Onan HDCAC, HDCAD Generator Sets Operator's Manual

Table of Contents
SAFETY PRECAUTIONS LL... 10 Le a eee ee ea aa ee ee a ee a ee a ea a ee a re aa ae ana na» 2
INTRODUCTION .........).es0srerrereacerecrenrineanerer neonana nereareneo 4
About This Manual ................ee0eeeanorrerera ti roo; eonrenrenrerEee 4
Model identification ............__rrerescarororearereei endo a à sa aa aa a ae 4
Fuel Recommendations ...... coir iii retires rains ena, 5
Engine Oil Recommendations .......12200 0044 eee eee ee aan ea a ee ae ea aan ane 5
Starting Batteries 0.0.0000 re ir i a ea ea a aa aa aa eau ‚ 5
Typical Gensel ooo er ee 5
Operator's Console .........e...eeesieeeeeerro eo rearen ti eren e eE. ... 6
Remote Control Panel... oii ie i retire ass 7
OPERATION i i ti tr tir tir rt te eee 8
Pre-Start Checks ........c.e.eseerreecrerererece.r ire ere re reece 8
Priming the Fuel System .............-.--e=.rrervervrrierecoeamarrre cenar. 8
Starting the Gensel... iii ie tee KR 8
Stopping the Gensel ..... iii ere ea 8
Automatic Starting and Stopping .........._ e ee ee 9
Loading the Genset .........._._.ec_eexedorerverererei cer aaron a econ ani 9
Resetting Circuit Breakers .........._.ee.eesrecuracrae dere dE rare a ana ae 10
Connecting to Utility Power 0000000000000 i ne. 10
Operating in Cold Weather... i i i i ce erica, 11
Operating in Hot Weather ....... ii i i eine 11
Operating at High Altitude ............—....reresrvrecsdaoas AAA 11
Operating in Dusty Environments .............e.re.eererivedarecdareer ten e. 11
Breaking In a New Engine .........._.ee_reeerearorerecrencorerorae anne, 11
Exercising the Genset ............._eoeeeceeererierorere enana. enana 11
Storing the Genset 1.100.024 04 aa aa ea aa da a a aa a ea Aa ae ee 4 a a es a aa „12
PERIODIC MAINTENANCE ...ee..ereeraocararneare cerceevacvrrereoenrierene KR 13
General Inspections ........._..._—e_ecerecerirecrcorereencrerrrecamare»..: A
Checking Engine Oil Level ................... fe eae Ra 15
Changing Engine Oil and Oil Filter .......... citi iene à 16
Maintaining the Battery and Battery Connections .........eerorredoerrara .. 17
Replacing the Air Filter Element .........._._e.-erescreerorererererena enano, 17
Cleaning the Spark Árrestor ........._.-.revnrrrecreriradensnorcereerance re en. 18
Replacing the Fuel Filter .................e—_ rre. eee area 19
Changing Coolant .........e.e.eeesesaarrerneoorarer en er PA 20
TROUBLESHOOTING oii titi re eet tet eee eae 21
SPE CIF CATIONS Lt tt ct eee a ee ae 28
EMISSIONS Lo ee ee eee eee 29
HOW TO OBTAIN SERVICE ..... citi i ire a a a a a ee a a aa see à 30
MAINTENANCE RECORD .........e.erocornooreesverenserncecarena rare rea aaa 31
Safety Precautions
Thoroughly read the OPERATOR'S MANUAL
before operating the genset. Safe operation and
top performance can only be obtained when
equipment is operated and maintained properly.
The following symbols in this manual alert you to po-
tential hazards to the operator, service person and
equipment.
NOSE alerts you to an immediate hazard
which will result in severe personal injury or
death.
. |[AWARNING| alerts you to a hazard or unsafe
practice which can result in severe personal in-
jury or death.
A CAUTION| alerts you to a hazard or unsafe
practice which can result in personal injury or
equipment damage.
Electricity, fuel, exhaust, moving paris and batteries
present hazards which can result in severe personal
injury or death.
GENERAL PRECAUTIONS
e Keep children away from the genset.
* Do not use evaporative starting fluids. They are
highly explosive.
e To prevent accidental or remote starting while
working on the genset, disconnect the nega-
tive (=) battery cable at the battery.
о Letthe 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.
o Keep the genset and iis compartment clean.
Excess oll and oily rags can catch fire. Dirt and
gear stowed in the compartment can restrict
cooling air.
« Make sure all fasteners are secure and torqued
properly.
Do not work on the genset when mentally or
physically fatigued or after consuming alcohol
or drugs.
You must be trained and experienced to make
adjustments while the genset is running—hot,
moving or electrically live parts can cause se-
vere personal injury or death.
Used engine oil has been identified by some
U. S. state and federal agencies as causing
cancer or reproductive toxicity. Do not ingest,
inhale, or contact used oil or its vapors.
Ethylene glycol, used as engine antifreeze, is
toxic to humans and animals. Clean up spills
and dispose of used engine coolant in accor-
dance with local environmental regulations.
Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible ma-
terials such as wood and cloth; Class B fires,
combustible and flammable liquid fuels and
gaseous fuels; Class C fires, live electrical
equipment. (ref. NFPA No. 10)
Genset installation and operation must comply .—
with all applicable local, state and federal codes |
and regulations.
GENERATOR VOLTAGE IS DEADLY
Generator electrical output connections must
be made by a trained and experienced electri-
cian in accordance with applicable codes.
The genset must not be connected to the public
utility or any other source of electrical power.
Back-feed could lead to electrocution of utility
personnel and damage to equipment. An ap-
proved switching device must be used to pre-
vent interconnections.
Use caution when working on live electrical
equipment. Remove jewelry, make sure cloth-
ing and shoes are dry, stand on a dry wooden
platform or rubber insulating mat and use tools
with insulated handles.
ENGINE EXHAUST IS DEADLY
Leam the symptoms of carbon monoxide poi-
soning in this manual,
Never sleep in the vehicle while the genset is
running unless the vehicle is equipped with a
working carbon monoxide detector.
Disable the automatic genset starting feature of
an inverter-charger or other automatic starting
device before storing the vehicle or parking it in
a garage or other confined space.
The exhaust system must be installed in accor-
dance with the genset Installation Manual,
Engine cooling air must not be used for heating
working or living spaces or compartments.
Make sure there is ample fresh air when operat-
Ing the genset in a confined area.
DIESEL FUEL IS COMBUSTIBLE
Do not smoke or turn electrical switches ON or
OFF where fuel fumes are present or in areas
sharing ventilation with fuel tanks or equip-
ment. Keep flames, sparks, pilot lights, arc-pro-
ducing equipment and all other sources of igni-
tion well away.
Fuel lines must be secured, free of leaks and
separated or shielded from electrical wiring.
Meblie-6
BATTERY GAS IS EXPLOSIVE
Wear safety glasses.
e Do not smoke.
e To reduce arcing when disconnecting or recon-
necting battery cables, always disconnect the
negative (=) battery cable first and reconnect it
last. |
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
® Do not wear loose clothing or jewelry near mov-
ing parts such as PTO shafts, fans, belts and
pulleys.
e Keep hands away from moving parts.
* Keep guards in place over fans, belts, pulleys,
and other moving parts. |
FLAMMABLE VAPOR CAN CAUSE A
DIESEL ENGINE TO OVERSPEED
Flammable vapor can cause a diesel engine to
overspeed and become difficult to stop, resulting in
possible fire, explosion, severe personal injury and
death. Do not operate a diesel-powered genset
where a flammable vapor environment can be
created by fuel spill, leak, etc. The owners and op-
erators of the genset are solely responsible for oper-
. ating the genset safely.
