anything
that could cause leakage. Repair all fuel leaks immediately.
If the engine oil was drained, refill as instructed in
Periodic Maintenance.
COOLING SYSTEM
If the engine coolant was drained, refill as instructed
in Periodic Maintenance.
Diesel fuel is combustible. Leaking
fuel could lead to fire and to severe personal injury or death. Repair fuel leaks immediately.
WARNING
WIRING
Verify that all wiring connections are tight and
installed properly. Check each of these connections:
CONTROL
Stop and start the genset several times at the control panel on the genset and at the remote control
board (if provided) to verify that they work properly.
• Load wires
• Control wires
MECHANICAL
• Ground straps
Stop the genset and inspect it for leaking gaskets,
loose fasteners, damaged components and interference with other equipment. Repair as necessary.
Inspect the generator compartment and verify that
there are no breaks or openings in the vapor-proof
wall that separates the compartment from the vehicle interior. Seal openings as necessary. Make
sure that all soundproofing material is in place.
• Battery cables
OUTPUT CHECK
Apply a full load to make sure the genset can produce its full rated output. Use a load test panel to apply a progressively greater load until full load is
reached.
17-1
18. Troubleshooting
TROUBLESHOOTING WITH TABLE 18-1
blink-blink-blink—pause—blink-blink-blink
—longer pause—
blink-blink-blink—pause—blink-blink-blink—...
To aid troubleshooting the genset controller causes
the status indicator light to blink the numeric code
assigned to the fault that caused shutdown. For a
brief description of the fault and step-by-step corrective action, refer to TABLE 18-1. TROUBLESHOOTING, which lists the fault codes in numerical
order.
RESTORING FAULT CODE BLINKING
The fault code stops blinking after five minutes.
Prior to Spec F, one touch to Stop restores fault
code blinking. Beginning Spec F, 3 touches to Stop
are required (also earlier Spec gensets with newer
replacement controller-inverter assemblies).
Many genset shutdowns can be avoided by performing periodic maintenance on schedule (TABLE 5-1.
PERIODIC MAINTENANCE SCHEDULE) and by not
running the genset out of fuel. Note that when the
genset and propulsion engine draw from the same
fuel tank, the fuel dip tubes are usually arranged so
that the genset will run out of fuel first. By marking
the genset empty point on the fuel gauge, it will be
easier to tell when the genset may run out of fuel.
NOTE: The last fault logged will blink even though
the condition that caused the shutdown may have
been corrected.
BYPASSABLE FAULTS: PRIOR TO SPEC F
When a fault condition persists, the genset shuts
down when an attempt is made to restart. Prior to
Spec F, (unless the controller assembly has been
replaced) there are four faults the genset controller
will bypass on a second attempt at restart:
FAULT CODE BLINKING
At fault shutdown, the status indicator light will repeatedly blink sets of 1, 2 or 3 blinks.
• No. 17—fuel pump fault
• No. 18—glow plug fault
• One blink indicates shutdown due to high engine coolant temperature.
• No. 23—oil pressure switch fault
• No. 24—temperature sender fault.
• Two blinks indicate shutdown due to a loss of
engine oil pressure.
Before making the second attempt at starting the
genset, however, consider the following:
• Three blinks is code for shutdown due to some
other abnormal condition.
• As long as the ambient temperature is greater
than 77° F (25° C), a glow plug fault (No. 18) will
not affect starting or operation. As the ambient
temperature keeps dropping, however, the
genset will eventually fail to start.
For a 1-blink or 3-blink fault code, one touch to Stop
brings up a second-level fault code. This code consists of 1, 2, 3 or 4 or blinks, a brief pause, and then
1 to 9 blinks. The first set of blinks represents the
tens digit and the second set of blinks the units digit
of the fault code number in Table 18-1. For example,
Fault Code No. 23 would be:
• Bypassing an oil pressure switch fault (No. 23)
or temperature sender fault (No. 24) could lead
to serious engine damage if the oil pressure
fails or the engine overheats.
blink-blink—pause—blink-blink-blink—...
Operating the genset under oil
pressure switch or temperature sender
fault conditions can lead to serious engine
damage. Read the Warranty regarding possible exclusions when operating the genset
under such conditions.
CAUTION
NOTE: Consciously avoid mistaking Fault Codes 11,
22 and 33 for Fault Codes 1, 2 and 3. The pauses between repetitions of the fault code are longer than the
pauses between the tens and units digits of the the
code. For example, Fault Code 33 would be:
18-1
TABLE 18-1. TROUBLESHOOTING
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
GENSET WON’T STOP RUNNING—STATUS INDICATOR LIGHT ON
(Faulty Stop Switch or grounded wiring)
@@@@
WARNING Removing genset panels or disconnecting fuel lines to stop a genset that won’t stop
can lead to severe personal injury or death from electrocution, contact with moving parts or fire.
• Try the genset Stop Switch if the remote Stop Switch does not work and vice versa.
• If possible, pinch flexible fuel hoses until the genset stops.
• Otherwise, let the genset run out of fuel before attempting service.
Corrective Action:
1. Try the genset Stop Switch if the remote Stop Switch does not work, and vice versa. If only the genset
Stop Switch works, go to Step 2. If neither switch works, or only the remote Stop Switch, go to Step 3.
2. Disconnect the remote control panel connector (J8/P8). While pressing the Remote Stop Switch,
check for electrical continuity between remote control connector pins J8-A and J8-E. Replace a
switch that does not close when pressed to Stop and repair or reconnect wiring as necessary.
3. Remove the front and top housing panels (p. 6-3) and disconnect engine harness connector P2 from
the controller (Figure 10-1, p. A-1, A-4). Reconnect the remote control panel (J8/P8) and while
pressing the respective Stop Switch, check for electrical continuity between:
A. Pin P2-3 (remote stop) and pin P2-2 (remote ground).
B. Pin P2-10 (local stop) and pin P2-11 (local ground).
C. Replace a switch that does not close when pressed to Stop, check for missing, bent or corroded
terminals and connector pins and repair or reconnect wiring as necessary.
4. Replace the controller assembly (p. 10-1).
GENSET WON’T STOP RUNNING—STATUS INDICATOR LIGHT OFF
(Binding governor mechanism, misadjusted speed stop)
@@@@
WARNING Removing genset panels or disconnecting fuel lines to stop a genset that won’t stop
can lead to severe personal injury or death from electrocution, contact with moving parts or fire.
• Try the genset Stop Switch if the remote Stop Switch does not work and vice versa.
• If possible, pinch flexible fuel hoses until the genset stops.
• Otherwise, let the genset run out of fuel before attempting service.
