Operator’s Manual

HDKBA

Printed in U.S.A. 981−0166B

06−03

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 California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.

diesel warnings

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by any means, is strictly prohibited.
 Supplement: 981-1049
Date: 09/04
Insert with-
Manual Number (Date): 981-0173 (08/04) 981-0174 (08/04) 981-0540 (08/04)
981-0170 (11/03) 981-0171 (11/03) 981-0526D (02/04)
981-0166B (06/03) 981-0167B (06/03) 981-0535 (10/02)
981-0161 (08/89) 981-0522B (07/99)

Purpose: These instructions supplement the instructions for filling the engine cooling system found in the
Periodic Maintenance sections of the Operator’s and Service Manuals listed above.

WARNING To prevent severe burns from hot coolant under pressure, carefully observe all of the
Safety Precautions and Instructions in the Manual for handling and filling coolant.

Instructions: Use a funnel when filling the cooling system through the fill opening (Figure 1) to prevent
coolant from entering the vent hose and blocking the escape of air as the system fills. The system will seem full
when it actually is not if the air cannot escape through the vent hose. If the vent hose does get blocked, pinch
the overflow hose and blow the vent hose clear.

CAUTION Coolant trapped in the vent hose will prevent the system from filling to its capacity, which
can lead to serious engine damage.

PRESSURE CAP
AND SYSTEM FILL
OPENING

FIGURE 1. TYPICAL COOLANT FILL OPENING WITH CONNECTED FILL, OVERFLOW AND VENT HOSES

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1 document
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Table of Contents
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Starting Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Typical Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operator’s Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remote Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Conducting the Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Starting the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Stopping the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Loading the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Resetting Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connecting to Utility Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operating in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating in Hot Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating at High Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating in Dusty Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Breaking in a New Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exercising the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Storing the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Conducting General Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Changing Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maintaining the Battery and Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacing the Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cleaning the Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Changing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
HOW TO OBTAIN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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Safety Precautions
Thoroughly read the OPERATOR’S MANUAL • Do not work on the genset when mentally or
before operating the genset. Safe operation and physically fatigued or after consuming alcohol
top performance can only be obtained when or drugs.
equipment is operated and maintained properly.
• You must be trained and experienced to make
The following symbols in this manual alert you to po- adjustments while the genset is running—hot,
tential hazards to the operator, service person and moving or electrically live parts can cause se-
equipment. vere personal injury or death.
• Used engine oil has been identified by some
alerts you to an immediate hazard U. S. state and federal agencies as causing
which will result in severe personal injury or cancer or reproductive toxicity. Do not ingest,
death. inhale, or contact used oil or its vapors.
WARNING alerts you to a hazard or unsafe • Ethylene glycol, used as engine antifreeze, is
practice which can result in severe personal in- toxic to humans and animals. Clean up spills
jury or death. and dispose of used engine coolant in accor-
dance with local environmental regulations.
CAUTION alerts you to a hazard or unsafe
practice which can result in personal injury or • Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible ma-
equipment damage.
terials such as wood and cloth; Class B fires,
Electricity, fuel, exhaust, moving parts and batteries combustible and flammable liquid fuels and
present hazards which can result in severe personal gaseous fuels; Class C fires, live electrical
injury or death. equipment. (ref. NFPA No. 10)
• Genset installation and operation must comply
GENERAL PRECAUTIONS with all applicable local, state and federal codes
• Keep children away from the genset. and regulations.
• Do not use evaporative starting fluids. They are GENERATOR VOLTAGE IS DEADLY
highly explosive.
• Generator electrical output connections must
• To prevent accidental or remote starting while be made by a trained and experienced electri-
working on the genset, disconnect the nega- cian in accordance with applicable codes.
tive ( - ) battery cable at the battery.
• The genset must not be connected to the public
• Let the engine cool down before removing the utility or any other source of electrical power.
coolant pressure cap or opening the coolant Back-feed could lead to electrocution of utility
drain. Hot coolant under pressure can spray personnel and damage to equipment. An ap-
out and cause severe burns. proved switching device must be used to pre-
• Keep the genset and its compartment clean. vent interconnections.
Excess oil and oily rags can catch fire. Dirt and • Use caution when working on live electrical
gear stowed in the compartment can restrict equipment. Remove jewelry, make sure cloth-
cooling air. ing and shoes are dry, stand on a dry wooden
• Make sure all fasteners are secure and torqued platform or rubber insulating mat and use tools
properly. with insulated handles.

