Onan BGD, NHD generator set Operator's Manual
Below you will find brief information for generator set BGD, generator set NHD. This document describes the operation and maintenance of the BGD and NHD commercial mobile generator sets, including safety precautions, fuel recommendations, starting and stopping procedures, break-in, operating conditions, troubleshooting, and maintenance schedules.
advertisement
Operator’s Manual
Model BGD and NHD Generator Sets
Printed in
U.S.A.
965-01 29 4-93
Safetv Precautions
Before operating the generator
set,
read the
Operator’s
Manual and become familiar with it and the ui ment.
Safo
and efficient opwatlon can be achieved
” I R
the unit is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and
precautions.
The following symbols, found throughout this manual, alert you to potentiall dangerous conditions tothe operator, service per- sonnel, or
tx
e equipment.
This symbol warns o f immediate haz- ards which will result in severe personai injuty or death.
@VZU”G
This symbol refers to a hazard or unsafe practice wbich can result in severe personal
Injuiy or death.
hi
refers to a hazard or unsafe practice which can resuit
in
personal injuv
or
prod- uct or property damage.
FUEL AND FUMES
ARE FLAMMABLE. Fire, explosion. and personal injury can result from improper practices.
DO NOTfill fuel tanks while engine is running. Fuel contact with hot engine or exhaust is a potential fire hazard. erator set or fuel tank.
Fuel lines must be adequately secured and free of leaks.
Fuel connection at the engine should be made with
an
a p provedflexiMe, norrconductive line. Do not use
copper
p i p
on
brittle. flexible lines
as
copper will work harden and become
Be sure all
fuel
supplies have a positive shutoff valve.
GASOLINE AND LPG FUEL MAY BE ACCIDENTAUY IG
BY ELECTRICALSPARKS, resentlngtheharsrdof
flre or explosion, jury
or which
can
resu
P
t
In severe personal death. When installlng the generator set:
In-
Do not tie electrical wiring to fuel lines.
Do not run electrical lines and fuel lines through the same compartment openings.
Keep electrical
and
fuel lines
as
far apart
as
possible.
Place a physical barrier between fuel lines and electrical lines wherever possible.
H
electrical and fuel lines must pass through the same com- partment opening, make certain that they are physically separated by running them through individual channels. or by passing each line through a separate piece of tubing.
DO
NOT SMOKE while servicing batteries. Lead acid bat- teries emit a highly explosive hydrogen gas that can
be
ig- nited by electrical arcing or by smoking.
EXHAUST GASES ARE DEADLY
0
Never sleep in
the
vehicle with the generator set running un- less vehicle is equipped with an operating carbon monoxide detector.
0
Provide an adequate exhaust system to properly expel dis- charged gases.
Inspect
exhaust system daily for leaks per the maintenance schedule. Ensure that exhaust manifolds are secure
and
not warped.
Do
not use exhaust gases to heat a compartment.
Be sure the unit is wall ventilated.
MOVING PARTS CAN CAUSE SEVERE PERSONAL
JURY
OR
DEATH
IN-
0
Before starting work on the generator set, disconnect batter- ies. This
will
prevent accidental arcing.
Keep your hands away from moving parts.
Make sure that fasteners on the generator set are
4
3.
Tighten
supports and
damps, keep guards in position over fans, drive belts, etc.
Do
not wear loose clothing or jewelry while working on gen- erator seis. Loose clothing and jewelry can become caught in moving parts. Jewelry can short out electrical contaqts and
cause
shock or burning.
If adjustment must be made while the unit is running. use ex- treme caution around hot manifolds, moving parts. etc.
ELECTRICAL SHOCK CAN CAUSE
SEVERE
PERSONAL
INJURY
OR
DEATH
Disconnect starting battery before removing protective shields or touching electrical equipment. Use rubber insula- tive mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment. Do not weardampclothing (particularlywetshoes) orallowskin sur- faces to be damp when handling electrical equipment.
Use extreme caution when working on electrical compo- nents. High voltages
can
death.
Follow all
state and local
&des.
Have all electrical installations performed by a qualified licensed electrician.
Tag open switches to avoid accidental closure.
DO
NOT
CONNECT GENERATOR
SET DIRECTLY
TO
ANY BUILDING ELECTRICAL SYSTEM. ages
can
Hatardous
creates a potential for electrocution
ar
property
I volt-
3.
Connect only through main switch is open.
an
and aftei g
Consult
an eledriaan in rbyyIy
;o
emergency power use.
GENERAL
SAFETY
PRECAUTIONS
Have afire extinguisher nearby. Maintain extinguisher prop erly and become familiar with its
use.
Extinguishers rated
ABC by the NFPA
are
appropriate for all applications. Con- sult the local fire department for the correct
type
of extin- guisher for various applications.
Hot coolants under pressure can cause severe personal in- jury. DO NOTopen a radiator pressure cap whilethe engine is running. Stop the engine and carefully bleed the system pressure.
Benzene and lead, fwnd in some gasoline, have been iden- tified by some state and federal agencies
as or
reproductive toxici. When checking, draining or adding gasdine, take care not to ingest, breathe the fumes,
or
con-
tact
gasoline.
Used engine oils have been identified by some state
or
fed- eral agencies
as
causing cancer or reproductive toxicity.
When checking
or
changing engine oil, take care not to
‘7-
gest, breathe
the
fumes, or contact used oil.