Corrective Action:
1. Remove the front and top housing panels (p. 6-3) and check the fuel rack return spring and replace
it if worn or broken (Figure 13-1). Make sure it is reassembled correctly.
2. Check for binding in the governor mechanism by pushing the actuator rotor clockwise by hand—
against the action of the fuel rack return spring. It should rotate smoothly about 1/2 inch (12 mm) and
return smoothly. If it binds or catches, remove the governor actuator base assembly and replace it
or service the internal engine governor mechanism (Figure 13-2) as necessary.
3. Readjust the actuator speed control lever stop so that the fuel rack can go to no-fuel (p. 13-4).
18-2
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
STATUS INDICATOR LIGHT STAYS ON
(Reversed battery connections)
Corrective Action: Reconnect the battery correctly.
ENGINE CRANKS WHEN BATTERY CONNECTED
(Faulty Start Switch or grounded wiring)
Corrective Action:
1. Disconnect the remote control panel connector (J8/P8). Check for electrical continuity between remote control connector pins J8-A and J8-C. Replace a switch that does not open when released and
repair or reconnect wiring as necessary.
2. Remove the front and top housing panels (p. 6-3) and disconnect engine harness connector P2 from
the controller (Figure 10-1, p. A-1, A-4). Reconnect the remote control panel (J8/P8) and check for
electrical continuity between:
A. Pin P2-1 (remote start) and pin P2-2 (remote ground).
B. Pin P2-12 (local start) and pin P2-11 (local ground).
C. Replace a switch that does not open when released and repair or reconnect wiring as necessary.
3. Replace the controller assembly (p. 10-1).
ENGINE WON’T CRANK—FUEL PUMP WON’T STOP
(Faulty Stop Switch or grounded wiring)
Corrective Action:
1. Disconnect the remote control panel connector. Check for electrical continuity between remote control connector pins J8-A and J8-E. Replace a switch that does not open when released and repair
or reconnect wiring as necessary.
2. Remove the front and top housing panels (p. 6-3) and disconnect engine harness connector P2 from
the controller (Figure 10-1, p. A-1, A-4). Reconnect the remote control panel (J8/P8) and check for
electrical continuity between:
A. Pin P2-3 (remote stop) and pin P2-2 (remote ground).
B. Pin P2-10 (local stop) and pin P2-11 (local ground).
C. Replace a switch that does not open when released and repair or reconnect wiring as necessary.
3. Replace the controller assembly (p. 10-1).
18-3
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
STATUS INDICATOR LIGHT DEAD
(Faulty connections, no battery voltage)
Corrective Action:
1. Try the genset Start Switch if the remote Start Switch does not work, and vice versa. Disconnect the
remote control panel (J8/P8) and try the genset Start Switch again. If nothing works, go to Step 2.
If only the genset start switch works, go to Step 9. If only the remote start switch works, go to Step 12.
2. Replace Fuse F1 (B+) if blown.
3. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery, vehicle
frame and genset.
4. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
5. Remove the front and top housing panels (p. 6-3). Check that all engine and battery harness wires
(p. A-1, A-3) are properly connected to the grounding bolt on the flywheel housing, to the B+ terminal
on the starter solenoid and to the battery terminal block (p. A-3). Clean and tighten connections and
replace wiring as necessary.
6. Disconnect engine harness connector P1 from the controller (Figure 10-1, p. A-1, A-4). Check for
B+ (12 VDC) at pin P1-8 and for continuity to ground at pin P1-7. Check for missing, bent or corroded
connector pins and faulty wiring and repair as necessary.
7. Disconnect engine harness connector P2 from the controller (Figure 10-1, p. A-1, A-4) and reconnect the remote control panel (J8/P8). Press the switch and check for electrical continuity between:
A. Pin P2-1 (remote start) and pin P2-2 (remote ground).
B. Pin P2-3 (remote stop) and pin P2-2 (remote ground).
C. Pin P2-12 (local start) and pin P2-11 (local ground).
D. Pin P2-10 (local stop) and pin P2-11 (local ground).
E. Replace switches that do not close when pressed, check for missing, bent or corroded terminals
and connector pins and faulty wiring and repair as necessary.
8. Replace the controller assembly (p. 10-1).
9. Disconnect the remote control panel (J8/P8). Check for electrical continuity between remote control
connector pins J8-A and J8-C. Replace a switch that does not close when pressed and repair or reconnect wiring as necessary.
10. Remove the front and top housing panels (p. 6-3) and disconnect engine harness connector P2 from
the controller (Figure 10-1, p. A-1, A-4) and reconnect the remote control panel (J8/P8). Press the
switch, check and for electrical continuity between:
A. Pin P2-1 (remote start) and pin P2-2 (remote ground).
B. Pin P2-3 (remote stop) and pin P2-2 (remote ground).
C. Replace a switch that does not close when pressed, check for missing, bent or corroded terminals and connector pins and faulty wiring and repair as necessary.
11. Replace the controller assembly (p.10-1).
12. Remove the front and top housing panels (p. 6-3) and disconnect engine harness connector P2 from
the controller (Figure 10-1, p. A-1, A-4). Press the switch and check for electrical continuity between:
A. Pin P2-12 (local start) and pin P2-11 (local ground).
B. Pin P2-10 (local stop) and pin P2-11 (local ground).
C. Replace a switch that does not close when pressed, check for missing, bent or corroded terminals and connector pins and faulty wiring and repair as necessary.
13. Replace the controller assembly (p.10-1).
18-4
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
STARTING BATTERIES RUN DOWN
(Marginal battery, battery connections or charging system or parasitic loads)
Corrective Action:
1. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery, vehicle
frame and genset.
2. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
3. Install or service a battery charging system in the vehicle if the genset is not so equipped.
4. If the genset is equipped with a battery charging system, check performance by measuring voltage
across the battery terminals while running the genset. Watch the meter while turning the genset circuit breaker (operator’s console) on and off several times. The battery charger is probably okay if
voltage jumps to more than 12 VDC each time the breaker is turned on. Check for parasitic loads
external to the genset and/or replace the battery.
5. If the battery charger does not seem to be working, remove the front housing panel (p. 6-3). If loose,
reconnect battery charger transformer input connectors J12 and J13 to the AC harness (p. A-2, A-4),
output connectors J14 and J15 to the battery charger (p. A-4) and the battery charger output lead
to the B+ terminal on the starter solenoid.
6. Disconnect transformer connectors J12 through J15 and check winding continuity across J12−J13
and across J14−J15. Replace the transformer if a winding is open (p. 15-1).