Introduction
ABOUT THIS MANUAL / — ~
IMPORTANT ENSINE INFORMATION
a , mm CUMMINS FOWER GENERATION
This manual covers the operation and maintenance CT e 1400 73rd Ave, NE
7 re ни t x A , Fn
of the HDCAC and HDCAD Series of generator sets Model foil Tn | Мипевров, Mid ERASE A
(gensets). Study this manual carefully and observe Sk i PH:
ali of its instructions and precautions. Keep this AC Volts: kVA: kW
manual and the genset Installation Manual with the Amps: Pf: RP:
other vehicle manuals, Fuel: Hz Bet:
Options: Wiring — Ciegram:
Operation, Periodic Maintenance and Trouble-
shooting provide the instructions necessary for op- insulation + NEMA Class Ambient
erating the genset and maintaining it ai top репог- [The engine family designation, engine displacement, state-
mance. The owner is responsible for performing ment of compliance with applicable FFA and / or California
; . \ emissions regulations appear in this block on the actual name-
maintenance In accordance with the PERIODIC plate on the genset.]
MAINTENANCE SCHEDULE (Page 13). This |
_ /
manual also includes genset specifications, infor-
mation on how to obtain service and information re-
garding compliance with emissions regulations.
This genset is not a life support sys-
tem. It can stop without warning. Children, per-
sons with physical or mental limitations, and
pets could suffer personal injury or death. À per-
sonal attendant, redundant power or an alarm
system must be used if genset operation is criti-
cal.
MODEL IDENTIFICATION
Be ready to provide the model and serial numbers
on the genset nameplate when contacting an Onan
dealer for parts or service, Figure 1 illustrates the
RECORD NUMBERS HERE
nameplate and its location. The gray boxes show
where the mode! and serial numbers appear. Every MODEL NUMBER:
character in these numbers is significant. (The last
character of the model number is the specification SERIAL NUMBER:
letter, which is important for obtaining the right
parts.) Record the model and serial numbers in the
boxes in Figure 1 so that they are easy to find when
you need them FIGURE 1. TYPICAL NAMEPLATE
Genuine Onan replacement parts are recom-
mended for best performance and safety.
FUEL RECOMMENDATIONS
Diesel fuel is combustible and can
cause severe personal injury or death. Do not
smoke near fuel tanks or fuel-burning equip-
ment or in areas sharing ventilation with such
equipment. Keep flames, sparks, piloi flames,
electrical arcs and switches and all other
sources of ignition well away. Keep a mullti-
class ABC fire extinguisher handy.
Use clean, fresh No. 2 diesel fuel (ASTM 2-D) when
the outdoor ambient temperature is above freezing,
and No. 1 diesel fuel (ASTM 1-D) when below freez-
ing. The fuel should have a Cetane number of at
least 45 for reliable starting.
ENGINE OIL RECOMMENDATIONS
Use AP! (American Petroleum Institute) perfor-
mance Class CH-4 engine oil or better, Also look for
the SAE (Society of Automotive Engineers) viscos-
ity grade. Referring to Figure 2, choose the viscosity
grade appropriate for the ambient temperatures ex-
pected until the next scheduled oil change. Multi-
grade olls such as SAE 15W-40 are recommended
for year-round use,
LI
15W40
| ИЕ!
Г
10W30, 10W40
5W30
Ст Г TY
32
OF ap -20 10 0 10 20 30 40 50 60 70 80 90 100 110 120
0
OC 234 20 23 48 -12 7 A 4 10 16 21 27 32 38 43 28
FIGURE 2, OIL VISCOSITY VS. TEMPERATURE
STARTING BATTERIES
The genset requires a 12 volt battery to power its
control and starting circuits. Reliable genset starting
and starter service life depend upon adequate bat-
tery system capacity and maintenance. See Specifi-
cations (Page 28) for battery requirements and Pe-
riodic Maintenance (Page 17) for battery care.
TYPICAL GENSET
Figure 3 illustrates a typical genset.
LA NN
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COOLING & VENTILATING AIR IN
AC OUTPUT SERVICE OPERATOR'S CONSOLE BATTERY EXHAUST
TERMINAL ACCESS (SEE FIGURE 4) CONNECTIONS CONNECTIONS
COYER
A 5
и
<— | A ACCESS FOR ENGINE e
JA “MAINTENANCE DN
CONNECTIONS
FIGURE 3. TYPICAL GENSET
OPERATOR’S CONSOLE
The console (Figure 4) has the following features:
Control Switch — This switch is used to start and
stop the genset, prime the engine fuel system and
restore the fault code (blinking status light).
Status Light - This is an LED (light emitting diode)
in the control switch which blinks rapidly during pre-
heat and cranking. After the genset starts up, this
light stays on continuously, indicating that the gen-
set is running and that the starter has disconnected.
If the genset shuts down, this light blinks in coded
fashion to indicate the nature of the fault shutdown
(see Troubleshooting, Page 21).
(Rapid blinking before cranking starts indicates that
the alow plugs are preheating the combustion
chambers. The controller automatically varies the
time based on engine temperature.)
Line Circuit Breaker(s) — The line circuit breakers
protect the AC power leads connected to the gen-
set.
Coolant Recovery Tank Fill Cap — The recovery
tank provides for coolant expansion. Replenish the
normal loss of coolani by filling here.
Hour Meter — The hour meter records the total run-
ning time of the genset. It cannot be reset.
CONTROL SWITCH
ESTATUS LIGHT
COOLANT RECOVERY
TANK FILL CAP
COOLANT RECOVERY
TANK FLUID LEVEL
>
HOUR METER
FIGURE 4. OPERATOR'S CONSOLE
REMOTE CONTROL PANEL
The vehicle probably has a control panel inside the
vehicle for remote control of the genset. Onan offers
three remote control kits as follows:
e Remote switch / status lamp (Figure 5).
e Remote switch / status lamp and hour meter
(Figure 6).
e Remote switch / status lamp and DC voltmeter
(Figure 7). |
The DC voltmeter indicates whether voltage across
the 12 VDC control system and battery is normal. If
the indicator consistently stays above or below the
normal zone, see MAINTAINING THE BATTERY
AND BATTERY CONNECTIONS (Page 17).
и 4
Cn GenSet
Start |
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FIGURE 5. REMOTE SWITCH
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Start
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Stop
CARER GenSet
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TOTAL HOURE-QUANTZ
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FIGURE 6. REMOTE SWITCH / HOUR METER
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Stop
Canaan GenSet
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FIGURE 7. REMOTE SWITCH / DC VOLTMETER
Operation
EXHAUST GAS IS DEADLY!
All engine exhaust contains carbon monoxide;
an odorless, colorless, poisonous gas that can
cause unconsciousness and death. Symptoms
of carbon monoxide poisoning include:
e Dizziness e Headache
о Nausea « Weakness and Sleepiness
e Vomiting e Inability to Think Coherently
IF YOU EXPERIENCE ANY OF THESE SYMP-
TOMS, 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 car-
bon 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 con-
fined area.
PRE-START CHECKS
Before the first start of the day and after every eight
hours of operation, inspect the genset as instructed
under GENERAL INSPECTIONS (Page 14). Keep
a log of maintenance and the hours run and perform
any maintenance that may be due. See Returning
the Genset to Service (Page 12) if the vehicle has
been in storage.
Before each start:
1. Make sure all vehicle CO detectors are work-
ing.
2. Check for signs of fue! and exhaust leaks and
damage to the exhaust system.