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 ENGINE EXHAUST IS DEADLY BATTERY GAS IS EXPLOSIVE
• Wear safety glasses.
• Learn the symptoms of carbon monoxide poi-
soning in this manual. • Do not smoke.
• To reduce arcing when disconnecting or recon-
• Never sleep in the vehicle while the genset is necting battery cables, always disconnect the
running unless the vehicle is equipped with a negative (- ) battery cable first and reconnect it
working carbon monoxide detector. last.

• The exhaust system must be installed in accor- MOVING PARTS CAN CAUSE SEVERE
dance with the genset Installation Manual. PERSONAL INJURY OR DEATH
• Engine cooling air must not be used for heating • Do not wear loose clothing or jewelry near mov-
working or living spaces or compartments. ing parts such as PTO shafts, fans, belts and
pulleys.
• Make sure there is ample fresh air when operat- • Keep hands away from moving parts.
ing the genset in a confined area. • Keep guards in place over fans, belts, pulleys,
and other moving parts.
DIESEL FUEL IS COMBUSTIBLE FLAMMABLE VAPOR CAN CAUSE A
DIESEL ENGINE TO OVERSPEED
• Do not smoke or turn electrical switches ON or
OFF where fuel fumes are present or in areas Flammable vapor can cause a diesel engine to
sharing ventilation with fuel tanks or equip- overspeed and become difficult to stop, resulting in
ment. Keep flames, sparks, pilot lights, arc-pro- possible fire, explosion, severe personal injury and
ducing equipment and all other sources of igni- death. Do not operate a diesel-powered genset
tion well away. where a flammable vapor environment can be
created by fuel spill, leak, etc. The owners and op-
• Fuel lines must be secured, free of leaks and erators of the genset are solely responsible for oper-
separated or shielded from electrical wiring. ating the genset safely.

Mobile-6

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Introduction
ABOUT THIS MANUAL

This manual covers the operation and maintenance

of the HDKBA Series of generator sets (gensets).
Study this manual carefully and observe all of its in- 5.5HDKBA-2732A
structions and precautions. Keep this manual and F000 123456
the genset Installation Manual with the other vehicle
manuals.

Operation, Periodic Maintenance and Trouble-

shooting provide the instructions necessary for op-
erating the genset and maintaining it at top perfor-
mance. The owner is responsible for performing [The engine family designation, engine displacement, state-
ment of compliance with applicable EPA and / or California
maintenance in accordance with the PERIODIC emissions regulations appear in this block on the actual name-
MAINTENANCE SCHEDULE (Page 13). This plate on the genset.]
manual also includes genset specifications, infor-
mation on how to obtain service and information re-
garding compliance with emissions regulations.

WARNING 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. A per-
sonal attendant, redundant power or an alarm
system must be used if genset operation is criti-
cal.

MODEL IDENTIFICATION

Be ready when contacting an Onan dealer for parts

or service to provide the model and serial numbers
on the genset nameplate. Figure 1 illustrates the
nameplate and its location. The numbers in the gray
boxes are typical model and serial numbers. Every
character in these numbers is significant. (The last
character of the model number is the specification RECORD NUMBERS HERE
letter, which is important for obtaining the right
parts.) Record the model and serial numbers in the MODEL NUMBER:
boxes in Figure 1 so that they are easy to find when
you need them. SERIAL NUMBER:

Genuine Onan replacement parts are recom-

mended for best performance and safety. FIGURE 1. TYPICAL NAMEPLATE

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 FUEL RECOMMENDATIONS grade oils such as SAE 15W-40 are recommended
for year-round use.
WARNING 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, pilot flames,
electrical arcs and switches and all other
sources of ignition well away. Keep a multi-
class ABC fire extinguisher handy.