7. Reconnect J12 and J13 and run the genset. Replace the battery charger if transformer output across
J14−J15 is approximately 16.3 VAC. If not, go to Step 8.
8. Disconnect J12 and J13 and measure voltage. Replace the transformer if there is approximately 120
VAC across J12−J13. If not, go to Step 9.
9. Replace or repair wiring in the AC harness if there is no voltage.
@@@@
WARNING This test involves operating the genset with housing panels removed. The panels guard against rotating parts and bare live electrical parts that can cause severe personal
injury or death. Keep your hands away from the engine pulleys, blower blades and electrical
terminal block TB3 on the controller housing (Figure 10-1).
18-5
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
ENGINE CRANKS BUT DOES NOT START
(Fuel delivery, glow plugs or engine are marginal)
Corrective Action:
1. Check fuel level. (Note: The genset fuel pickup is probably higher than the vehicle engine pickup.)
2. Prime the engine fuel system.
3. Check the engine air filter and remove any blockage.
4. Replace Fuse F3 (glow plugs) if blown. If it blows again, go to Step 8.
5. Check for fuel and air leaks at each fitting in the fuel supply line. (Note: White smoke indicates air
in the fuel.)
6. Conduct a fuel flow test and service as necessary (p. 14-1).
7. Remove the top housing panel (p. 6-3) and observe the governor actuator rotor (Figure 13-1) while
cranking. (Remember to reattach the leads after removing the cover.) The rotor should rotate
smoothly through about 1/2 inch (12 mm). If it does not, check for binding in the governor mechanism
by pushing the actuator rotor clockwise by hand—against the action of the fuel rack return spring.
It should rotate smoothly about 1/2 inch (12 mm) and return smoothly. If it binds or catches, remove
the governor actuator base assembly and replace it, or service the internal engine governor mechanism (Figure 13-2), as necessary.
8. Remove the front and top housing panels (p. 6-3) and check out the glow plug system as follows:
A. If the glow plugs are not working, it can be the result of a failed temperature sensor which results
in a no start.
B. If loose, reconnect spade connector HR-1 to the glow plug bus bar at the front of the engine,
engine harness connectors A1-J7 and A1-J8 to the leads from the controller assembly (Figure 10-1, p. A-1, A-4), and the engine harness ground connections to the flywheel housing.
C. Disconnect HR-1 from the glow plug bus bar and A1-J8 from the controller assembly (p. 10-1).
Check for continuity (ground short) between either connector and ground. Replace wiring as
necessary.
D. Remove the glow plug bus bar along side the engine valve cover and check for electrical continuity between each glow plug terminal and ground. Replace any open glow plug (p. 12-1).
Note: If a glow plug does not come out after unscrewing it, or the end has broken off, it will
be necessary to remove the engine head. Glow plugs can swell if preheat voltage is greater than 14 volts, such as when a battery booster is used for starting.
E. Check for B+ on the glow plug bus bar while pressing Start. Replace the controller assembly
if B+ is not available for preheat in accordance with Table 10-1.
9. Service the engine (p. 12-1).
18-6
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
STARTER ENGAGES-DISENGAGES
(Cranking voltage dips below 6 volts—low battery charge, poor connections, long cables)
Corrective Action:
1. Have the vehicle propulsion engine running while trying to start the genset—the battery charging
alternator may be able to maintain starting voltage high enough to get the genset started.
2. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery, vehicle
frame and genset.
3. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
4. Increase battery cable size or run parallel cables.
5. Remove the front and top housing panels (p. 6-3) Check that all engine and battery harness wires
(p. A-1, A-3) are properly connected to the grounding bolt on the flywheel housing, to the B+ terminal
on the starter solenoid and to the battery terminal block (p. A-3). Clean and tighten connections and
replace wiring as necessary.
6. Disconnect engine harness connector P1 from the controller (Figure 10-1, p. A-1, A-4). Check for
B+ (12 VDC) at pin P1-8 and for continuity to ground at pin P1-7. Check for missing, bent or corroded
connector pins and faulty wiring and repair as necessary.
NO POWER—GENSET RUNNING, RUN LIGHT ON
(Line circuit breaker OFF or tripped or faulty wiring)
Corrective Action:
1. Reset or turn “On” the line circuit breaker on the genset operator’s console.
2. Reset or turn “On” the line circuit breakers on the main distribution panel in the vehicle.
3. Check the voltage at genset AC output terminal block TB2. If there is approximately 120 VAC across
TB2-1 and TB2-3 and across TB2-2 and TB2-4, repair or reconnect the wiring between the genset
and the vehicle. If there is no voltage, go to Step 4.
4. Remove the front and top housing panels (p. 6-3) and check for proper AC harness connections at
TB3, TB2 and the line circuit breakers (Figure 10-1, p. A-2, A-4). Reconnect wiring as necessary and
tighten all terminal screws and nuts.
5. Check for electrical continuity across the terminals of each breaker (p. A-2). Replace a circuit breaker which lacks electrical continuity when “On”.
6. Run the genset and measure voltages. If there is approximately 120 VAC across TB3-1 and TB3-2,
replace the AC wiring harness. If there is no voltage, replace the controller assembly (p. 10-1).
@@@@
WARNING This test involves operating the genset with housing panels removed. The panels guard against rotating parts and bare live electrical parts that can cause severe personal
injury or death. Keep your hands, clothing, jewelry, and hair away from the engine pulleys,
blower blades and electrical terminal block TB3 on the controller housing (Figure 10-1).
18-7
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
GENSET HUNTS UNDER FULL LOAD
(Fuel delivery marginal, governor misadjusted)
Corrective Action:
1. Prime the engine fuel system by holding the control switch down in its Stop position for at least 1 minute.
2. Check for fuel and air leaks at each fitting in the fuel supply line.
3. Conduct a fuel flow test and service as necessary (p. 14-1).
4. Connect a source of known fuel quality, prime the fuel system, and run the genset. If performance
improves, replace the bad fuel in the supply tank.
5. Readjust high-idle speed (p. 13-5).
HIGH TEMPERATURE—FAULT CODE NO. 1
(Engine coolant or inverter heat sink temperature exceeded design limit)
Corrective Action: Check the second-level fault code by touching Stop. The second-level fault will be
either No. 33 or No. 34.
LOW OIL PRESSURE—FAULT CODE NO. 2
(Low oil pressure cutoff switch did not open)
Corrective Action:
1. Check engine oil level and add oil as necessary.
2. Drain excess oil (above dipstick Full mark).
3. Remove the top housing panel (p. 6-3). Reconnect engine harness spade connector S2 to the low
oil pressure cutout switch (Figure 12-2) if it is loose (short to ground will cause shutdown).