3. To prevent overheating and to reduce fouling
with dust and debris, make sure the genset’s
normal ground clearance is not being reduced
by sloping ground, curbs, logs or other objects.
Repark the vehicle if necessary and/or remove —
any objects blocking the air inlet or air outlet.
4, Turn off air conditioners and other large ap-
pliances.
PRIMING THE FUEL SYSTEM
The fuel system should be primed after replacing’
the fuel filter or running the genset out of fuel. To
prime the fuel system hold the control switch down
In its Stop position for at least 1 minute.
STARTING THE GENSET
Start the genset from the genset control panel or re-
mote control panel inside the vehicle.
1. Push and hold the switch at START until the
genset starts. The status indicator light on the
switch flashes during preheat and cranking. It
will come on solid when the starter disconnects,
indicating that the genset is running. (Depend-
ing on how.cold it is, preheat can take up to
15 seconds, extending the time that the light
blinks.)
Excessive cranking can over-
heat and damage the starter motor. Do not
crank for more than 30 seconds at a time.
Wait at least 2 minutes before trying again.
2. See Troubleshooting (Page 21) if the genset
does not start after several tries.
3. For top performance and engine life, especially
in colder weather, let the engine warm up for
two minutes before connecting appliances.
4, Check for fuel, exhaust and coolant leaks. Stop
the genset immediately if there is a fuel, ex-
haust or coolant leak and have it repaired.
STOPPING THE GENSET
Turn off air conditioners and other large appliances
and let the genset run for two minutes to cool down.
Then push the switch to STOP.
AUTOMATIC STARTING AND STOPPING
The vehicle may be equipped with an inverter-char-
ger or other automatic genset starting device. Al-
ways follow the device manufacturer's instructions
and safety precautions to enable automatic genset
starting.
CARBON MONOXIDE is deadly!
MOVING PARTS and ELECTRICITY can cause
severe personal injury or death. To reduce ex-
posure to these hazards, always disable auto-
matic genset starting before:
* Sleeping in vehicle, unless vehicle has a
working CARBON MONOXIDE detector
« Parking vehicle in garage or confined space
* Parking vehicle for storage |
» Servicing genset
» Servicing batteries
« Servicing electrical appliances
« Fueling vehicle.
LOADING THE GENSET
The genset can power AC motors, air conditioners,
AC/DC converters and other loads. How much load*
can be powered depends upon the genset power
rating. The genset will shut down or its circuit break-
ers will trip if the sum of the loads exceeds genset
power. See Troubleshooting (Page 21).
Elevation above Sea .
Level Maximum Power
at/below 500 ft (152 m) 12,000 W (rated)
| at 2500 ft (762 m) 11,280 W
at 5500 ft (1676 m) 10,200 W
10,200 W minus 360 W
above 5500 ft (1676 m) every 1000 ft (305 m)
To avoid overloading the genset and causing shut-
downs, compare the sum of the loads of the ap-
pliances that are likely to be used at the same time to
the power rating of the genset. It may be necessary
to run fewer appliances at the same time—the
sum of the loads must not be greater than gen-
set rating.
The genset may shut down due 1o overload when a
large motor or air conditioner is started or cycles off
and then on again, even though the sum of the loads
is less than genset rating. The reason for this is that
a motor's startup load is much larger than its running
load. It may be necessary to run fewer ap-
pliances when large motors and air condition-
ers are cycling on and off.
Maximum power decreases as altitude increases
because air density decreases. For every 1000-foot
(305 m) increase in elevation you can expect power
to decrease approximately 3 percent. Table 1
shows the results of typical calculations. It may be
necessary to run fewer appliances at higher alti-
tudes.
TABLE 1. POWER VS. ALTITUDE
* Equipment load and genset power are measured in terms of watts (VW) or kilowatts (kW), where 1 kilowatt (kW) = 1000 watts (W).
RESETTING CIRCUIT BREAKERS
If a circuit breaker in the main power distribution
panel of the vehicle or on the genset (Figure 8} trips,
either a circuit shorted or too many appliances were
running. Note that the genset will continue to run af-
ter a circuit breaker trips.
If a circuit breaker trips, disconnect or turn off as
many loads as possible and reset the circuit break-
er. (Push the circuit breaker to OFF to reset it and
then to ON to reconnect the circuit.) If the circuit
breaker trips right away, either the electrical dis-
tribution system has a short or the circuit breaker is
faulty. Call a qualified electrician.
If the circuit breaker does not trip, reconnect the ap-
pliances, one by one, up to a total load that does not
overioad the genset or cause the circuit breaker to
trip. If a circuit breaker trips right away when a piece
of equipment is connected, the equipment probably
has a short. |
Electrical equipment and tools must be used and
maintained properly and be properly grounded to
cause the line circuit breakers to trip when short cir-
cuits occur.
Short circuits in electrical equip-
ment and tools can cause fire and electrical
shock leading to severe personal injury or
death. Read and follow the equipment and tool
manufacturer’s instructions and warnings re-
garding use, maintenance and proper ground-
ing.
CONNECTING TO UTILITY POWER
A vehicle with provisions for connecting utility power
must have an approved device to keep the genset
and utility from being interconnected. See the gen-
set Installation Manual for more information.
interconnecting the genset and the
public utility (or any other power source) can
lead to electrocution of utility line workers,
- equipment damage and fire. Use an approved
switching device to prevent interconnections,
10
LINE CIRCUIT
BREAKER(S)
FIGURE 8. LINE CIRCUIT BREAKER
OPERATING IN COLD WEATHER
Make sure the engine oll viscosity is appropriate for
the cold weather temperatures. See ENGINE OIL
RECOMMENDATIONS (Page 5). Be sure to
change the oil if a sudden drop in temperature oc-
curs.
OPERATING IN HOT WEATHER
Pay particular attention to the following items when
operating the genset in hot weather:
1. Make sure nothing blocks airflow to and from
the genset.
2. Make sure engine oil viscosity is appropriate for
the ambient temperatures. See ENGINE OIL
RECOMMENDATIONS (Page 5).
3. Keep the genset clean.
4. Perform maintenance due. See PERIODIC
MAINTENANCE SCHEDULE (Page 13).
OPERATING AT HIGH ALTITUDE
For the effect of altitude on maximum power, see
LOADING THE GENSET (Page 9).
OPERATING IN DUSTY ENVIRONMENTS
Pay particular attention to the following items when
operating the genset in dusty environments:
1. Do not let dirt and debtis accumulate inside the
genset compartment. Keep the genset clean.
2. Perform air cleaner maintenance more often.
See PERIODIC MAINTENANCE SCHEDULE
(Page 13).
11
3. Change engine oil more often. See PERIODIC
MAINTENANCE SCHEDULE (Page 13).
4, Keep containers of engine oil that have been
opened tightly closed to keep out dust.
BREAKING IN A NEW ENGINE
Proper engine break-in on a new genset or on one
with a rebuilt engine is essential for top engine per-
formance and acceptable oil consumption. Run the
genset at approximately 1/2 rated power for the first
2 hours and then at 3/4 rated power for 2 more
hours,
Proper engine oil and oil level are especially critical
during break-in because of the higher engine tem-
peratures that can be expected. Change the oil if not
appropriate for the ambient temperatures during
break-in. See ENGINE OIL RECOMMENDATIONS
(Page 5). Check oil level twice a day or every
4 hours during the first 24 hours of operation and
change the oil and oil filter after the first 50 hours of
operation.
EXERCISING THE GENSET
Exercise the genset at least 2 hours each month if
use is infrequent. Run the genset at approximately
1/2 rated power. A single two hour exercise period is
better than several shorter periods.