Use clean, fresh No. 2 diesel fuel (ASTM 2-D) when

the outdoor ambient temperature is above freezing, FIGURE 2. OIL VISCOSITY VS. TEMPERATURE
and No. 1 diesel fuel (ASTM 1-D) when below freez-
ing. The fuel should have a Cetane number of at
STARTING BATTERIES
least 45 for reliable starting.
The genset requires a 12 volt battery to power its
control and starting circuits. Reliable genset starting
ENGINE OIL RECOMMENDATIONS and starter service life depend upon adequate bat-
tery system capacity and maintenance. See Specifi-
Use API (American Petroleum Institute) perfor- cations (Page 29) for battery requirements and Pe-
mance Class CH-4 engine oil or better. Also look for riodic Maintenance (Page 17) for battery care.
the SAE (Society of Automotive Engineers) viscos-
ity grade. Referring to Figure 2, choose the viscosity TYPICAL GENSET
grade appropriate for the ambient temperatures ex-
pected until the next scheduled oil change. Multi- Figure 3 illustrates a typical genset.

ACCESS TO COOLANT AC OUTPUT & REMOTE LIFTING EYE HOT AIR OUT
PRESSURE CAP CONTROL CONNECTIONS COVER (END & BOTTOM)

OIL
FILL

EXHAUST
TAILPIPE EXIT
(END, BACK & BOTTOM)
CONTROL
SWITCH

FUEL
COOLANT LEVEL CONNECTIONS
CHECK

AIR IN FOR COOLING, COM- ACCESS BELOW FOR OIL,

BUSTION & VENTILATION AIR & FUEL FILTERS & OIL BATTERY
(SIDE & BOTTOM) & COOLANT DRAIN VALVES CONNECTIONS

FIGURE 3. TYPICAL GENSET

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 OPERATOR’S CONSOLE
ACCESS TO OIL FILL ACCESS TO
The console (Figure 4) has the following features: COOLANT CAP & COOLANT
PRESSURE DIPSTICK RECOVERY
Control Switch - This switch is used to start and CAP TANK
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 22).
(Rapid blinking before cranking starts indicates that
the glow plugs are preheating the combustion
chambers. The controller automatically varies the
time based on engine temperature.)
Line Circuit Breakers - The line circuit breakers
protect the AC power leads connected to the gen-
set.

Coolant Pressure Cap - The coolant pressure cap COOLANT

LINE CIRCUIT CONTROL SWITCH LEVEL SIGHT
is under the access plate. Fill coolant here when re- BREAKERS & STATUS LIGHT HOLE
filling the system.

Coolant Recovery Tank - The recovery tank is

mounted inside the genset and provides for coolant FIGURE 4. OPERATOR’S CONSOLE
expansion. The coolant level is visible through the
sight hole on the front of the genset. The fill cap is
under the access cover. Replenish the normal loss
of coolant here.

Oil Fill Cap and Dipstick - Check and fill engine oil.

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 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:
• Remote switch / status lamp (Figure 5).
• Remote switch / status lamp and hour meter
(Figure 6).
• Remote switch / status lamp and DC voltmeter FIGURE 5. REMOTE SWITCH
(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).