4. Disconnect engine harness connector P2 (p. A-1) from the controller assembly (Figure 10-1) and
the pressure switch. Check both ends for electrical continuity to ground. Replace wiring as necessary
if the lead is shorted to ground.
5. Install an oil pressure gauge in place of the pressure switch and observe oil pressure after the engine
has run a few minutes (let RV models step down to low idle speed). Replace the low oil pressure
cutoff switch if engine oil pressure is 14 psi (98 kPa) or greater. Service the engine if engine oil pressure is less than 14 psi (98 kPa). (Simulate normal switch operation to keep the genset running during the test by starting with connector S2 grounded and removing it from ground when the engine
starts.)
@@@@
WARNING This test involves operating the genset with housing panels removed. The panels guard against rotating parts and bare live electrical parts that can cause severe personal
injury or death. Keep your hands, clothing, jewelry, and hair away from the engine pulleys,
blower blades and electrical terminal block TB3 on the controller housing (Figure 10-1).
18-8
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
SERVICE CHECK FAULT—CODE NO. 3
(A second-level fault occurred)
Corrective Action: Check the second-level fault code by touching Stop. The second-level fault will be
one of the following in this table. See Page 18-1 for a description of how the fault code blinks.
SERVICE CHECK FAULT—CODE NO. 4
(Begin Spec K)
Corrective Action: Set has been commanded to crank, and cranks for a total of 35 seconds continuous, without the set starting (speed exceeding − 1200 RPM) Typical troubleshooting should be related
to an out of fuel condition (see FC36) − check fuel flow and return, actuator operation, wiring, etc.
OVERLOAD—CODE NO. 8
(Models HDKAH & HDKAV only: Load exceeded110 percent of genset rating for 2 minutes)
Corrective Action: Reduce load and restart
18-9
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
OVERCURRENT FAULT—CODE NO. 11
(AC output short)
Logic: If inverter is enabled and inverter short circuit is indicated for > 3 counts.
Corrective Action:
1. Turn−off the genset line circuit−breaker. If the genset no longer shuts down, the genset is probably
okay − check for and repair a short−circuit in the vehicle, wiring or shorted battery−charger transformer.
• Short Circuit Test:
− Check resistance across inverter output terminals (with and without breaker).
− Meter should read ’Open’ if there are no shorts.
− If meter reads a low resistance value, it indicates a short either in wiring and/or loads.
2. Remove battery charger loads and transfer switch/es connected directly to the inverter output. Also
remove any motor starting loads such as Air conditioners, Vacuum cleaners etc.
Note: If this step resolves the issue, check to see if there are any issues with specific loads.
3. Check whether the vehicle engine and genset share the same starting battery, if so and this fault
occurs when cranking the vehicle engine, low battery voltage maybe causing this shutdown. Increase battery capacity or connect to house battery or install a separate battery and battery charging
system for the genset. If the genset still shuts down and has spec # ”11296” in the Model Number,
go to step 4. if not, go to step 5.
4. Remove the front and top housing panels (p. 6-3) and disconnect the AC harness (p. A-2) from TB3
on the controller assembly (Figure 10-1). Reconnect the short grounding lead in the harness to
TB3−2 so that the genset will run. If the genset no longer shuts down, find and repair the short in the
AC harness, reconnecting the line circuit breaker, output terminal block (TB2) and battery−charger
as necessary.
5. Perform PMA stator test (p. 11-1). If all values are within spec, go to step 6.
6. Replace the controller assembly.
Document all details of the troubleshooting steps including load type and conditions.
INVERTER OVERVOLTAGE FAULT—CODE NO. 12
(Controller not able to regulate to rated voltage)
Corrective Action:
1. Check whether the vehicle engine and genset share the same starting battery. If so, and this fault
occurs when cranking the vehicle engine, low battery voltage may be causing this shutdown. Increase battery capacity or install a separate battery and battery charging system for the genset.
2. Replace the controller assembly (p. 10-1).
18-10
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
INVERTER UNDERVOLTAGE FAULT—CODE NO. 13
(Controller not able to regulate to rated voltage)
Corrective Action:
1. Check whether the vehicle engine and genset share the same starting battery. If so, and this fault
occurs when cranking the vehicle engine, low battery voltage may be causing this shutdown. Increase battery capacity or install a separate battery and battery charging system for the genset.
2. Remove the front and top housing panels (p. 6-3).
A. If loose, reconnect the leads of current transformer (p. A-2, A-4) to controller leads J9 and J10.
If that does not work, check resistance. If electrical resistance is not 15 to 25 ohms, replace the
current transformer.
B. Check for proper connections between the generator (PMA) and the controller assembly and
reconnect as necessary.
C. Check for a shorted generator stator winding (p. 11-1). If a winding is shorted, replace the stator.
3. Replace the controller assembly (p. 10-1).
INVERTER OVERFREQUENCY FAULT—CODE NO. 14
(Controller not able to regulate to rated frequency)
Logic: With inverter enabled, set is running at rpm > 800 and inverter frequency > 102.5% rated for 5
samples (125ms).
Corrective Action:
1. Reduce the number of connected appliances, especially when air conditioners and on board battery−charger are running.
2. Replace the controller assembly.
Document all details of the troubleshooting steps.
INVERTER UNDERFREQUENCY FAULT—CODE NO. 15
(Controller not able to regulate to rated frequency)
Logic: With inverter enabled, set is running with rpm > 800 and inverter frequency < 97.5% rated for 5 samples (125ms).
Corrective Action:
1. Reduce the number of connected appliances, especially when air conditioners and battery charger
are running.
2. Verify that air−conditioners are working properly.
3. Remove the top housing panel (p. 6-3) and check for correct connections at terminal TB3−1 and
TB3−2 (Figure 10-1).
4. Check PMA connections for continuity. Reconnect PMA leads and retest.
5. Check high idle adjustments.
6. If problem is not resolved, replace the controller assembly.
Document all details of the troubleshooting steps.
18-11
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
FUEL PUMP FAULT—CODE NO. 17*
(Controller sensed open circuit)
Corrective Action:
1. Try priming the fuel system by holding the control switch at Stop. If the fuel pump functions, the fault
was improperly declared and will probably not recur.
2. If loose, reconnect the two fuel pump leads (p. A-1, A-4). They are accessible through the access
door in the skid-base, and also through an access door in the front panel on some models.
3. Disconnect the fuel pump leads from the engine wiring harness and connect the white fuel pump lead
to the positive (+) terminal of a 12 volt battery and the black lead to the negative (−) terminal. Replace
the pump if there is no audible sound or vibration.