Remove all unnecessary grease and oil from the unit.
Accu- mulated grease
and
oil can cause overheating and engiy damage, which presents a potential fire hazard.
DO NOT store anything in the generator mmparbn
as or
gas
cam,
oily rags, chains, wooden blocks, propane cylinders, etc. A fire could result
or
the g
;
0
lr
set
operation (cooling, noise and vibration) may be ad- versely aff ected.
Keep
the compartment floor clean
and
Do
not work
on
RV-9
.
.
.
.
.
.
Table of Contents
SECTION TITLE
1
2
3
4
PAGE
SAFETY PRECAUTIONS
INTRODUCTION
................................
Inside Front Cover
.....................................................
1-1
About This Manual
How to Obtain Service
SPECIFICATIONS
OPERATION
.................................................
1-1
..............................................
1-1
...................................................
........................................................
....................................................
...............................................
..............................................
.................................................
...............................................
.............................................
....................................................
MAINTENANCE
.....................................................
..........................................
.............................................
.................................................
...........................................................
.....................................................
.........................................................
.....................................
.......................................................
...................................................
..........................................................
.........................................................
.......................................................
Cleaning Carburetor. Combustion Chamber
.........................................
Inspect and Clean Engine (internal)
..................................
i
Redistribution or publication of this document, by any means, is strictly prohibited.
Redistribution or publication of this document, by any means, is strictly prohibited.
I
Section
1
Introduction
s
*
ABOUT THIS MANUAL
This manual covers the operation and maintenance
of
the
BGD and
NHD commercial mobile generator sets.
For
more information, see these publications:
ElectricaVMechanicaI Fundamentals
(publication
932-0408)
Onan Generator Traininq Manual
(publication
932-0404)
BGD/NHD Installation Manual
(publication
965-0629)
BGD/NHD Service Manual
(publication
965-0529)
Read this manual carefully, and follow all warnings and cautions. Using the genset properly and following a regular maintenance schedule can bring about longer unit life, better performance, and safer operation. The generator set must be installed properly to operate safely.
HOW
TO OBTAIN
SERVICE
When the set needs service, call an authorized service center and give them the complete model number and serial number listed on the generator set nameplate.
Factory-trained parts and service centers can handle all service needs. The Parts and Service Center Directory
(publication
F-115,
Time
Rating
Insulation
1
I
I
I
I
I
I
1
( 5 )
I
Bat.
-
NEMA Class Ambient 40°C
FIGURE 1-1. ONAN NAMEPLATE
.
-
1-1
Redistribution or publication of this document, by any means, is strictly prohibited.
Redistribution or publication of this document, by any means, is strictly prohibited.
Section
2.
Specifications
4
,
MODEL BGD
General
Weight
Overall Dimensions
(H x L x W)
Minimum Free Area for
Ventilating Air
Minimum Vertical Clearance
At Air Discharge Outlet
Required Exhaust
Pipe Material
Engine Oil Capacity (Dry Filter)
Control Panel Fuse
(Fl)
Ignition/Choke Fuse (F2)
Spark Plug Gap
204 pounds (92 kg)
14 x 25-l/4
x
19 In.
(356 x 641 x 478 mm)
85 sq. In.
(548 sq. cm)
2 In. (51 mm)
18 gauge, 1-38 In. ID rigid steel tubing
3.5 quarts (3.3 L)
5 amps slow-blow
10 amps
0.025 In. (0.64 mm)
Fuel Connections
Maximum Gasoline Supply Pressure
(at Carburetor)
Maximum Gasoline Fuel Pump Lift
Gasoline Supply Fitting
Min./Max. Propane Supply Pressure
(Vapor Withdrawal)
Propane Supply Connection
(Vapor Withdrawal)
Propane Supply Connection
(Liquid Withdrawal)
Battery
Voltage
Cold Cranking Amps (SAE J537) for
Ambients Above/Below Freezing
Minimum Required Voltage at Starter
Motor Terminals During Cranking
Battery Charging Voltate (at No-Load AC)
Battery Charging Voltate (at Full-Load AC)
Maximum Continuous
Battery Charging Amperage
Trickle Battery Charging Amperage
6 psi (41 kPa)
3 Ft. (0.9 m)
1/4 In.
ID
hose barb
7/14 In.
(178/356 mm) WC
3/4 In. NPTF tapping
1/4 In. NPTF tapping
12
360/450
8
14.4
14.6
10
0.5
2-1
MODEL NHD
230 pounds (1 04 kg)
14-518 x 25-9/16 x 21-1/16 In.
(371 x 649 x 535 mm)
85 sq. In.
(548 sq. cm)
2 In. (51 mm)
18 gauge, 1-3/8 In. ID rigid steel ubing
3/5 quarts (3.3 L)
10 amps
0.025 In. (0.64 mm)
6 psi (41 kPa)
3 Ft. (0.9 m)
114 In. ID hose barb
7/14 In.
(178/356 mm) WC
3/4 In. NPTF tapping
1/4 In. NPTF tapping
12
360/450
8
14.4
14.6
10
0.5
Redistribution or publication of this document, by any means, is strictly prohibited.
Specifications (Cont.)