Exercising a genset drives off moisture, re-lubri-
cates the engine, replaces stale fuel and removes
oxides from electrical contacts. The result is better
starting, more reliable operation and longer engine
life.
STORING THE GENSET
Proper storage is essential for preserving top gen-
set performance and reliability when the genset
cannot be exercised regularly and will be idle for
more than 120 days.
Storing the Genset
1.
Push the genset line circuit breaker OFF
(Page 10).
. Change the engine oil and attach a tag indicat-
ing oil viscosity. See ENGINE OIL REC-
OMMENDATIONS (Page 5).
. Disconnect the battery cables (negative [-]
cable first) from the starting battery and store
the battery according to the battery manufac-
turer's recommendations. See MAINTAINING
THE BATTERY AND BATTERY CONNEC-
TIONS (Page 17).
. Plug the exhaust tail pipe io keep out dirt, mois-
ture, bugs, etc.
. Close the fuel supply valve (if so equipped).
. Disable the automatic genset starting feature of
an inverter-charger or other automatic starting
device. В
12
CARBON MONOXIDE is deadly
and can accumulate to dangerous levels in
garages and other confined spaces. Dis-
able the automatic genset starting feature
of an inverter-charger or other automatic
starting device before storing the vehicle.
Returning the Genset to Service
1.
Check the oil tag on the genset and change the
oil if the viscosity indicated is not appropriate for
the temperatures expected. See ENGINE OIL
RECOMMENDATIONS (Page 5).
. Reconnect the starting battery (negative [-]
cable last). See MAINTAINING THE BATTERY
AND BATTERY CONNECTIONS (Page 17).
. Remove the plug from the exhaust tailpipe.
. Change the air filter element if it is dirty
(Page 17).
. Open the fuel supply valve (if so equipped).
. Inspect the genset. See CONDUCTING GEN-
ERAL INSPECTIONS (Page 14).
. Push the genset line circuit breaker ON
(Page 10) when the genset is ready to power
appliances. |
. Enable the automatic genset starting feature of
an inverter-charger or other automatic starting
device following the device manufacturer's in-
structions and safety precautions.
Periodic Maintenance
Periodic maintenance is essential for top perfor-
mance and long genset life. Use Table 2 as a guide
for normal periodic maintenance. In hot and dusty
environments some maintenance procedures
should be performed more frequently, as indicated
by the footnotes in the table. Keeping a log of main-
tenance performed and hours run (Page 31) will
help you keep genset maintenance regular and pro-
vide a basis for supporting warranty claims.
Maintenance, replacement or repair of emission
control devices and systems may be performed by
any engine repair establishment or individual. How-
ever, warranty work must be completed by an au-
thorized Onan dealer.
TABLE 2. PERIODIC MAINTENANCE SCHEDULE
MAINTENANCE FREQUENCY
MAINTENANCE OPERATION Every her Every Every y pr y
Hours Hours Hours Hours Hours °
General Inspections . 14
Check Engine Oil Level ° 15
Check Engine Coolant Level e 14
Clean and Check Battery e” 17
Clean Spark Arrestor od 18
Change Engine Oil and Oil Filter . o1.2,3 16
Check V-Belt Tension of —
Replace Engine Air Filter of: 3 17
Replace Fuel Filter > 19
Check Coolant Anti-freeze Protection 3 19
Flush Coolant System af 14
Replace Coolant Pressure Cap e? 14
Replace Engine V-belt «> 6 —
Replace Coolant Hoses and Thermostat e5:6 —
Adjust Engine Valve Lash 5, 6 —
Service Fuel Injectors „5, © —
1 —~ Perform more often when operating in dusty conditions,
2 — Perform more often when operating in hot weather.
3 - Perform at least once a year.
4 — Perform at least once every two years.
5 — Perform ai least once every five years,
6 — Must be performed by a qualified mechanic (authorized Onan dealer).
7 — Tighten or replace the belt in accordance with the Service Manual if it can be deflected more than 1/2 in (12 mm) by thumb,
13
GENERAL INSPECTIONS
Inspect the genset before the first start of the day
and after every eight hours of operation.
Oil Level
Check engine oil level (Page 15).
Engine Coolant System
A CAUTION| Operating the genset when coolant
level is low can cause serious engine damage.
Check the coolant level and look for coolant leaks
around the bottom of the genset and on the ground
below. Minor leaks that can be replenished by daily
additions of coolant to the recovery tank should be
repaired by a qualified service technician as soon as
possible. Larger leaks are cause for shutting down
the genset until it can be repaired.
Exhaust System
EXHAUST GAS IS DEADLY! Do not
operate the genset if there is an exhaust leak or
any danger of exhaust gases entering or being
drawn into the vehicle.
Look and listen for exhaust system leaks while the
genset is running. Shut down the genset if a leak is
found and have it repaired before operating the gen-
set again.
L ook for openings or holes between the genset
compariment and vehicle cab or living space if the
genset engine sounds louder than usual. Have all
such openings or holes closed off or sealed to pre-
vent exhaust gases from entering the vehicle.
Replace dented, bent or severely rusted sections of
the tailpipe and make sure the tailpipe extends at
least 1 inch (25.4 mm) beyond the perimeter of the
vehicle.
Do not park the vehicle in high grass
or brush. Contact with the exhaust system can
cause a fire. |
14
Park the vehicle so that the genset exhaust gases
can disperse away from the vehicle. Barriers such
as walls, show banks, high grass and brush and oth-
er vehicles can cause exhaust gases to accumulate
in and around the vehicle.
Do not operate power ventilators or exhaust fans
while the vehicle is standing with the genset run-
ning. The ventilator or fan can draw exhaust gases
into the vehicle.
Fuel System
Check for leaks at hose, tube and pipe fittings in the
fuel supply system while the genset is running and
while it is stopped. Check flexible fuel hose sections
for cuts, cracks, and abrasions. Make sure the fuel
line is not rubbing against other parts. Replace worn
or damaged fuel line parts before leaks occur.
Diesel fuel leaks can lead to fire. Do
not operate the genset if operation causes fuel
to leak.
Prime the fuel system if the genset ran out of fuel.
Battery Connections
Check the battery terminals for clean, tight connec-
tions. Loose or corroded connections have high
electrical resistance which makes starting harder.
See MAINTAINING THE BATTERY AND BATTERY
CONNECTIONS (Page 17).
Mechanical
Look for mechanical damage and listen for unusual
noises. Check the genset mounting bolts.
To prevent overheating and to reduce fouling with
dust and debris, make sure the genset's normal
ground clearance is not being reduced by sloping
ground, curbs, logs or other objects. Repark the ve-
hicle if necessary and/or remove any objects block-
ing the air inlet or air outlet.
CHECKING ENGINE OIL LEVEL
State and federal agencies have de-
termined that contact with used engine oil can
cause cancer or reproductive toxicity. Avoid
skin contact and breathing of vapors. Use rub-
ber gloves and wash exposed skin.
1.
2.
Park the vehicle on level ground, shut down the
genset and remove the service access panel.
Pull out the oil dip stick, wipe it clean, reinsert
it and pull it out again to check the oil level (Fig-
ure 9).
. Add or drain oil as necessary. See ENGINE OIL
RECOMMENDATIONS (Page 5). Keep the
oil level between the FULL and ADD marks,
LA CAUTION| Too much oil can cause high oil
consumption. Too little oil can cause severe
engine damage. Keep the oil level between
the FULL and ADD marks.
. Reinsert the dipstick and secure the oil fill cap
and maintenance access panel,
15
FIGURE 9. CHECKING ENGINE OIL LEVEL
CHANGING ENGINE OIL AND OIL FILTER
State and federal agencies have de-
termined that contact with used engine oil can
cause cancer or reproductive toxicity. Avoid
skin contact and breathing of vapors. Use rub-
ber gloves and wash exposed skin.