4. Remove the front and top housing panels (p. 6-3) and disconnect engine harness connector P1 (Figure 10-1, p. A-1, A-4) from the controller assembly. Check for electrical continuity between pin P1-2
and connector E2-1 and between E2-2 and ground and repair as necessary. Also check for missing,
bent or corroded terminals and connector pins and repair or reconnect as necessary.
* − This is a bypassable fault discontinued beginning Spec F.
GLOW PLUG CIRCUIT PROTECTION FAULT—CODE NO. 18*
(Controller sensed short circuit)
Corrective Action:
1. Remove the top housing panel (p. 6-3) and, if loose, reconnect engine harness spade connector
HR-1 (p. A-1, A-4) to the glow plug bus bar at the front of the engine (short to ground will cause shutdown).
2. Disconnect engine harness connector HR-1 at the glow plug bus bar and A1-J8 at the controller assembly. Check for continuity between either connector and ground (ground short). Replace the engine harness if it is shorted to ground.
3. Replace the controller assembly (p. 10-1).
* − This is a bypassable fault discontinued beginning Spec F.
GOVERNOR ACTUATOR FAULT—CODE NO. 19
(Controller sensed open or short circuit)
Corrective Action:
1. Remove the front housing panel (p. 6-3) and reconnect the engine wiring harness connectors E1-1
and E1-2 to the governor actuator if they are loose. Polarity does not matter.
2. Measure actuator coil resistance with a digital ohmmeter. Replace the actuator stator assembly if
coil resistance is not 1.7 to 2.8 ohms.
3. Disconnect engine harness connector P1 from the controller assembly (Figure 10-1, p. A-1, A-4).
Check for electrical continuity between pin P1-1 and quick connector E1-1 and between E1-2 and
ground. Replace the engine harness if either leg lacks electrical continuity. Also check for missing,
bent or corroded terminals and connector pins and repair or reconnect as necessary.
18-12
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
STARTER SOLENOID CIRCUIT PROTECTION FAULT—CODE NO. 21*
(Controller sensed short circuit)
Corrective Action:
1. Open the maintenance access door and reconnect engine harness quick connector K-1 to the starter
motor solenoid if it is loose (p. A-1, A-4).
2. Disconnect engine harness connector K-1 from the starter solenoid and connect battery positive (+)
by means of a switch and jumper to energize the solenoid. If the starter does not crank the engine
when the solenoid is energized, remove the starter motor assembly. Replace the starter motor assembly or solenoid, as necessary (p. 16-1).
3. Remove the top housing panel (p. 6-3) and reconnect engine harness connector A1-J6 to the lead
from the controller/inverter assembly if it is loose (Figure 10-1).
4. Disconnect engine harness connector A1-J6 at the controller/inverter assembly and connector K1
at the starter solenoid and check for continuity to ground from either connector (ground short). Replace the engine harness if it is shorted to ground.
5. Replace the controller assembly (p. 10-1).
* − Discontinued beginning Spec F.
GOVERNOR ACTUATOR OVERLOAD FAULT—CODE NO. 22
(Duration of operation at or near full-duty cycle beyond design limit)
Corrective Action:
1. Reduce the number of connected appliances, especially when air conditioners and battery chargers
are running.
2. Check for fuel and air leaks at each fitting in the fuel supply line.
3. Conduct a fuel flow test and service as necessary (p. 14-1).
4. Replace the engine air filter (p. 5-6) and clean the spark-arrest muffler (p. 5-5).
5. Remove the front and top housing panels (p. 6-3). Check for binding in the governor mechanism by
pushing the actuator rotor clockwise by hand—against the action of the fuel rack return spring. It
should rotate smoothly about 1/2 inch (12 mm) and return smoothly. If it binds or catches, remove
the governor actuator base assembly and replace it or service the internal engine governor mechanism (p. 13-2) as necessary.
6. Check for an open or shorted PMG stator winding (p. 11-1). (The controller will drive the actuator
harder to compensate for loss of output.)
7. Readjust high-idle speed (p. 13-4).
8. Service the fuel injectors and injection pump as necessary (p. 12-1).
9. Check fuel injection timing (p. 12-1).
10. Service a worn engine (p. 12-1).
18-13
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
LOW OIL PRESSURE CUTOFF SWITCH FAULT—CODE NO. 23*
(Controller sensed switch still open during start—not a running fault**)
Corrective Action:
1. Remove the top housing panel (p. 6-3). If loose, reconnect engine harness spade connector S2 to
the low oil pressure cutoff switch (Figure 12-2).
2. Disconnect engine harness connector P2 from the controller assembly (Figure 10-1, p. A-1, A-4).
Check for electrical continuity between pin P2-9 and connector S2 and for missing, bent or corroded
connector pins and repair as necessary.
3. Check for loose or corroded ground connections between the engine and the base and the base and
controller assembly and repair as necessary.
4. Replace the low oil pressure cutoff switch.
* − This is a bypassable fault prior to Spec F.
** − Beginning Spec F, this fault is enabled 20 seconds after the genset stops and is declared during start.
COOLANT TEMPERATURE SENDER FAULT—CODE NO. 24*
(Controller did not sense temperature change during first 5 minutes of operation)
Corrective Action:
1. Remove the top housing panel (p. 6-3). If loose, reconnect engine harness spade connector E3-1
to the coolant temperature sender (Figure 10-1, p. A-1, A-4).
2. Disconnect engine harness connector P1 from the controller assembly. Check for electrical continuity between pin P1-12 and connector E3-1 and for missing, bent or corroded connector pins and repair as necessary.
3. Replace the coolant temperature sender.
* − This is a bypassable fault prior to Spec F. Note also that an open circuit is sensed as cold temperature, resulting in maximum pre-heat and
post-heat times.
ENGINE ABOVE SPEED TARGET FAULT—CODE NO. 25
(Governor unable to regulate to target speed)
Corrective Action:
1. Remove the front and top housing panels (p. 6-3). Check the fuel rack return spring and replace it
if it is worn or broken (Figure 13-1). Make sure it is reassembled correctly.
2. Check for binding in the governor mechanism by pushing the actuator rotor clockwise by hand—
against the action of the fuel rack return spring. It should rotate smoothly about 1/2 inch (12 mm) and
return smoothly. If it binds or catches, remove the governor actuator base assembly and replace it
or service the internal engine governor mechanism (Figure 13-2) as necessary.
3. Readjust high-idle speed (p. 13-5).
18-14
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
ENGINE BELOW SPEED TARGET FAULT—CODE NO. 26
(Governor unable to regulate to target speed)
Corrective Action:
1. Reduce the number of connected appliances, especially when air conditioners and battery chargers
are running.