MODEL BGD
50 Hertz
(1500 RPM)
60
Hertz
(1 800
RPM)
Gasoline Fueled Sets
Rated Power Output
Full-Load Current
At
11 0/220 Volts
At 120/240 Volts
Full-Load Current
31-Phase Generators
At
11
01220
Volts*
At 120/240 Volts*
Gasoline Consumption
Under Full-Load
Under Half-Load
Under No-Load
Propane Fueled Sets
Rated Power Output
Full-Load Current
(1 -Phase Generators)
At
11 0/220 Volts
At
120/240 Volts
Propane Consumption
Under Full-Load
Under Half-Load
Under No-Load
4.0 kW
36.4R8.2 amps
-
21.0/10.5 amps
-
0.73 gph (2.8 Uh)
0.53 gph (2.0 Uh)
0.35 gph (1.3 Uh)
3.5 kW
31.8/15.9 amps
-
0.98 gph (3.7 Uh)
0.65 gph (2.5 Uh)
0.4 gph (1.5 Uh)
4.5 kW
-
37.5A8.8 amps
-
21.7/10.8 amps
0.8 gph (3.0 Uh)
0.6 gph (2.3 Uh)
0.4 gph (1.5 Uh)
4.0 kW
-
33.3116.7 amps
1.3 gph (4.9 Uh)
0.8 gph (3.0 Uh)
0.5 gph (1.9 Uh)
MODEL NHD
50 Hertz
(1500 RPM)
60
Hertz
(1 800
RPM)
5.0 kW 6.5 kW
45.5/22.7 amps
-
-
54.2l27.1 amps
26.3/13.2 amps
-
-
31.3/15.7 amps
0.8 gph (3.0 Uh)
0.57 gph (2.2 L/h)
0.35 gph (1.3 Uh)
1.3 gph (4.9 Uh)
0.7 gph (2.5 Uh)
0.4 gph (1.5 Uh)
5.0 kW
6.3 kW
45.5122.7 amps
-
-
52.5126.3 amps
1.18 gph (4.5 Uh)
0.78 gph (3.0 Uh)
0.5 gph (1.9 Uh)
1.7 gph
(6.4
Uh)
1.05 gph
(4.0
Uh)
0.65 gph (2.5 Uh)
*
.
*
-
These values are for generators having a Series-Delta connection.
2-2
Redistribution or publication of this document, by any means, is strictly prohibited.
BGD/NHD
Fuel)
SPARK
BOARD
FUSE
PLUG
\
CARBURETOR
BRACKET WITH RELAYS
AND
BAllERY
CHARGING
NEGATIVE (-)
BATTERY
CABLE
BAlTERY
CABLE
CONNECTION
.
UNE CIRCUIT
BREAKERS
*\
FUEL
PUMP
AND FUEL
INLET
MISW-lSr
10
AivrP
\
REMOTE
START
CABLE
CONNECTION
ninru
I IT
BGD/NHD
. .
LPG
Fuel)
P
11110 anmr
SPARK
BOARD
FUSE
PLUG
.
CARBURETOR
AND GOVERNOR
ADJUSTMENTS
I
SPARK
AIR
IGNITION
COIL
BRAGKETWlTHREIAYSAND
BAllERY
CHARGING
REGULATOR
I
BAiTERY CABLE
CONNECTION
(NON-EXTENDED
SHAFT
MODELS)
MOUNTlNG
TRAY
LINE
CIRCUIT
.
BREAKERS
B A T E
FIGURE
2-1.
BGD/NHD GENERATOR SETS
Redistribution or publication of this document, by any means, is strictly prohibited.
2-3
\
Redistribution or publication of this document, by any means, is strictly prohibited.
.
Section 3.
Operation
EXHAUST
GAS IS
DEADLY!
Exhaust gases contain carbon monoxide, an odorless and colorless gas. Carbon monoxide is poisonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning can include:
Dizziness
Nausea
Headache
Weakness and Sleepiness
0
Throbbing in Temples
Muscular Twitching
Vomiting
Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCEANY
OF
THESESYMPTOMS, GET OUT
INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical affen- tion. Shut repaired. down the unit and do not operate until it has been inspected and
Never sleep in vehicle with thegenerator set running unless the vehicle inferior is equipped with an operating carbon monoxide defector. Protection against carbon monoxide inhalation also includes proper exhaust system installation and visual and audible inspection of the complete exhaust system at the start of each generafor set operation.
BEFORE STARTING
General Inspection
Inspect the set and the entire exhaust system before startup. Check for looseand damaged components and fasteners, and correct all problem areas.
k&@@!d
Exhaust gas presents the hazard of severe personal injury or death.
Make certain fhaf all exhaust components work cor- rectly and are secure.
Do not start the set while it
is
connected to a load. First, make certain that any output switching device is in the
“Utility” position, and that the vehicle AC distribution panel breakers are
off
(open). Do not start the set if exhaust gases will not be effectively expelled away from the vehicle. Make sure that the vehicle is not parked in high grass
or brush.
See Starting and Stopping in this section.
Fire can cause severe personal injury or death.
Do
not operate the generator set when the vehicle is parked in high grass or brush.
Exhaust gases can cause severe
k@%!%l
personalinjury or death. Neveroper- ate the generator set unless the exhaust outlet is clear of walls, snow banks, or any obstructions that can prevent exhaust gases from dissipating. Never operate any exhaust fan in the vehicle when thegenerafor set is running: an exhaust fan can draw exhaust gas into the vehicle.