Refer to Table 2 for scheduled engine oil change.
Change oil more often in hot and dusty environ-
ments.
1.
Place a pan under the oil drain plug (Figure 10),
run the genset until warm and shut it off.
. Remove the maintenance access panel and
the oil fill cap (Page 15), unscrew the oil drain
plug (24 mm hex head) and drain all the oil from
the engine. Reinstall the oil drain plug se-
curely.
. Spin off the oil filter canister (Page 15) and
clean the filter mounting surface on the engine
block. Remove the old gasket if it remains,
. Make sure the gasket is in place on the new fil-
ter and apply a thin film of clean oil to the gas-
ket. Spin the new filter on until the gasket just
touches the block. Turn it an additional 1/2 to
3/4 tum. Do not overtighten.
. Refill with 6.7 quarts (6.3 liters) of oil and check
the level (Page 15).
. Dispose of the used oil and oil filter according
to local environmental regulations.
16
OIL DRAIN PLUG
(24 MM HEX HEAD)
FIGURE 10. OIL DRAIN PLUG
MAINTAINING THE BATTERY AND
BATTERY CONNECTIONS
Arcing at battery terminals or in
light switches or other equipment, and flames or
sparks, can ignite battery gas causing severe
personal injury—Ventilate battery area before
working on or near battery—Wear safety
glasses—Do not smoke—Switch work light ON
or OFF away from battery—Stop genset and dis-
connect charger before disconnecting battery
cables--Disconnect negative (-) cable first and
reconnect last.
Refer to Table 2 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 terminalis tight.
2. Remove battery cables with a battery terminal
puller.
3. Make sure which terminal is positive (+) and
which is negative (-) before making battery
connections, always removing the negative (~)
cable first and reconnecting it last to reduce
arcing.
REPLACING THE AIR FILTER ELEMENT
Refer to Table 2 for scheduled air filter element re-
placement. In dusty environments the filier element
should be inspected and changed more frequently.
The air filter is accessible through the front service
access opening (Figure 11). Loosen the three
screws that secure the coolant recovery tank to the
top housing panel (removed to show air filter). and
move the tank out of the way. To change the air filter
element, remove the end cap, withdraw the element
and reassemble with a new air filter element. Se-
cure the maintenance access door.
17
AIR FILTER
HOUSING
FIGURE 11. AIR FILTER
CLEANING THE SPARK ARRESTOR
Reier to Table 2 for scheduled cleaning of the spark
arrestor muffler (which meets U.S. Forest Service
requirements). Cleaning is required for maximum
genset performance.
A hot muffler can cause severe
burns. Let the muffler cool down before remov-
ing or installing the cleanout plug.
The muffler is mounted inside the genset housing.
The spark arrestor cleanout plug is located on the
side of the muffler and is accessible through the top
service access cover (Figure 12). Clean out the
muffler as follows:
. Remove the top service access cover.
. Remove the cleanout plug (7/16 inch square
head) from the muffler and secure the top ac-
cess cover before running the genset. With the
cover in place there will be enough air flow to
cool the engine properly and carry the soot out
of the compariment,
. Start the genset and load it nearly to full power.
Let the genset run for about five minutes to ex-
pel the soot.
. Stop the genset, allow the muffler to cool down,
reinstall the cleanout plug and secure the ser-
Vice access cover.
7/16 INCH
SQUARE HEAD
FIGURE 12. SPARK ARRESTOR CLEANOUT PLUG
18
REPLACING THE FUEL FILTER
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
switches, arc-producing equipment and all oth-
er sources of ignition well away. Keep a type
ABC fire extinguisher in the vehicle.
Close any fuel line shutoff valve before discon-
necting the fuel line from the filter.
AWARNING| To prevent accidental or remote
starting while working on the genset, discon-
nect the negative (-) battery cable at the battery.
See Table 2 for scheduled fuel filter replacement. A
dirty fuel filter may be the cause of a failure to start.
The fuel filter is accessible through the front service
access door (Figure 13).
Wipe dirt off the fuel hose fittings at
the fuel filter before disconnecting the hoses so
as to keep dirt out of the fuel system.
Removing the Fuel Filter: Take care to spill as little
fuel as possible when disconnecting the filter from
the fuel line. Close any shut off valve in the fuel line.
Wipe dirt off the fuel hose fittings at the 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 comers
on the nuts. Dispose of the fuel filter according to io-
cal regulations.
Installing the Fuel Filter: Rotate the filter half a
turn around its mounting stud if the fittings interfere
with the bracket. It only fits properly one way.
Connect the fuel fittings before tightening the filter
mounting nut. Take care not to crossthread the fuel
fittings. Thread them in by hand and tighten one fiat
past seating.
Prime the fuel system by holding the control switch
down in its Stop position for at least 1 minute after
replacing the fuel filter. Priming is necessary to dis-
place the air in the new filter and fill it with fuel.
FUEL
INJECTOR
(1 OF 3)
FUEL
FILTER
—
—
+
-—
—
HOSE FITTING
{TO INJECTOR PUMPS)
FILTER MOUNTING
NUT
TUBING FITTING
(FROM LIFT PUMP)
FUEL INJECTOR
PUMP
(1 OF 3)
FUEL LIFT
PUMP
FIGURE 13. FUEL FILTER
19
CHANGING COOLANT
Refer 1o Table 2 for scheduled maintenance. The
engine cooling system is filled with a 50/50 mixture
of ethylene giycol anti-freeze and water when the
genset leaves the factory, which is suitable for tem-
peratures down to -34° F (-379 C).
Recommended Coolant Mixture
Use the best quality ethylene glycol antifreeze solu-
tion available. It should be fully formulated with rust
inhibitors and coolant stabilizers. Use fresh water
that is low in minerals and corrosive chemicals. Dis-
tilled water is best. The cooling system has a
6.1 quart (5.8 L) capacity.
Pressure Cap
Replace the pressure cap (Figure 14) every two
years (seals detetioraie and leak). Proper cooling
system pressure (14 psi) is essential for optimal en-
gine cooling and minimal coolant loss.
Draining and Cleaning the Cooling System
AWARNING | Hot coolant spray can cause severe
burns. Let the engine cool before releasing the
pressure cap or removing the drain cap.
Let the engine cool before removing the pressure
cap. Relieve any remaining pressure by turning the
pressure cap slowly, without pushing down. When
the pressure has been relieved, push down on the
cap, tum it the rest of the way and withdraw it. Then
remove the coolant drain cap (Figure 14) and drain
the coolant inio a suitable container.
Ethylene glycol antifreeze is con-
sidered toxic. Dispose of it according to local
regulations for hazardous substances.
Flush and clean the cooling system before refilling.
Radiator cleaning chemicals are available at local
auto parts stores. Follow the instructions for clean-
ing and flushing that come with the cleaning solu-
tion.
Refilling the Cooling System
Wet the O-ring in the coolant drain cap with coolant
and thread the cap on just snug with a wrench. To
avoid damaging the O-ring, do not torque to more
than 5 lb-ft (6.8 N-m). Replace the O-ring if snug-
ging the cap a little tighter does not stop leakage.
Fill the system with coolant through the fill opening.
Pull the hose connected to the pressure cap assem-
bly out as far as it will go. When the coolant level
reaches the fill opening, start and operate the gen-
set for a few minutes and shut it down. Add more
coolant if necessary and secure the pressure cap.
Fill the recovery tank with coolant mixture to the
COLD mark.