2. Prime the engine fuel system.
3. Check for fuel and air leaks at each fitting in the fuel supply line.
4. Conduct a fuel flow test and service as necessary (p. 14-1).
5. Replace the engine air filter (p. 5-6) and clean the spark-arrest muffler (p. 5-5).
6. Connect a source of known fuel quality, prime the fuel system and run the genset. If performance
improves, replace the bad fuel in the supply tank.
7. Remove the front and top housing panels (p. 6-3). Check for binding in the governor mechanism by
pushing the actuator rotor clockwise by hand—against the action of the fuel rack return spring (Figure 13-1). It should rotate smoothly about 1/2 inch (12 mm) and return smoothly. If it binds or catches,
remove the governor actuator base assembly and replace it or service the internal engine governor
mechanism (Figure 13-2) as necessary.
8. Readjust high-idle speed (p. 13-4).
9. Service the fuel injectors and injection pump, as necessary (p. 12-1).
10. Check fuel injection timing (p. 12-1).
11. Service a worn engine (p. 12-1).
18-15
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
PMA SENSE LOST FAULT—CODE NO. 27
(Controller unable to sense PMA frequency)
Logic: If between cranking and run_down, rpm = 0 and dc bus voltage present for > 2 seconds.
Corrective Action:
1. Check for proper connections between the generator (PMA) stator (Figure 11-2) and the controller
assembly (Figure 10-1) and reconnect as necessary.
2. Disconnect the PMA leads from the control. Using InPower, turn on the control starter relay in controller assembly (Refer to Step 7).
@@@@
WARNING Do Not crank for more than 30 seconds.
3. Connect Digital Multi Meter (DMM) to the PMA leads. While the engine is cranking, measure the voltage between PMA leads T1−T2, T2−T3 and T3−T1 using DMM. Set DMM to AC and range. Do not
crank the engine for more than 30 seconds.
A. If all of the leads measure > 20Vrms, replace controller−assembly.
B. If any of the leads measure < 20Vrms, troubleshoot PMA (Refer Step 6).
TIP:
• If values of all leads (T1−T2, T2−T3 and T3−T1) is < 20Vrms, problem is with the rotor.
• If value of one/more leads is < 20Vrms, problem lies with the stator.
4. After measuring the PMA leads, turn−off control starter relay in controller assembly (Refer Step 7E)
using InPower.
5. Run the set again and check if fault is cleared.
6. PMA Troubleshooting Steps:
A. Check for PMA to Ground shorts.
• Use a digital multimeter to measure resistance between each PMA lead to Ground.
− Meter will read ’Open’ if there are no shorts.
− If meter reads a finite resistance, it indicates a short.
B. Check for an open generator stator winding (p. 11-1). If winding is open, replace the stator.
@@@@ Ensure actuator is at zero and/or fuel is Off.
CAUTION
C. Remove top housing panel (p. 6-3), check PMA rotor and integrity of the magnets. Attempt to
bar the engine by hand to check for jammed magnets. Replace the rotor if damaged.
Note: If the rotor is damaged, Do Not replace the controller−assembly. Replace the rotor first and
check to verify if that solves the problem.
7. Steps for turning on the control starter relay in controller assembly using Inpower:
A. Enable the parameter “Starter Override Request”.
B. Turn on the parameter “Startes Override Command”.
C. To verify, check to see if “Starter Override Status” = on.
D. To switch off starter relay, turn off the parameter “Starter Override Command”.
E. To verify, check to see if “Starter Override Status” = off.
18-16
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
DC SENSE LOST FAULT—CODE NO. 28
(Controller unable to sense DC bus voltage)
Corrective Action:
1. Open the circuit breaker. If the fault does not persist, check for and disconnect excessive loads from
the genset before starting.
2. Check for proper connections between the generator (PMA) stator (Figure 11-2) and the controller
assembly (Figure 10-1) and reconnect as necessary.
3. Replace the controller assembly (p. 10-1).
HIGH BATTERY VOLTAGE FAULT—CODE NO. 29
(Voltage across battery system greater than 17.5 volts)
Corrective Action:
1. Check battery bank connections and reconnect if necessary so that the 12 volt batteries serving the
genset are connected in parallel (12 volt) rather than in series (24 volt).
2. Select a lower battery booster charge rate.
OVERSPEED FAULT—CODE NO. 31
(Engine speed greater than 3600 rpm)
Corrective Action:
1. Remove the front and top housing panels (p. 6-3). Check for binding in the governor mechanism by
pushing the actuator rotor clockwise by hand—against the action of the fuel rack return spring (Figure 13-1). It should rotate smoothly about 1/2 inch (12 mm) and return smoothly. If it binds or catches,
remove the governor actuator base assembly and replace it or service the internal engine governor
mechanism (Figure 13-2) as necessary.
2. Readjust high-idle speed (p. 13-4).
3. Replace the controller assembly (p. 10-1).
18-17
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
LOW CRANKING SPEED FAULT—CODE NO. 32
(Cranking speed less than 180 rpm for more than 2 seconds)
Logic: If CRANK and generator frequency < 3Hz for > 2 seconds.
Corrective Action:
Troubleshooting for Fault Code 32 is divided into 2 failure modes:
1. The engine does not crank.
2. The engine cranks.
If The Engine Does Not Crank
1. Inspect fuse F2. If blown, inspect wiring connections for shorts to chassis or other shorts. Replace
fuse and repeat test.
2. Check battery voltage at the genset terminal − should be 11 0.2V or above. Replace/recharge
battery as necessary.
3. Inspect battery connections at the terminals. Check DC system and cables.
4. Follow the steps below to troubleshoot and verify control starter relay (in controller assembly) and
starter motor assembly. In the steps below the numbers in parenthesis refer to the wiring diagram
on page A-5.
A. Using InPower, turn ON the control starter relay (in controller assembly) (Refer Step 5).
B. Measure voltage at A1−J6−K1 (1) at starter assembly. If measured voltage is > 10V, replace
starter assembly.
C. If measured voltage is < 10V, unplug A1−J6−K1 at the Starter Assembly (2).
D. Measure voltage at A1−J6−K1 (2) at the harness. It should measure approximately Battery voltage.
• If it measures approximately battery voltage, replace starter motor
• If it does not measure approximately battery voltage or measures less than 10V, unplug J6
(4) from A1−J6 (3) at controller assembly and measure voltage at J6 (4) on controller assembly.
− If measured voltage at (4) < 10V, then disconnect A1−J5 (5) from J5 (6) and measure
voltage at A1−J5 (5). If value is > 10V at A1−J5 (5), then replace controller assembly.