FIGURE 6. REMOTE SWITCH / HOUR METER

FIGURE 7. REMOTE SWITCH / DC VOLTMETER

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Operation
WARNING EXHAUST GAS IS DEADLY! Repark the vehicle if necessary and/or remove
any objects blocking the air inlet or air outlet.
All engine exhaust contains carbon monoxide; 4. Turn off air conditioners and other large ap-
an odorless, colorless, poisonous gas that can pliances.
cause unconsciousness and death. Symptoms
of carbon monoxide poisoning include: PRIMING THE FUEL SYSTEM
• Dizziness • Headache The fuel system should be primed after replacing
• Nausea • Weakness and Sleepiness the fuel filter or running the genset out of fuel. To
• Vomiting • Inability to Think Coherently prime the fuel system hold the control switch down
in its Stop position for at least 1 minute (starts in
IF YOU EXPERIENCE ANY OF THESE SYMP- 2 seconds).
TOMS, GET INTO FRESH AIR IMMEDIATELY. If
symptoms persist, seek medical attention. Shut STARTING THE GENSET
down the genset and do not operate it until it has
been inspected and repaired. Start the genset from the genset control panel or re-
mote control panel inside the vehicle.
Never sleep in the vehicle while the genset is
running unless the vehicle has a working car- 1. Push and hold the switch at START until the
bon monoxide detector. The exhaust system genset starts. The status indicator light on the
must be installed in accordance with the genset switch flashes during preheat and cranking. It
Installation Manual. Make sure there is ample will come on solid when the starter disconnects,
fresh air when operating the genset in a con- indicating that the genset is running. (Depend-
fined area. ing on how cold it is, preheat can take up to
15 seconds, extending the time that the light
CONDUCTING THE PRE-START CHECKS blinks.)
CAUTION Excessive cranking can over-
Before the first start of the day and after every eight heat and damage the starter motor. Do not
hours of operation, inspect the genset as instructed crank for more than 30 seconds at a time.
under CONDUCTING GENERAL INSPECTIONS Wait at least 2 minutes before trying again.
(Page 14). Keep a log of maintenance and the hours
run and perform any maintenance that may be due. 2. See Troubleshooting (Page 22) if the genset
See Returning the Genset to Service (Page 12) if does not start after several tries.
the vehicle has been in storage. 3. For top performance and engine life, especially
in colder weather, let the engine warm up for
Before each start: two minutes before connecting appliances.
1. Make sure all vehicle CO detectors are work- 4. Check for fuel, exhaust and coolant leaks. Stop
ing. the genset immediately if there is a fuel, ex-
2. Check for signs of fuel and exhaust leaks and haust or coolant leak and have it repaired.
damage to the exhaust system.
STOPPING THE GENSET
3. To prevent overheating and to reduce fouling
with dust and debris, make sure the genset’s Turn off air conditioners and other large appliances
normal ground clearance is not being reduced and let the genset run for two minutes to cool down.
by sloping ground, curbs, logs or other objects. Then push the switch to STOP.

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 LOADING THE GENSET TABLE 1. TYPICAL APPLIANCE LOADS
Appliance Load (watts)
The genset can power AC motors, air conditioners,
AC/DC converters, battery chargers and other ap- Air Conditioner 1400-2000
pliances. How much appliance load* can be pow- Inverter/Battery Charger Up to 3000
ered depends upon the genset power rating. The DC Converter 300-1200
genset will shut down or its circuit breakers will trip if Refrigerator 600-1000
the sum of the loads exceeds genset power. See
Microwave Oven 1000-1500
Troubleshooting (Page 22).
Electric Frying Pan or Wok 1000-1500
To avoid overloading the genset and causing shut- Electric Stove Element 350-1000
downs, compare the sum of the loads of the ap- Electric Water Heater 1000-1500
pliances that are likely to be used at the same time to
Electric Iron 500-1200
the power rating of the genset. Use Table 1 or the
ratings on the appliances themselves (if so marked) Electric Hair Dryer 800-1500
to obtain the individual appliance loads. It may be Coffee Percolator 550-750
necessary to run fewer appliances at the same Television 200-600
time—the sum of the loads must not be greater Radio 50-200
than genset rating.
Electric Drill 250-750
Note that the genset may shut down due to overload Electric Broom 200-500
when a large motor or air conditioner is started or Electric Blanket 50-200
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
appliances when large motors and air condi- TABLE 2. POWER VS. ALTITUDE
tioners are cycling on and off.
Elevation above Sea
Maximum Power
Note also that maximum power decreases as alti- Level
tude increases because air density decreases. For at/below 500 ft (152 m) 5500 W (rated)
every 1000-foot (305 m) increase in elevation you at 2500 ft (762 m) 5170 W
can expect power to decrease approximately 3 per-
cent. Table 2 shows the results of typical calcula- at 5500 ft (1676 m) 4675 W
tions. It may be necessary to run fewer ap- above 5500 ft (1676 m)
4675 W minus 165 W
pliances at higher altitudes. every 1000 ft (305 m)

* Appliance load and genset power are measured in terms of watts (W) or kilowatts (kW), where 1 kilowatt (kW) = 1000 watts (W).