Lubrication
Check the engine oil level
often.
Keep the level near the fill indicator FULL mark. Do not overfill. See Section 4,
Maintenance, for instructions.
Fuel
Make certain thatthe fuel tanks are
full
before operating the set See Recommended
Fuels
in this section of the manual.
Gasoline and LPG fuel present the
JQWAR”GI
hazard of fire or explosion, which can result in severe personal injury or death. Do not smoke or allow any flame, spark, pilot light, arc- producing equipment or other ignition sources around fuel or fuel components. Keep a type ABC fire exfin- guisher nearby.
Redistribution or publication of this document, by any means, is strictly prohibited.
3-1
I -
RECOMMENDED FUELS
Gasoline Models
Use clean, fresh unleaded gasoline. (Leaded regular may be used if necessary.) Unleaded fuel promotes longer service intervals, longer spark plug life, and less carbon clean-out maintenance. Leaded fuel creates deposits on the cylinder heads, which cause power loss. These deposits must be removed periodically.
Unleaded gas may be used after leaded gas only if these
[ deposits are removed.
fngine damage may result from alternating unleaded and leaded
(regular) gasoline, unless lead deposits are removed
from
the cylinder head area before switching to unleaded gasoline.
LPG
Models (liquid
and
vapor withdrawal)
Use commercial propane or HD-5 grade LPG in a mix- ture of at least 90 percent propane. Propane fuels other than HD-5 may contain more than 2.5 percent butane, and may cause poor engine starting in low temperatures
(below
32"
F
or 0" C).
A manual shutoff valve must be mounted on the propane fuel supply tank. Open this valve fully when running the set, to make certain that theexcess flow valve will close if the propane fuel line is broken.
STARTING AND STOPPING
This section describes starting and stopping proce- dures. For the first startup of a new set, see Break-in
Procedure in this section.
1.
Move the start-stop switch (set-mounted or remote) to START. Release the switch when the set starts.
2.
Let the unit warm up before switching in the load.
During warmup, make sure that the set runs smoothly.
3.
Switch the load into the circuit by closing a breaker at the distribution panel. See Section 2 of this man- ual for set load ratings.
-
loading can cause high operat-
Continuous generafor set over- ing temperatures that could damage the generator windings.
Keep the load within the nameplate
rating.
4. To stop the set, remove the load and let the unit run three to five minutes to cool down. Then move the start-stop switch to STOP.
BREAK-IN PROCEDURE
To prevent high oil consumption or glazing of
the engine cylinders, break in the set as follows:
1. Start the set and apply a load equal to half its capac- ity.
2. Run the set for two hours with this load.
3.
Run the set for another two hours at three-quarters capacity.
4. Change the engine oil after the first 50 hours of operation, and every 150 hours after that. See Sec- tion
4,
Maintenance, for instructions.
This procedure only begins the break-in process. For optimum set performance, make certain not to
N n the set for extended periods without load during the first 150 to 200 hours of use.
OPERATING CONDITIONS
Hot
Weather
Keep the engine cooling fins clean at all times, espe- cially when the outside temperature is higher than
90"
F./33"
C. Make sure that airflow to the set is not blocked.
Cold Weather
Use the correct oil weight for cold weather. See Section
4, Maintenance,for the type of oil to use. Change oil only after the engine
s
warm. If sudden temperature changes occur and the oil is not the correct weight, replace it with the proper oil.
Gasoline Models Only:
Below
70'
F
move the air
preheater lever (see Figure 2-1) to WINTER. Above 70"
F
(21
' move the lever to SUMMER.
u
3-2
Redistribution or publication of this document, by any means, is strictly prohibited.
b
k%@!@l
Operation of the preheater
when
femperatures are above 70' F. (21'
C.)
may cause erratic operation, and may result in reduced engine power
and
reduced engine life. For this reason, leave the preheater in the SUMMER posi- tion at high ambient temperatures.
High
Altitudes
Engine power
output
decreases
roughly four per- cent for each
1000 feet
(310
m)
above sea level, after the first 1000 feet. If the set runs poorly above
2000 feet (620
m.),
turn the carburetor main fuel adjustment to a slightly leaner fuel mixture. This is a sensitive adjustment. Note that the carburetor has an altitude decal on the float
bowl.
Set the indi- cator on the
main
jet adjustment to the altitude re- quired.
3.
Change the engine oil every 50 operating hours.
4. Keep oil in
a
dust-tight container.
5.
Clean the governor linkage regularly. See Section 4,
Maintenance, for this procedure.
GENERATOR SET EXERCISE
Moisture can condense in the engine if it is not run often enough to reach normal operating temperature. This moisture can damage the engine.
To
prevent moisture damage, run the generator set at one-half load two hours every four weeks. (See Section
2, Specifications, for the wattage rating.) Use a long exercise period rather than several short periods.
REMOTE CONTROL
The remote control allows starting the set from the cab of the vehicle. This control includes a start-stop switch and an indicator lamp that lights when the set is running.
See
3-2.
Using the Remote
Control
Move the start-stop switch to START, and hold it until the light turns on to show that the set is running. Release
3-2.
GENERATING LAMP
(ILLUMINATES WHEN
SET
OPERATING)
FIGURE
3-1. CARBURETOR MAIN ADJUSTMENT SCREWS
laCAUTlONl
Fuelmixtureadiustment needles and
seats can easily by damaged. when
adjusting
fuel
mixture settings, never force the fuel mixture adjustment needles against their seats.