− If measured voltage at (5) < 10V, verify wiring.
5. Steps for turning on the control starter relay in controller assembly using Inpower:
A. Enable the parameter ”Starter Override Request”.
B. Turn on the parameter ”Starter Override Command”.
C. To verify, check to see if ”Starter Override Status” = on.
D. To switch off starter relay, turn off the parameter ”Starter Override Command”.
E. To verify, check to see if ”Starter Override Status” = off.
18-18
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
LOW CRANKING SPEED FAULT—CODE NO. 32 (CONT.)
(Cranking speed less than 180 rpm for more than 2 seconds)
If The Engine Cranks
While the start button is pressed, Monitor the parameters ”waveform period”, ”Inverter dc voltage” using
Inpower and refer to table below:
Note: Waveform period <80000 indicates Normal cranking speed. Waveform period >80000 indicates
unit is cranking too slow.
Condition No.
1
Waveform Period
80000−140000
2
30000000 for > 4s
Symptom
Engine cranking slow
Engine cranks normal
but control does not
sense PMA output
Troubleshooting
See step 1
See step 2
Step 1: Engine cranking slow
1. Verify engine setup for ambient conditions.
2. Low/weak batteries cause starting issues. Monitor battery voltage during crank. It must be > 8V.
Ideally it should be greater than 9V.
A. If the battery voltage is 8V, inspect battery connections at the terminals.
Step 2: Engine cranks normal but control does not sense PMA output
1. Check for proper connections between the generator (PMA) stator (Figure 11-2) and the controller
assembly (Figure 10-1) and reconnect as necessary.
2. Disconnect the PMA leads from the control. Using InPower, turn on the control starter relay in controller assembly (Refer Step 7).
@@@@
WARNING Do Not crank for more than 30 seconds.
3. While the engine is cranking, use a digital multimeter (DMM) set to AC and range to measure the
voltage between PMA leads T1−T2, T2−T3 and T3−T1. Do Not crank for more than 30 seconds.
A. If any of the leads measure > 20Vrms, replace controller−assembly.
B. If any of the leads measure < 20Vrms, troubleshoot PMA. (Refer Step 6.)
TIP:
• If values of all leads (T1−T2, T2−T3 and T3−T1) is > 20Vrms, problem is with the magnetic
field.
• If value of one/more leads is < 20Vrms, problem lies with the stator.
4. Turn−off control starter relay in the inverter (Refer Step 7D) using InPower after measuring the leads
5. Run the set again and check if fault is cleared.
18-19
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
LOW CRANKING SPEED FAULT—CODE NO. 32 (CONT.)
(Cranking speed less than 180 rpm for more than 2 seconds)
6. PMA Troubleshooting Steps:
A. Check for PMA to Ground shorts.
1). Use a digital multimenter to measure resistance between each PMA lead to Ground.
a). Meter will read ’Open’ if there are no shorts.
b). If meter reads a finite resistance, it indicates a short.
B. Check for an open generator stator winding (p. 11-1). If winding is open, replace the stator.
@@@@ Ensure actuator is at zero and/or fuel is Off.
CAUTION
C. Remove top housing panel (p. 6-3), check PMA rotor and integrity of the magnets. Attempt to
bar the engine by hand to check for jammed magnets. Replace the rotor if damaged.
Note: If the rotor is damaged, Do Not replace the controller−assembly. Replace the rotor first and check to
verify if that solves the problem.
7. Steps for turning on the control starter relay in controller assembly using Inpower:
A. Enable the parameter ”Starter Override Request”.
B. Turn on the parameter ”Starter Override Command”.
C. To verify, check to see if ”Starter Override Status” = on.
D. To switch off starter relay, turn off the parameter ”Starter Override Command”.
E. To verify, check to see if ”Starter Override Status” = off.
HIGH ENGINE COOLANT TEMPERATURE FAULT—CODE NO. 33
(Engine coolant temperature exceeded design limit)
Corrective Action:
1. Check the engine coolant level and add coolant and repair leaks as necessary.
2. Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset.
3. Reduce the number of appliances connected at the same time. (Note that high altitude and high ambient temperature decrease engine cooling capacity.)
4. Look for a broken or worn coolant pump drive belt (Figure 12-2) and replace as necessary. (Visible
through the maintenance access door in the skid-base.)
5. Remove the air intake grille in the skid-base and check to see that the cooling blower (Figure 11-2)
is secure and that the blades are not fouled.
6. Check for air leaks in the housing—missing or loose housing panels and access covers, including
the access covers for the fuses and AC terminals.
7. Clean and flush the cooling system to remove coolant passage fouling.
8. Remove the top housing panel (p. 6-3). If loose, reconnect engine harness spade terminal connector
E3-1 to the coolant temperature sender (Figure 12-2) (If the lead is loose and touching ground, the
controller will sense a high engine temperature.)
9. While the top housing panel is off (Step 6-3), check for fouling of the radiator air passages and clear
out dust and debris with compressed air directed from below (reverse of normal air flow).
10. Replace the coolant thermostat (Figure 12-2).
11. If the genset overheats only underway, see the coach manufacture regarding air baffles or other
means to direct cooling air into the genset.
18-20
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
HIGH INVERTER TEMPERATURE FAULT—CODE NO. 34
(Inverter heat sink temperature exceeded design limit*)
Corrective Action:
1. Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset.
2. Remove the air intake grille in the skid-base and clean the heat sink fins (Figure 10-1) if they are
fouled. Also check to see that the cooling blower (Figure 11-2) is secure and that the blades are not
fouled.
3. Reduce the number of appliances connected at the same time. (Note that high altitude and high ambient temperature decrease cooling capacity.)
4. Replace the controller assembly (p. 10-1) if the genset cannot carry rated load.
*− Prior to Spec F, use compressed air to cool off the fins of the heat sink if it is necessary to get the genset started right away. Beginning Spec F, the
genset will run for 2 minutes after being restarted, which is enough time to cool down the heat sink if the connected load is less than 2 kW.
CONTROL CARD FAILURE FAULT—CODE NO. 35
(Microprocessor EEPROM error during self-test)
Corrective Action: Report this failure to the Factory and replace the controller assembly (p.10-1). This
fault occurs when using obsolete software.
ENGINE STOPPED FAULT—CODE NO. 36
(Engine stopped without command by controller)
Corrective Action:
1. Check fuel level. (Note: The genset fuel pickup is probably higher than the vehicle engine pickup.)
2. Prime the engine fuel system if the genset ran out of fuel.
3. Check for fuel and air leaks at each fitting in the fuel supply line. (Note: White smoke indicates air
in the fuel.)