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 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
overload the genset or cause the circuit breaker to
trip. If a circuit breaker trips right away when an ap-
pliance is connected, the appliance probably has a
short.
LINE CIRCUIT
Electrical appliances and tools must be used and BREAKER(S)
maintained properly and be properly grounded to
cause the line circuit breakers to trip when short cir- FIGURE 8. LINE CIRCUIT BREAKERS
cuits occur.
WARNING Short circuits in electrical ap-
pliances 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.
WARNING 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.

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 OPERATING IN COLD WEATHER 3. Change engine oil more often. See PERIODIC
MAINTENANCE SCHEDULE (Page 13).
Make sure the engine oil viscosity is appropriate for
4. Keep containers of engine oil that have been
the cold weather temperatures. See ENGINE OIL
opened tightly closed to keep out dust.
RECOMMENDATIONS (Page 5). Be sure to
change the oil if a sudden drop in temperature oc- BREAKING IN A NEW ENGINE
curs.
Proper engine break-in on a new genset or on one
OPERATING IN HOT WEATHER with a rebuilt engine is essential for top engine per-
formance and acceptable oil consumption. Run the
Pay particular attention to the following items when genset at approximately 1/2 rated power for the first
operating the genset in hot weather: 2 hours and then at 3/4 rated power for 2 more
1. Make sure nothing blocks airflow to and from hours. See LOADING THE GENSET (Page 9).
the genset.
Proper engine oil and oil level are especially critical
2. Make sure engine oil viscosity is appropriate for during break-in because of the higher engine tem-
the ambient temperatures. See ENGINE OIL
peratures that can be expected. Change the oil if not
RECOMMENDATIONS (Page 5).
appropriate for the ambient temperatures during
3. Keep the genset clean. break-in. See ENGINE OIL RECOMMENDATIONS
4. Perform maintenance due. See PERIODIC (Page 5). Check oil level twice a day or every
MAINTENANCE SCHEDULE (Page 13). 4 hours during the first 24 hours of operation and
change the oil and oil filter after the first 50 hours of
OPERATING AT HIGH ALTITUDE operation.

For the effect of altitude on maximum power, see EXERCISING THE GENSET
LOADING THE GENSET (Page 9).
Exercise the genset at least 2 hours each month if
OPERATING IN DUSTY ENVIRONMENTS use is infrequent. Run the genset at approximately
1/2 rated power. See LOADING THE GENSET
Pay particular attention to the following items when (Page 9). A single two hour exercise period is bet-
operating the genset in dusty environments: ter than several shorter periods.
1. Do not let dirt and debris accumulate inside the Exercising a genset drives off moisture, re-lubri-
genset compartment. Keep the genset clean. cates the engine, replaces stale fuel and removes
2. Perform air cleaner maintenance more often. oxides from electrical contacts. The result is better
See PERIODIC MAINTENANCE SCHEDULE starting, more reliable operation and longer engine
(Page 13). life.

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 STORING THE GENSET Returning the Genset to Service
Proper storage is essential for preserving top gen- 1. Check the oil tag on the genset and change the
set performance and reliability when the genset oil if the viscosity indicated is not appropriate for
cannot be exercised regularly and will be idle for the temperatures expected. See ENGINE OIL
more than 120 days. RECOMMENDATIONS (Page 5).

Storing the Genset 2. Reconnect the starting battery (negative [ - ]

1. Push the genset line circuit breaker OFF cable last). See MAINTAINING THE BATTERY
(Page 10). AND BATTERY CONNECTIONS (Page 17).
2. Change the engine oil and attach a tag indicat- 3. Remove the plug from the exhaust tailpipe.
ing oil viscosity. See ENGINE OIL REC-
OMMENDATIONS (Page 5). 4. Change the air filter element if it is dirty
3. Disconnect the battery cables (negative [ - ] (Page 17).
cable first) from the starting battery and store
the battery according to the battery manufac- 5. Open the fuel supply valve (if so equipped).
turer’s recommendations. See MAINTAINING
THE BATTERY AND BATTERY CONNEC- 6. Inspect the genset. See CONDUCTING GEN-
TIONS (Page 17). ERAL INSPECTIONS (Page 14).
4. Plug the exhaust tail pipe to keep out dirt, mois- 7. Push the genset line circuit breaker ON
ture, bugs, etc. (Page 10) when the genset is ready to power
5. Close the fuel supply valve (if so equipped). appliances.