.
Extremely Dusty or
Dirty
Conditions
1.
Keep the generator set and its cooling surfaces as clean as possible.
2.
Service the air cleaner frequently.
3-3
/
RUNNING
TIME
METER
\
BATTERY
CONDITION
METER
ES.1684-1
FIGURE 3-2. REMOTE CONTROL PANELS
Redistribution or publication of this document, by any means, is strictly prohibited.
If the switch is held at START for ten seconds and the light does not go on, release the switch, wait two min- utesand try again. If the second try does not succeed, try the control on the set. If the light still does not go on, there may be an open circuit in the remote wiring. Con- tact an authorized service center for assistance.
The optional running time meter indicates total hours of generator set use. During scheduled maintenance, record the figure
on
the meter.
The battery condition meter shows the condition of the battery and charging circuit. This meter should remain in the normal range. If it reads high or low most of the time, contact a service center.
IGNITION/CHOKE
FUSE
(F2)
Spec
F
generator sets
include a
separate fuse for the ignition and electrically controlled automatic
illustrates the location of this
on
the side of the control panel.
H
FUSE HOLDER
FIGURE 3-3. IGNITlONlCHOKE
FUSE
F2 LOCATION
OUT-OF-SERVICE PROTECTION
If the set cannot be exercised, and it will not be used for
30 days or longer, perform the following storage procedure.
Generator Set Storage Procedure
1. Run the set at one-half load for one hour. See Sec- tion 2, Specifications, for the wattage rating.
2. Close the fuel supply and remove the air filter. As the set runs out of fuel, squirt fogger (a thick oil formu- lated for internal engine protection; Onagard brand is recommended) into the carburetor intake. Reas- semble the air filter.
3. Stop the set. Remove the spark plugs. Pour one tablespoon (about
30
ml) of standard engine oil into each spark plug hole. Crank the engine for 10 seconds. Replace the spark plugs.
4. Change the oil after the exhaust system is cool.
5. Disconnect the cables from the starting battery.
Returning the Generator Set to Operation
1. Inspect the generator set.
2. Check the battery electrolyte level, and reconnect the cables.
3. Check the air filter. If the element is dirty, replace it.
4. Check the engine oil level.
5. Turn on the fuel supply.
6. Start the set at the set-mounted control. Start-up may be slow, due to oil in the cylinders. The set will run roughly, with asmokyexhaust, until the oil in the cylinders is burned. If the set does not start, replace the spark plugs.
7. Apply one-half load to the set until it runs smoothly.
Run the set for an hour.
8.
Remove the load and let the set run three to five minutes to cool down. Then move the start switch to the STOP position. The generator set is now ready for operation.
d
3-4
Redistribution or publication of this document, by any means, is strictly prohibited.
TROUBLESHOOTING GUIDE
This troubleshooting guide provides solutions to many common generator set problems.
If
these suggestions do not help, contact an authorized Onan service representative.
-1
Many troubleshooting procedures present hazards which can result in severe personal injury or death. Only qualiiied service personnel with knowledge of iuels, electricity, and machinery hazards should perform sewjce procedures. Review safety precautions on inside cover page.
Problem
FAILS TO CRANK
CRANKS SLOWLY
CRANKS
BUT
WON’T START
EXHAUSTING BLACK SMOKE
UNIT RUNS THEN STOPS
UNIT RUNS BUT SURGES
Probable Cause
1. Low battery.
2.
Bad battery connection.
3.
Blown fuse.
4. B+ circuit breaker tripped.
Solution
1.
Check battery electrolyte level.
2. Clean and tighten all battery and cable connections.
3. Replace fuse on control box. See specifications for proper fuse rating.
4.
Wait for circuit breaker to return to local ambient temperature to reset.
1.
Low battery.
2. Bad battery connection.
3. Oil is too heavy.
4.
Load connected.
1. See “Fails to Crank”, #l.
2.
See “Fails to Crank“, #2.
3.
Replace with lighter oil.
4.
Remove load.
1. Fuel below genset pick-up level in tank.
2. Fuel supply shutoff valve closed.
3.
Carbon deposits
on
spark plugs.
4.
Fuse F2 has blown.
1. Add fuel.
2. Fully open fuel supply valve.
3. Remove spark plugs and clean.
4.
Replace the fuse.
1.
Rich fuel mixture.
2. Dirty air filter.
3. Choke stuck.
1. Out
of
fuel.
2.
Low oil level.
3. Excess oil.
1. Turn main fuel adjustment in
1/8 turn (location of adjustment is
2. Replace air filter.
3.
See authorized representative.
1.
Refill fuel tank.
2. Add oil if necessary.
3. Reduce engine oil level.
1.
Loose or worn spark plug leads.
2.
Ignition coil, wiring, or control components defective.
1. Check security of spark plug leads at spark plugs and ignition coil. Replace leads if worn.
2. Contact an authorized service center.
A
hotgenerator set can cause severe burns. Always allow the generator set to cool before performing any maintenance or service.
Redistribution or publication of this document, by any means, is strictly prohibited.
3-5
Redistribution or publication of this document, by any means, is strictly prohibited.
Section
4.