Coolant Level Check
Check coolant leve! in the recovery tank (Figure 14)
before the first startup of each day and fill to the
COLD mark if necessary.
RECOVERY TANK
FILL CAP (BLUE)
RECOVERY TANK N
FLUID LEVEL В
PRESSURE CAP
AND SYSTEM
„“ и
A и
—
COOLANT DRAIN CAP (19 MM HEX)
TORQUE TO 5 LB-FT {6.8 N-M) MAX
FIGURE 14. ENGINE COOLING SYSTEM FILL AND DRAIN CAPS
20
Troubleshooting
TABLE 3. TROUBLESHOOTING lists the shutdown
codes in numerical order along with step-by-step
corrective actions. If you are unable to resolve the
problem after taking the corrective actions sug-
gested, contact an authorized Onan dealer. See
How to Obtain Service (Page 30).
First note the following:
e Maintaining engine oil and coolant levels,
keeping battery connections ciean and tight,
watching the fuel gauge, not overioading the
genset, keeping the air inlet and outlet open-
ings clear, etc. will prevent most shutdowns.
e When the genset and vehicle engine share a
common fuel tank the fuel dip tubes are usually
arranged so that the genset will run out of fuel
first. Marking the genset empty point on the fuel
gauge will make it easier to tell when to stop the
genset before running it out of fuel.
Fault Codes
The genset controller provides extensive diagnos-
tics by causing the status indicator light on the Con-
trol Switch to blink in a coded fashion. Following a
fault shutdown, the indicator light will repeatedly
blink 1, 2, 3 or 4 blinks at a time.
e One blink indicates shui down due to high tem-
perature.
21
e Two blinks indicate shutdown due to a loss of
engine oil pressure,
e Three blinks indicate a service fault. Press
Stop once to cause the two-digit, second-level
shutdown code to blink. (Pressing Stop again
will stop the blinking.) The two-digit code con-
sists of 1, 2, 3, 4 or 5 blinks, a brief pause, and
then 1 to 9 blinks. The first set of blinks repre-
sents the tens digit and the second set of blinks
the units digit of the shutdown code number.
For example, shutdown code No. 36 appears
as:
blink-blink-blink—pause—blink-blink-blink-blink-blink-blink—
long pause—repeat
e Four blinks indicate that cranking exceeded a
preset time (20 seconds if ambient temperature
is above 32° F[0° C], 30 seconds if below) with-
out starting.
e Note: shutdown code Nos. 3 and 4 are first level
faults. Avoid interpreting them as second-level
shutdown code Nos. 33 and 44, which have not
been assigned as shutdown codes.
Restoring Fault Code Blinking
The shutdown code stops blinking after five min-
utes. Press Stop three times within three seconds
to restore blinking. Note that the last fault logged
will blink, even after the condition that caused
the shutdown has been corrected.
TABLE 3. TROUBLESHOOTING
MN WARNING ] Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
NO RESPONSE--DEAD STATUS INDICATOR LIGHT
(Poor connections, faulty wiring or dead battery)
Corrective Action:
1. Try starting the genset at the operator's console if it does not start at the remote panel.
2. Clean and tighten the battery cable connections at the battery and at the genset.
3. Recharge or replace the battery. Refer to the battery manufacturer's recommendations.
THE STARTING BATTERIES DO NOT MAINTAIN A CHARGE
(The battery, battery connections or charging system are in marginal condition)
Corrective Action:
1. Clean and tighten the battery cable connections at the battery and at the genset.
2. Recharge or replace the battery. Refer to the battery manufacturer's recommendations.
THE STARTER ENGAGES AND DISENGAGES
(Cranking voltage dips below 6 volts because of low battery charge or poor connections)
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 battery cable connections at the battery and at the genset.
3. Recharge or replace the battery. Refer to the battery manufacturer's recommendations.
THERE IS NO POWER WHEN THE GENSET IS RUNNING
(A line circuit breaker is OFF, tripped or malfunctioning)
Corrective Action:
1. Reset or turn ON the line circuit breaker on the genset (Page 10).
2. Reset or tum ON any other circuit breaker in the power supply system.
THE GENSET WILL NOT STOP RUNNING (THE RUN LIGHT IS OFF)
(The governor mechanism is stuck or binding)
Corrective Action: Close the fuel supply valve, if provided, or squeeze off the fuel supply line and see
an authorized Onan dealer.
22
TABLE 3. TROUBLESHOOTING (CONT.)
Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
Ah
HIGH TEMPERATURE FAULT--CODE NO. 1
(First-level fault code--engine coolant temperature exceeded 230% + [110° C])
Corrective Action:
1. Check the engine coolant level and add coolant as necessary (Page 20).
2. Check for and remove any objects blocking the ait inlet or outlet openings in the bottom and sides
of the genset.
3. Flush the coolant system to remove coolant passage fouling {Page 20).
LOW OIL PRESSURE FAULT—CODE NO. 2
(First-level fault code—the low oil pressure cutoff switch is open)
Corrective Action:
1. Check the engine oil leve! and add oil as necessary (Page 15).
2. Drain the excess oil if the oil level is above the Full mark on the dipstick. (The oil will foam if the level
is too high and result in possible loss of oil pressure.)
SERVICE CHECK—CODE NO. 3
(First-level fault code—a second-level fault occurred)
Corrective Action: Check the second-level fault code by momentarily pressing Stop. The second-lev-
el fault will be one of the following in this tabie.
OVERCRANK FAULT—CODE NO. 4
(First-level fault code—Cranking without starting exceeded 20 to 30 seconds, depending on n ambient)
Corrective Action:
1. Check the fuel level and refill as necessary. (Note: The genset fuel pickup is probably higher than
the vehicle engine fuel pickup.)
2. Check for fuel (air) leaks at all fuel fittings and tighten as necessary. Prime the engine fuel system
by holding the control switch at Stop for one minute.
3. Check the engine air filter (Page 17) and remove any blockage.
4. Check for mechanical damage.
. Replace the fuel filter (Page 19).
O1
OVERVOLTAGE FAULT—CODE NO. 12
(The controller is not able to regulate to rated voltage)
Corrective Action: See an authorized Onan dealer.
23
TABLE 3. TROUBLESHOOTING (CONT.)
Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safely Precautions.
UNDERVOLTAGE FAULT—CODE NO. 13
(The controller is not able to regulate to rated voltage)
Corrective Action: Turn OFF the line circuit breaker on the operator's console. If the genset now runs,
run it with fewer connected loads.
OVERFREQUENCY FAULT—CODE NO. 14
(The controller is hot able to regulate to rated frequency)
Corrective Action:
1, Check for a tripped genset circuit breaker, reset it if necessary, and run with fewer connected loads.
(A breaker tripping under load can cause frequency to overshoot.)
2. Check for fuel {air) leaks at all fuel fittings and tighten as necessary. Prime the engine fuel system
by holding the control switch at Stop for one minute. (Air bubbles can disrupt frequency.)
UNDERFREQUENCY FAULT—CODE NO. 15
(The controller is not able {o regulate to rated frequency)
Corrective Action:
1. Turn OFF the line circuit breaker. If the genset now runs, run it with fewer connected loads, especially
those with high motor starting loads such as air conditioners. |
2. Check the fuel level and refill as necessary. (Note: The genset fuel pickup is probably higher than
— the vehicle engine fuel pickup.)
3. Check for fuel (air) leaks at all fuel fittings and tighten as necessary. Prime the engine fuel system
by holding the control switch at Stop for one minute. (Air bubbles can disrupt frequency.)
4. Check the engine air filter (Page 17) and remove any blockage.
5. Check for mechanical damage.
6, Replace the fuel filter (Page 19).