4. Check the engine air filter and remove any blockage.
5. Check for mechanical damage.
6. Check auxiliary fuel pump (if equipped).
7. Conduct a fuel flow test and service as necessary (p. 14-1).
8. Remove the front and top housing panels (p. 6-3) and disconnect engine harness connectors P1 and
P2 from the controller (Figure 10-2, p. A-1, A-4, ). Check for missing, bent or corroded connector pins
and faulty wiring and repair as necessary.
9. Service the engine (p. 12-1).
INVALID GENSET CONFIGURATION FAULT—CODE NO. 37
(Genset configuration is preprogrammed at the factory)
Corrective Action: Corrective Action: Replace the controller assembly (p. 10-1). The controller assembly must be configured at the factory.
18-21
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
OVERCURRENT FAULT—CODE NO. 38
(Too many loads connected)
Corrective Action:
1. Reduce the number of appliances running at the same time, especially those with high motor starting
loads such as air conditioners. Start up with no load and let the genset run for five minutes to cool
down the inverter.
2. If the appliance and air conditioner loading patterns have remained the same but genset performance has deteriorated:
A. Check for fuel and air leaks at each fitting in the fuel supply line. (Note: White smoke indicates
air in the fuel.)
B. Conduct a fuel flow test and service as necessary (p. 14-1).
C. Remove the front and top housing panels (p. 6-3). Check for binding in the governor mechanism
by pushing the actuator rotor clockwise by hand—against the action of the fuel rack return spring
(Figure 13-1). It should rotate smoothly about 1/2 inch (12 mm) and return smoothly. If it binds
or catches, remove the governor actuator base assembly and replace it or service the internal
engine governor mechanism (Figure 13-2) as necessary.
D. Readjust high-idle speed (p. 13-4).
E. Service the fuel injectors and injection pump as necessary (p. 12-1).
F. Service a worn engine (p. 12-1).
LOW BATTERY VOLTAGE FAULT—CODE NO. 39*
(Battery voltage dropped below 9 volts while genset running)
Logic: If power supply shutdown is indicated and battery voltage < 9.5V during wakeup state
Corrective Action:
1. Inspect connections at battery and genset.
2. Avoid running the genset while cranking the propulsion engine, specially in installations where genset batteries are used to supplement vehicle engine batteries
3. Check battery voltage at the genset terminal −typical should be 11V 0.3V or above. If not, replace/
recharge battery.
Note: Due to the long battery cables, battery voltage at the genset terminal may be lower than at battery
terminals.
4. Check Battery Voltage at the genset terminal ”while cranking engine”. If battery Voltage drops < 9V
0.2V, replace/recharge the battery.
Note: Battery voltage dipping below 9V during crank indicates a potentially weak battery. Battery needs
to be replaced.
* − Fault Code Active for Specs A−E and beginning M
Fault Inactive for Specs F−L
18-22
TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
Some genset service procedures present hazards that can result in severe personal
WARNING
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
PROCESSOR FAULT—CODE NO. 42*
(Microprocessor ROM error during self-test)
Corrective Action: Replace the controller assembly (p. 10-1).
* − Beginning Spec F and replacement controller assemblies
PROCESSOR FAULT—CODE NO. 43*
(Microprocessor RAM error during self-test)
Corrective Action: Replace the controller assembly (p. 10-1).
* − Beginning Spec F and replacement controller assemblies
INVERTER POWER SUPPLY FAULT—CODE NO. 46*
(Low battery voltage or power supply device failure)
Logic: If input indicates power supply shutdown for 3 samples at 32ms rate.
Corrective Action:
1. Avoid running the genset while cranking the propulsion engine, specially in installations where genset batteries are used to supplement vehicle engine batteries.
2. Inspect battery cable connections at the battery, vehicle frame, and genset.
3. Check battery voltage at the genset terminal −typical voltage should be 11V 0.3V or above. If not,
replace/recharge battery.
Note: Due to the long battery cables, battery voltage at the genset terminal may be lower than at battery
terminals.
4. Check battery voltage at the genset terminal ”while cranking engine”. If battery Voltage drops to <
9V 0.2V, replace/recharge the battery.
Note: Battery voltage dipping below 9V during crank indicates a potentially weak battery. Battery needs
to be replaced.
5. Remove battery charger or unplug the battery charger from its AC source, before cranking.
6. Replace the controller assembly (p 10-1).
* − Beginning Spec F and replacement controller assemblies
18-23
TIE TO AC
HARNESS
SECURE TO TOP OF CONTROLLER
HOUSING WITH SUPPORT CLIP
SECURE TO TOP OF INTAKE RESONATOR WITH SUPPORT CLIP
SECURE TO END OF
INTAKE RESONATOR
WITH SUPPORT CLIP
LATER MODELS
EARLIER MODELS
ENGINE WIRING HARNESS
A-1
SECURE TO TOP OF CONTROLLER
HOUSING WITH SUPPORT CLIP
TIE WITH ENGINE
HARNESS
HARNESS WHEN GENSET IS NOT
EQUIPPED WITH BATTERY CHARGER
CURRENT
TRANSFORMER
HARNESS WHEN GENSET IS
EQUIPPED WITH BATTERY CHARGER
EARLIER MODELS
NOT USED
TWO LEADS WHEN GENSET IS
EQUIPPED WITH A BATTERY
CHARGER
LATER MODELS
AC WIRING HARNESS
A-2
SECURE PCB
GROUND HERE
SECURE HARNESS SUPPORT CLIPS HERE
SECURE HARNESS SUPPORT CLIPS HERE
SECURE GND
CABLE HERE
SECURE B+
CABLE HERE
EARLIER MODELS ONLY
BATTERY WIRING HARNESS
A-3
CONTROLLER/INVERTER ASSEMBLY
PRIOR TO SPEC F
WIRING DIAGRAM
A-4
CONTROLLER/INVERTER ASSEMBLY
1
3
4
5
6
2
Ref #
Description
1. INPUT TERNINAL AT STARTER SOLENOID.
2. A1−J6−K1 HARNESS CONNECTION AT STARTER SOLENOID.
3. A1−J6−K1 HARNESS CONNECTION AT CONTROL ASSEMBLY.
4. J6 TERMINAL AT CONTROL ASSEMBLY.
5. A1−J5−K1 HARNESS CONNECTION AT CONTROL ASSEMBLY.
6. J5 TERMINAL AT CONTROL ASSEMBLY.
WIRING DIAGRAM FOR FC32 TROUBLESHOOTING
A-5
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email www.cumminsonan.com/contact
www.cumminsonan.com
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are trademarks of Cummins Inc.
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