Maintenance
V
Establish a maintenance and service schedule
for the
generator set, and stick to it. Consult an authorized service center if the set will be used in extreme cold, heat,
dust,
humidity, or altitude, and shorten the mainte- nance intervals. Keep a log of all service and mainte- nance, for warranty support. Use the schedule to deter- mine the maintenance required, then see this manual for the procedure.
Accidentally starfing the generator set during maintenance can cause severe personal injury or death. Disconnect both generator set starting battery cables, negative
(-1
cable first, before performing maintenance,
GENERAL INSPECTION
Inspect the entire generator'set at least once every eight operating hours. Start the set, and check for visible and audible faults.
EXHAUST
Examine the exhaust system for leaks. Inspect the generator compartment for holes which might let exhaust gas enter the vehicle.
Do
it runs louder than usual, if the compartment has holes to the interior,
or
if the exhaust system has leaks. Consult a service center as soon as possible, and do not run the set until the problem is corrected.
1 1-
Exhaust gas presents the hazard of severe personal injury or death. If there areany exhaust leaks,
do
not operate thegenera- tor set, and have the exhaust system repaired
as
soon as possible.
SPARK ARRESTER
The exhaust spark arrester
is
needed to operate the set safely. It requires periodic cleaning to work correctly.
Check the maintenance schedule for cleaning intervals.
Spark Arrester
Cleaning
Procedure
1.
Remove the 1
/ 8
inch pipe plug from the bottom of the muffler.
2. Run the generator set with load for five minutes.
3.
Stop the generator set and let the muffler cool.
4.
Replace the pipe plug in the muffler.
ENGINE OIL
Be sure the crankcase is filled with oil to the FULL mark
on the oil level indicator (Figure 4-1). Use the same
brand when adding oil between changes. See Recom- mended Engine Oil in this section.
FILL
TO
HERE
,
DO
RUN
THE SET
WHEN
THE
OIL LEVEL
IS BELOW
THIS
MARK
LS1138-3
FIGURE 4-1.
OIL DIP
STICK
Add
oil
until it reaches the
FULL
mark on the oil level indicator. Do not overfill: excess oil may foam in the crankcase and stop the engine. Replace the oil level indicator tightly to avoid leakage.
Hot oil
can
cause severe personal injury.
Do
not check the oil level while the generator set is running: oil may blow
out
the filler.
Redistribution or publication of this document, by any means, is strictly prohibited.
PERIODIC MAINTENANCE SCHEDULE
Service These Items 8
After Each Cycle of
Indicated Hours
50
150 200 300
General lnsoection
1
Check Oil Level
I
Check Batterv Electrolvte Level
I
Clean
Out
Spark Arrester
Clean and Lubricate Governor Linkage
Change Crankcase Oil and Oil Filter
Change Air Filter
Clean Fuel Filter
Replace Spark Plugs
Clean Cooling Fins
Clean Carburetor
L?
Combustion Chamber w/Onan
"4C"
~ ~~
1
Clean Generator Set
~
~ ~~~~~ ~
I
Inspect and Clean Internally Engine Combustion Chamber
~~
I
Replace Autochoke vacuum sustain valve (if applicable)
Adjust Carburetor
Check Generator Brushes
Exercise Generator Set
Adjust
Output Voltage
X'
1 x 1
I
I
I x
I
I l x I
X
X2.6
X2
x3
X4.8
I
I
I I
I x7
X
I
X I
I
I
I
x5
I I I I
x9
As Required
As Required
As Required
As
Required
I
I
I
1
2
4
5
6
7
8
9
3
-
With set running, visually and audibly check exhaust system for leaks.
-
Every 150 operating hours or once a year, whichever is first. Perform more often in extremely dusty conditions
(i.e., check monthly, and change if dirty).
-
Equipped on LPG models. Customer option for gasoline models.
-
Or replace annually, or prior to storage, whichever is first.
-
Have your Onan service center perform this task, by removing cylinder heads.
-
First oil change during first year or 50 hours of operation, whichever is first.
-
During periods of nonuse, exercise for 2 hours every 4 weeks.
-
Refer to Out-of-Service Protection if unit
is
to be stored.
-
Have your Onan service center perform this task.
V
4-2
Redistribution or publication of this document, by any means, is strictly prohibited.
V
Oil Level Checking Procedure
The
generator set
must be bel
when checking
the oil
indicator.
1. Remove the oil level indicator and wipe it with a clean rag.
2. Screw the indicator back into position (fully in).
3. Unscrew the indicator again, and check the oil level
on
the indicator stem.
4. Add oil to the
FULL
mark on the indicator.
Oil
DrainingXhanging Procedures
Figure 2-1 shows the oil drain, oil filter, and oil level indica-
tor. In dusty or dirty conditions, change the oil more fre- quently than the maintenance schedule says.
Run
the
engine unlil hot bebre draininglchanging
the oil.
Oil
Draining Procedure
1.
Place a pan under the oil drain valve.
2.
Open the valve and
let
the oil drain from the engine.
3. Close the valve. Dispose of the old oil properly.
Recommended Engine Oil
Use oil with the API (American Petroleum Institute) designa- tion
SG. Oil
should
be
labeled
as
passing
MS
Sequence
Tests
(also known as
ASTMG-1V Sequence Tests). Figure
shows recommended
viscosity
and temperatures.