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Periodic Maintenance
Periodic maintenance is essential for top perfor- help you keep genset maintenance regular and pro-
mance and long genset life. Use Table 3 as a guide vide a basis for supporting warranty claims.
for normal periodic maintenance. In hot and dusty Maintenance, replacement or repair of emission
environments some maintenance procedures control devices and systems may be performed by
should be performed more frequently, as indicated any engine repair establishment or individual. How-
by the footnotes in the table. Keeping a log of main- ever, warranty work must be completed by an au-
tenance performed and hours run (Page 32) will thorized Onan dealer.

TABLE 3. PERIODIC MAINTENANCE SCHEDULE

MAINTENANCE FREQUENCY

P
MAINTENANCE OPERATION Every Every Every
Every After First Every a
150 500 1000
Day 50 Hours Month g
Hours Hours Hours
e

General Inspection • 14
Check Engine Oil Level • 15
Check Engine Coolant Level • 21
Clean and Check Battery •2 17
Clean Spark Arrestor •3 18
Change Engine Oil and Oil Filter • •1, 2, 3 16
Replace Engine Air Filter •1, 3 17
Replace Fuel Filter •3 19
Check Coolant Anti-Freeze Protection •3 14
Flush Coolant System •4 14
Replace Coolant Pressure Cap •4 14
Replace Engine V-belt (Coolant Pump) •5, 6 -
Replace Coolant Hoses and Thermostat •5, 6 -
Adjust Engine Valve Lash •5, 6 -
Service Fuel Injectors •5, 6 -
Check Generator Bearings, Drive Belt, Belt
•5, 6 -
Tensioner & Drive Coupling
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 at least once every five years.
6 - Must be performed by a qualified mechanic (authorized Onan dealer).

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 CONDUCTING GENERAL INSPECTIONS WARNING Do not park the vehicle in high grass
or brush. Contact with the exhaust system can
Inspect the genset before the first start of the day cause a fire.
and after every eight hours of operation.
Park the vehicle so that the genset exhaust gases
can disperse away from the vehicle. Barriers such
Oil Level as walls, snow banks, high grass and brush and oth-
er vehicles can cause exhaust gases to accumulate
Check engine oil level (Page 15). in and around the vehicle.

Engine Coolant System Do not operate power ventilators or exhaust fans

while the vehicle is standing with the genset run-
CAUTION Operating the genset when coolant ning. The ventilator or fan can draw exhaust gases
level is low can cause serious engine damage. into the vehicle.

Check the coolant level and look for coolant leaks Fuel System
around the bottom of the genset and on the ground
below. Minor leaks that can be replenished by daily Check for leaks at hose, tube and pipe fittings in the
additions of coolant to the recovery tank should be fuel supply system while the genset is running and
repaired by a qualified service technician as soon as while it is stopped. Check flexible fuel hose sections
possible. Larger leaks are cause for shutting down for cuts, cracks, and abrasions. Make sure the fuel
the genset until it can be repaired. line is not rubbing against other parts. Replace worn
or damaged fuel line parts before leaks occur.
Exhaust System WARNING Diesel fuel leaks can lead to fire. Do
not operate the genset if operation causes fuel
WARNING EXHAUST GAS IS DEADLY! Do not
to leak.
operate the genset if there is an exhaust leak or
any danger of exhaust gases entering or being Prime the fuel system if the genset ran out of fuel.
drawn into the vehicle.
Battery Connections
Look and listen for exhaust system leaks while the
genset is running. Shut down the genset if a leak is Check the battery terminals for clean, tight connec-
found and have it repaired before operating the gen- tions. Loose or corroded connections have high
set again. electrical resistance which makes starting harder.
See MAINTAINING THE BATTERY AND BATTERY
Look for openings or holes between the genset CONNECTIONS (Page 17).
compartment and vehicle cab or living space if the
genset engine sounds louder than usual. Have all Mechanical
such openings or holes closed off or sealed to pre-
Look for mechanical damage and listen for unusual
vent exhaust gases from entering the vehicle.
noises. Check the genset mounting bolts.
Replace dented, bent or severely rusted sections of To prevent overheating and to reduce fouling with
the tailpipe and make sure the tailpipe extends at dust and debris, make sure the genset’s normal
least 1 inch (25.4 mm) beyond the perimeter of the ground clearance is not being reduced by sloping
vehicle. ground, curbs, logs or other objects. Repark the ve-
hicle if necessary and/or remove any objects block-
Check all CO monitors to assure proper operation. ing the air inlet or air outlet.