GOVERNOR ACTUATOR FAULT—CODE NO. 19
(The controller sensed that the actuator circuit is either open or shorted)
Corrective Action: See an authorized Onan dealer.
24
TABLE 3. TROUBLESHOOTING (CONT.)
Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
GOVERNOR OVERLOAD FAULT—CODE NO. 22
(The duration of operation at or near full-duty cycle was beyond the design limit)
Corrective Action:
1. Reduce the number of appliances running at the same time, especially those with high motor starting
loads such as air conditioners.
2. Check for fuel (air) leaks at all fuel fittings and tighten as necessary. Prime the engine fuel system
by holding the control switch at Stop for one minute.
3. Replace the engine air filter (Page 17) and clean the spark-arrest muffler (Page 18).
4. Replace the fuel filter (Page 19).
TEMPERATURE SENDER FAULT—CODE NO. 24
(The controller sensed that the sender circuit is either open or shorted)
Corrective Action: See an authorized Onan dealer.
AC VOLTAGE SENSE FAULT—CODE NO. 27
(The controller was unable to sense output voltage)
Corrective Action: See an authorized Onan dealer.
HIGH BATTERY VOLTAGE FAULT—CODE NO. 29
(The controller sensed battery system voltage greater than 19 volts)
Corrective Action:
1. Check battery bank connections and reconnect, if necessary, so that the 12 voit batteries serving
the genset are connected in parallel (12 volt) rather than in series (24 volt).
2. Select a lower battery booster charge rate.
LOW CRANKING SPEED FAULT—CODE NO. 32
(Cranking speed less than 100 rpm [2.5 Hz, generator] for more than 12 seconds)
Corrective Action: |
1. Have the vehicle propulsion engine running while trying to start the genset. (The battery charging
alternator may be able io maintain starting voltage high enough to get the genset staried.)
2. Clean and tighten the battery cable connections at the battery and at the genset.
3. Recharge or replace the battery. Refer to the battery manufacturer's recommendations.
4. Replace engine oil with oil of proper viscosity for ambient temperatures. (High oil viscosity can slow
down cranking speed.)
25
TABLE 3. TROUBLESHOOTING (CONT.)
Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
CONTROL CARD FAULT—CODE NO. 35
(Microprocessor EEPROM error during self-test)
Corrective Action: See an authorized Onan dealer.
ENGINE STOPPED FAULT—CODE NO. 36
(The genset stopped without a command from the controlier)
Corrective Action:
1. Check the fuel level and refill as necessary. (Note: The genset fuel pickup is probably higher than
the vehicle engine fuel pickup.)
2. Check for fuel (air) leaks at all fuel fittings and tighten as necessary. Prime the engine fuel system
by holding the control switch at Stop for one minute.
3. Check the engine air filter (Page 17) and remove any blockage.
. Check for mechanical damage.
. Replace the fuel filter (Page 19).
or A
FIELD OVERLOAD FAULT—CODE NO. 38
(Field voltage exceeded 150 VDC)
Corrective Action:
1, Reduce the number of air conditioners running at the same time (and other appliances that cause
low power factor).
2. Have the air conditioners and other appliances checked for proper operation. (A locked compressor
rotor can cause very low power factor.)
SHORTED ROTOR FAULT—CODE NO. 41
(The rotor circuit is shorted to ground)
Corrective Action: See an authorized Onan dealer.
PROCESSOR FAULT—CODE NO. 42
(Microprocessor ROM error during self-test)
Corrective Action: See an authorized Onan dealer.
PROCESSOR FAULT—CODE NO. 43
(Microprocessor RAM error during self-test)
Corrective Action: See an authorized Onan dealer.
26
TABLE 3. TROUBLESHOOTING (CONT.)
Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions,
SPEED SENSE FAULT—CODE NO. 45
(Controller unable to sense quadrature frequency)
Corrective Action: Check the fuel level and fill as necessary. Then prime the engine fuel system by
holding the control switch at Stop for one minute and try restarting.
OVERPRIME FAULT—CODE NO. 57
(Prime mode exceeded 3 minutes)
Corrective Action: Check for and remove any object that may be holding either control switch (remote
or local) in the prime (stop) position.
27
Specifications
Model HDCAC
Model HDCAB
GENSET CONTROLLER: Integrated Microprocessor Based Engine and Generator Controller
GENERATOR: Single-Bearing, 4-Pole Rotating Field, 1800 RPM
Power (@1.0 power factor) 10,000 W 12,000 W
Voltage 120 / 240 120 / 240
Frequency 60 Hz 60 Hz
Number of Phases 1 1
Current 41.7 amps per leg 50 amps per leg
Line Circuit Breaker 2-pole, 45 amp 2-pole, 50 amp
FUEL CONSUMPTION:
No-load 0.11 gph (0.41 Iph) 0.11 gph (0.41 Iph)
Half-load 0.62 gph (2.34 ph) 0.75 gph (2.84 Iph)
Full-load 1.10 gph (4.16 Iph) 1.33 gph (5.03 Iph)
ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection, 4-Stroke Cycle Diesel
Bore | 3.27 in (83 mm)
Stroke 3.62 in (92 mm)
Displacement
91 in3 (1,496 ce)
Compression Ratio 22:1
Fuel Injection Timing (BTDC) 19°
Firing Order 1-3-2
Cylinder Compression Test
370 psi (2.55 mPa) minimum @ 250 rpm
Fuel Nozzle Injection Pressure
1900 psi (13.1 mPa)
Valve Lash: Intake & Exhaust (cold)
0.008 in (0.20 mm)
Oil Capacity (with filter)
6.7 quart (6.3 liter)
Cooling System Capacity
6.1 quart (5.8 liter)
DC SYSTEM:
Nominal Batiery Voltage
12 volts
Minimum Battery Capacity
CCA (Cold Cranking Amps)
475 amps down to 0° F (-17% C)
650 amps down to —20° F (-29° C)
Max. Regulated Charging Current
20 amps
WEIGHT: 660 Ibs (300 kg)
SIZE (L x W x H): 41.4 x 24,5 x 27 in (105 x 62 x 68.6 cm)
- SOUND LEVEL: 68 dB(A) @ 10 ft (3m) & 54 dB(A) @ 50 ft (15m)—in “free field site” E half load
28
Emissions
This genset meets the requirements of California’s
Exhaust Emissions Standards as stated on the
nameplate. Figure 1 (Page 4) illustrates where
this information appears on the nameplate.
California users of these gensets should be aware
that unauthorized modifications or replacement of
fuel, exhaust, air intake, or speed control system
components that affect engine emissions are pro-
hibited. Unauthorized modification, removal or re-
placement of the genset label is prohibited.
You should carefully review Operator (Owner),
Installation and other manuals and information you
receive with your genset. If you are unsure that the
installation, use, maintenance or service of your
genset is authorized, you should seek assistance
from an approved Onan dealer.
California genset users may use Table 4 as an aid in
locating information related to the California Air Re-
sources Board requirements for emissions control.
TABLE 4. EMISSIONS CONTROL INFORMATION
Emissions Warranty Information
The California emissions control warranty statement is located in
the same packet of information as this manual when the genset is |
shipped from the factory.
Engine Valve Clearance (Lash)
See Specifications (Page 28).
Engine Fuel Requirements
The engine is certified to operate on diesel fuel. See FUEL REC-
OMMENDATIONS (Page 5).
Engine Lubricating Oil Requirements
See ENGINE OIL RECOMMENDATIONS (Page 5).
Engine Adjustments
High Idie Speed. This is a service procedure requiring trained
personnel and proper tools. See the Service Manual.