I
I
I
I I
I
“ C
-30
-20 -10
b
10
20
%
40
TEMPERATURE RANGE YOU EXPECT BEFORE NEXT
OIL CHANGE
LSll38
FIGURE 4-2. SAE VISCOSITY GRADES
Oil consumption may be higher with a multigrade oil than with asingle-gradeoil. Forthis reason,single-grade oilsare recommended, unless wide temperature variations are possible.
Oil Filter Changing Procedure
1. Place an oil pan under
the
oil filter position on the engine.
2.
Turn the filter counterclockwise to remove it
3. Coat the new filter gasket with clean engine oil.
Turn the new filter clockwise until itsgasketjust touches the filter mounting base, then tighten it another half turn.
Refer to Section 2, Specifications, for engineoil capac- ity. See Recommended Engine Oil in thissection forthe right
type of
oil.
4-3
Redistribution or publication of this document, by any means, is strictly prohibited.
BATTERY CARE
To increase battery life, perform the following steps. liEEGI
Accidental starting of the set can cause severe personal injury
or
death. Disconnect the batfery cables when repairs are made to the engine, controls,
or
generafor. Always disconnect the negative
(-1
cable first, to minimize the possibility of arcing.
,
Some solvents can damage the gov- ernor's nylon joint. Read the manu- facturer's instructions before using any lubricanfs or solvents near the governor linkage.
AIR
FILTER
In dusty conditions, change the air filter often. To release the filter, remove the through-bolt on the outside of the
air cleaner housing (Figure 4-4).
1. Keep the battery case clean and dry.
2. Make certain that the battery cable connections are clean and tight. To remove the cables, use a termi- nal puller tool.
AIR PREHEATER
3.
Identify the cable as positive (+) or negative (-) before making the connection. Always connect the ground (negative) cable last, for less chance of arcing.
4. Add water (drinking quality or better) as needed to reach thesplit-level marker in the battery. The water in the electrolyte evaporates, but the sulphuric acid remains. For this reason, add water, not electrolyte to the battery.
PREHEATER
ACTUATOR L N E R
5. Avoid overcharging the battery. Stop the charge when the electrolyte specific gravity is 1.260, at
80"
F
(27'
C.)
-1
Bafferies present the hazard of explosion, which can result i n severepersonalinjury.
Do notsmoke orallow any fire, flame, spark, pilot light, arc-producing equipment
or
other ignition sources around the battery area. Do not disconnect battery cables while the generator set is cranking
or
running: batteries give off explosive gases.
GOVERNOR LINKAGE
The nylon governor linkagemust movefreelythrough its range of travel. This joint is self-lubricating, and requires no lubricant Wipe the joint with a dry cloth to clean it
*GASOLINE
MODELS ONLY
FS1593-25
FIGURE
4-4.
REPLACING THE AIR FILTER
(Gasoline units only) The carburetor
k@!@!!l
air preheater hose can easily be damaged by rough handling. When removing the air cleaner housing, be carefulnot to damage the carbure-
tor
air preheater hose, which is attached to the housing.
v
b
-1592
FIGURE
4-3.
GOVERNOR LINKAGE
4-4
Redistribution or publication of this document, by any means, is strictly prohibited.
+
V
FUEL FILTER (LPG VERSIONS)
removes
solid
impurities from the
LP gas, beforethey reach the regulator and carbure- tor. A magnet in the filter housing attracts iron and rust particles, and a filter element traps other particles. The fuel filter operates at fuel tank pressure, so it must be reassembled carefully after cleaning, to avoid leakage.
To
maintain the LPG fuel filter, purge the fuel system first, as described below.
Fuel System Purging Procedure
1. Close the shutoff valve at the fuel tank.
2. Start and run the generator set until it is out of fuel.
3.
Crank the engine a few times after it stops, to make certain that it has no fuel.
4.
Move thevehicle to a well-ventilated location that is far from fire, flame, pilot lights, arc-producing equipment, or other ignition source.
5. Remove the vehicle negative (-) battery ground cable and the generator set negative (-) ground cable from their batteries.
6. Close the generator set fuel system shutoff valves and all other fuel shutoff valves.
LP gas presents the hazard
of
fire or explosion, which can result in severe personal injury or death. Eliminate all sources
of
ignition, such as pilot lights, spark- ing electrical equipment, flames, lit cigareffes, etc. before purging the fuel system. Provide adequate ventilation to dissipate LP gas as it is released.
7. Open the section of flexible fuel line at the solenoid valve just enough to let the gas escape slowly.
8.
Disconnectthe fuel supply hose from thecarburetor and hold it clear of the set
9. Press and hold the primer button on the regulator to release LP gas from the fuel system. When gas can no longer be heard escaping from the open end
of
the fuel supply hose, reconnect the hose to the carburetor and move to the procedures described in LPG Fuel Filter Cleaning Procedure in this section.
LPG
Fuel Filter Cleaning Procedure
1.
Remove the four capscrews
and
lock washers that hold the filter bowl to
.
b
MAGNET
O-RINGSEAL
FIGURE 4-5. LIQUID
LPG
FUEL FILTER
BODY
2.
Separate the filter bowl from the filter body and discard the O-ring seal.
3.
Remove the nut and washer from the center stud and pull out the filter element
4.
If the filter element is clogged, wash the element in kerosene and blow it dry with low pressure(30 psi or
207 kPa) compressed air. Replace the filter element if damaged.
lZE@%l
Kerosene presents the hazard of fire or explosion, which can cause severe personal injury or death. smoke while using kerosene,
Do
not
or
expose kerosene to any fire, flame, spark, pilot light, arc-producing equipment or other ignition sources. Use great care when cleaning
with
kerosene.
5.
Wipe the center stud magnet clean of rust and scale deposits. Do not tap the magnet to loosen deposits: this may damage it
6.
Install a clean filter element using two new gaskets. Tighten the center and stud nuts.
7.
Place a new O-ring in the filter bowl sealing groove.
4-5
Redistribution or publication of this document, by any means, is strictly prohibited.
8.
Line upthe reference markon the filter bowl with the reference mark on the filter body, and install the capscrews. Tighten the capscrews 56 to 74 in-lb
(6.5 to
8.3
Nom) torque. Pressurize the fuel system and check the filter for leaks.
LPG presents the hazard of fire or
laWAR"G1
explosion, which can result in severe personal injury or death. After the filter assembly is assembled and the fuel shutoff valve is turned on, apply a soap or detergent solution to the joint, to check for leaks. If there is a leak, bubbles will show in the area;
turn
off the shutoff valve immediately. If theprob-
/em cannot be determined, call the nearest Onan ser- vice center.
SPARK PLUGS
A
spark plug with heavy combustion deposits can make the generator set misfire, run rough, or stop when a load is applied. When the plugs are removed, inspect and
a plug is discolored orfouled, replace it
0
Black deposits indicate a rich mixture.
Wet plugs indicate misfiring (gasoline fuel only).
Badly or frequently fouled plugs indicate that a major tuneup is needed.
SPARK PLUG
GAP
(SEE SPECIFICATIONS)
FIGURE
4-6.
MEASURING PLUG GAP
ES1374
CLEANING THE CARBURETOR AND
COMBUSTION CHAMBER
WITH ONAN
"4C"
lnhalation of chemical sprays
lii@@El
can
death. Use safety goggles to protect eyes and a respi- rator or painter's mask to prevent inhaling any chemi- cal that may spit back from the carburetor during this procedure. Also, work
in
a well-ventilated area so that other personnel will not inhale any fumes.
@@@%I
can cause severe personal injury or death.
Do
not allow any spark, flame, pilot light, lit cigarette, or other ignition source near the generator set when perform- ing this procedure. Keep a fire extinguisher rated ABC near the work area.
Perform these steps to keep the carburetor and intake manifold clean, and to keep carbon deposits off the combustion chamber.
If engine pinging or power loss occur, consult an authorized service center.
Before performing this procedure, move the vehicle to an outdoor location, far from any flame, spark, pilot light, arc-producing equipment or other ignition sources.
Open all AC circuit breakers, and remove the plug from the spark arrester muffler.
1.
Start the generator set and let it warm up to normal operating temperature.
2.
Stop the generator set
3.
Remove the air cleaner housing and air filter.
4.
Restart the generator set, and spray the
4C into the carburetor. Directthespray to wash the choke plate and inside walls of the carburetor. Spray as much as possible into the carburetor without stalling the engine.
The spray enters the combustion chamber and softens the carbon, which flakes
off
and exits through the exhaust pipe. When about an ounce of
4C remainsin the can,flood the engine until it stops.
5.
Wait 15 minutes, while the 4C continues to soften the carbon.
6.
Restart the engine, with no load connected.
Increase the load gradually to full load. Let the set run a few minutes under full load to get rid of the carbon.
*
~
..
*
4-6
Redistribution or publication of this document, by any means, is strictly prohibited.
<
I
CLEANING THE GENERATOR
SET
Clean the generator set every six months,
or
more often
in
severe conditions. Remove dust with a damp cloth.
Use steam to remove tar or other residue (do not steam- clean the set while it
is
running). Protect the generator, air cleaner, control box, fuel solenoid, and electrical connectors from cleaning solutions. Do
not
clean with solvents; they may damage electrical connectors.
INSPECT AND CLEAN ENGINE
(INTERNAL)
Widely varying operating conditions, light loads (less than 50 percent), and fuel with additives and impurities can degrade engine performance and shorten engine life.
Have the combustion chamber inspected internally
for
wear and carbon buildup after 300 hours. Because this means removing the cylinder head, it must only bedone by an authorized service representative, who is trained in genset maintenance and repair.
4-7
Redistribution or publication of this document, by any means, is strictly prohibited.
Redistribution or publication of this document, by any means, is strictly prohibited.
Redistribution or publication of this document, by any means, is strictly prohibited.
Onan Corporation
1400
73rd Avenue N.E.
Minneapolis, MN
55432
1-800-888-ON AN
612-574-5000
International
Use
Telex:
275477
Fax:
61 2-574-8087
Onan is a registered trademark
of Onan Corporation
Redistribution or publication of this document, by any means, is strictly prohibited.
8
advertisement
Key Features
- Provides instructions for operation
- Includes safety precautions
- Offers troubleshooting guide
- Details maintenance schedule
- Covers fuel recommendations
- Explains break-in procedures
- Defines operating conditions
- Describes remote control features
- Includes battery care instructions
- Covers spark arrester cleaning
Frequently Answers and Questions
What models are covered in this manual?
What types of fuel are recommended for these generator sets?
How often should I check the engine oil level?
How do I clean the spark arrester?
Related manuals
advertisement