Engine Emission Control System
The engine emission control system consists of engine design
and precision manufacture. (1FI)
29
How to Obtain Service
When you need service, parts, or product literature
(such as the Service Manual) for your genset, con-
tact the nearest authorized distributor, Onan has
factory-trained representatives to handie your
needs for genset parts and service.
Call 1-800-888-ONAN to contact the nearest Cum-
mins/Onan or Onan-only distributor in the United
States or Canada. (This automated service utilizes
touch-tone phones only). Select OPTION 1
(press 1) to be automatically connected to the dis-
tributor nearest to you. |
If you are unable to contact a distributor using the
automated service, consult the Yellow Pages. Typi-
‘cally, our distributors are listed under:
GENERATORS — ELECTRIC,
ENGINES ~ GASOLINE OR DIESEL, or
RECREATIONAL VEHICLES — EQUIPMENT,
PARTS AND SERVICE.
If you are outside North America, call Onan Corpo-
ration at 1-763-574-5000 from 7:30 AM to
30
4.00 PM, Central Standard Time, Monday through |
Friday, or fax 1-763-528-7229.
Before calling for service, have the following infor-
mation available:
1. The complete genset model number and serial
number. See Model Identification (Page 4).
2. The date of purchase
3. The nature of the problem. See Troubleshoot-
ing (Page 21).
If you have difficulty in arranging service or resolv-
ing a problem, please contact the Service Manager
at the nearest Cummins/Cnan distributor for assis-
tance.
Improper service or replacement of
parts can result in severe personal injury, death,
and/or equipment damage. Service personnel
must be trained and experienced in performing
electrical and/or mechanical service.
Maintenance Record
Record all periodic and unscheduled maintenance and service. See Periodic Maintenance (Page 13),
HOUR
DATE METER MAINTENANCE OR SERVICE PERFORMED
READING
Record the name, address, and phone number of your authorized Onan service center.
31
1
—
OUTLINE DRAWING
500-3869
, 101.5
4X 3/8-16 MOUNTING HOLE | GENERATOR COOLING AIR a — 263.| ———
[11.4]
3 ENGINE COMBUSTION AJR INTAKE
COOLING AIR - 305.6 = 363.1 — 171.2 DAS 27 — | 285,5 — — — ==—— — 256,7 — — | 42.21
VITAE NS [12.031 [14.291 [6,741 em E ' 11.21 [101 CIT
x E \ я | PR OUT ‘| . I Y - | a ф | i i
LT] Г [1 5 1
Id Z Fl. Во |-
-— - + - — > Г 7 19) 477 | OL ER: 124.1
| 28.6 | 7 i Z% _ 96.6 | 17 1
| 1.181 |, "e ME as [4] | ZA
ir [0.291
Blot» | 524 i . y
480, | | 92,45 GENERATOR AIR | T | | Li = 3 J ne
. + [4 a +
509 [18.9] o. CENERAT 480.1 i | OIL BRAIR Y | 13,87 1 OPTIONAL EXHAUST
[23.6) | | 7.6 [18.3] i | 7 439.8
; ‚61 Н | 7 .
1 I 43 Ци | Г [17.3]
| 7 i
45 | A| Л
{1.11 ih 170.6 I Л
| | d OIL DRAIN os! | ZN | (1) Ma _
542 _ 4" ! ‘= str tv E 4 |s172xÿ Л
£2.53) | ; DD = Y == = ЛЕ В НЮ = 7
` = a PNC. |
4X 16 À 18] —m 135,6 . [= 305,6 = 126,4 96 220,5
[0,241 [7.131 1955 = [1,27 contri ATA | [123 [5] [3,81 [8.7] OOLING AJR DISCHARGE
24.6 =
DUNTING 4 X 378-16 UNC
[0.97] не 456 === 205 TAKE | -
[17,81 (8.11 QOLING AIR i FLOOR PLAN - SECTION C-C
1037 1 m 149, 5 m} ERVICE COVER FOR ACCESS TO
140.61 FLOOR PLAN - SECTION C-C [4.9] 3/4 CONDUIT СТОЙ LUGS, INJECTORS, 0
W/O OPTOLNAL SECONDARY AC REMOTE —| 108,5 |=— TARTER AND OTHER COMPONENTS
|
| =m a A Fr a Bu. UL Г ju. 2 pl EJ KOTE:
ЧА LO
7 Br o 1. PRIMARY DIMENSIONS ARE MILLIMETERS,
35 dl { В] и DIMENSIONS IN [ 1 ARE INCHES.
STOP [1.42 ) 2. COMPARTMENT SHALL ALLOW OPENING AND CLOSING OF SERVICE
BATTERY CHARGE DISABLE sie 5 7 ACCESS DOOR AND ACCESS TD THE FOLLOWING COMPONENTS:
a | o STARY-STOP SKITCH, CIRCOIT BREAKER, COOLANT
| o FILL AÑD CHECK, AND COOLANT GRAIN. | |
SEE DETAIL С |
s © 3. MINIMUM UNIT CLEARANCE FROM COMPARTMENT SURFACES:
D ! TOP 12.5 [.50]
ALL SIDES 6.4 1.25]
o 486.7
i ] 2 à [19,2]
START я 4. MINIMUM INSTALLATION SIZE 15 697.1 [27.51 HIGH Y
E, o o ‚8 [25] WIDE X 1097 [43.21 LONG AND VARIES WITH
| | J MOUNTING KIT USED AND SERVICE DOOR ACCESS. |
REMOTE ROTO DETAIL DETAIL € B= o о 123.5 5. MATES WITH PACKARD METRI-PACK TM CONKECTOR
SCALE 1/1 COOLANT FILL E od DESCRIPTION OTY PACKARD PART HO. — ONAN PART HO,
we = - ww wr rr CONNECTOR | 12045808 323-1710
PLUG-CAVITY 3 (2059158 323-1712
Cd Naron it A SE
[15,9 0 -
83.1 1 section B-B HOUSTHG-LOCK I [2176336 323-1718
= (ny THESE TERMINALS AND HOUSING ARE DESIGNED TO BE USED
WITH 18-22 GAUGE WIRE ONLY.
SEE ACCESSORY CATALOG FOR COMPLETE MATING HARNESSES.
664.2 wo
6, UNIT WEIGHT 300.3 ¥G [652 LBS)
4" CONDUIT [26.15]
a — 210 —l /7—AC CIRCUIT
* CONDUIT 18.3] y BREAKER ©
3/4" CONDU
[4.3]
61.2
[2.42
Ele
38.9
ACCESS PANEL
[1.31]
SWITC
SERVICE COVER FOR ACCESS Tt
A-1
USH BLOCK
STOF/ STARE
HOUR METER—
32.8
11.3)
FÜ
LEVEL
ERYICE ACCESS DOOR FOR
OIL FILL, OIL FILTER,
DIPSTICH, AIR FILTER,
FUEL FILTER,
& COOLANT PRESSURE CAP
IL FILTER
IDE CIL FILL
US
#7 Ч
LT i
YHAUST
5 5 ais
57.4
| [2.31
: : / [ 137.4
5 5 5 15.4]
Do
= a 8
U. + 7 , = o
\ = se e = | re
82.1 EXHAUST FLANGET4.B „IC
e COLANT DEALN [2.9)
, 29 — —— 19 #
(0.8)
pr 1053. 6 - [3.12
| [41.5]
24 5/16-18 UNC-28
EXHAUST
66.7
[2.63]
23.2
61.2
[2.4/1]
46,7
[3.81]
CONNECT ION
UNC STUDS
[13.4] [1.14]
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