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 CHECKING ENGINE OIL LEVEL
Park the vehicle on level ground and shut off the OIL FILL PLUG
AND DIPSTICK
genset before checking engine oil level.

WARNING Crankcase pressure can blow hot

engine oil out the fill opening causing severe
burns. Always stop the genset before removing
the oil fill plug or drain.
1. Pull the oil fill plug and dipstick out of the oil fill
neck (Figure 9). The plug may be difficult to pull
straight out. It is easier if you tilt the plug in its
socket while pulling out. Wipe off the dipstick
and thread it back into the fill neck and seat the
plug, which snaps into its socket. Remove the
plug and dipstick again and check the oil level
on the dip stick.
2. Add or drain oil as necessary. See ENGINE OIL KEEP OIL LEVEL
BETWEEN THESE TWO
RECOMMENDATIONS (Page 5). Keep the BEADS ON DIPSTICK
oil level between the high and low beads on the
end of the dipstick, as shown. It is not neces-
sary to add oil between oil changes if the oil has
not dropped more than 1/3 of the way between
the high and low beads. Approximately 1 pint
(0.4 liter) can be added if the oil level is at the
lower bead.
CAUTION Too much oil can cause high oil
consumption. Too little oil can cause severe
engine damage. Keep the oil level between
the high and low beads on the dipstick. FIGURE 9. CHECKING ENGINE OIL LEVEL

3. Secure the oil fill plug, which snaps into its

socket.

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CHANGING ENGINE OIL AND OIL FILTER OIL DRAIN OIL DRAIN
Refer to Table 3 for scheduled engine oil change. VALVE HOSE
Change oil more often in hot and dusty environ-
ments.
WARNING 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.
WARNING To prevent accidental or remote
starting while working on the genset, discon-
nect the negative (- ) battery cable at the battery.
1. Run the genset until warm and shut it off.
2. Pull the oil dipstick (Page 15) out a couple of
inches (50 mm) so that the oil will drain faster. OIL FILTER

3. Remove the bottom access cover (Figure 10)

and direct the end of the drain hose into a con-
tainer.
4. Open the drain valve to drain all of the old oil.
5. Close the drain valve.
6. Spin off the oil filter canister and clean the filter
mounting surface on the engine block. Remove
the old gasket if it remains. FIGURE 10. OIL DRAIN PLUG AND OIL FILTER
7. 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 turn. Do not over tighten.
8. Refill with 2 quarts (1.9 liters) of oil and check
the level (Page 15).
9. Secure the maintenance access covers for
proper engine cooling and for protection from
hazardous moving parts and hot exhaust man-
ifolds.
WARNING Do not run the genset with the
maintenance access covers off. Contact
with hazardous moving parts and hot ex-
haust manifolds can cause severe personal
injury.
10. Dispose of the used oil and oil filter according
to local environmental regulations.

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 MAINTAINING THE BATTERY AND
BATTERY CONNECTIONS
Refer to Table 3 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:

WARNING Arcing at battery terminals or in

light switches or other equipment, and flames or
sparks, can ignite battery gas causing severe AIR FILTER ELEMENT
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. FILTER HOUSING

1. Keep the battery case and terminals clean and

dry and the terminals tight.
2. Remove battery cables with a battery terminal
puller.
3. Make sure which terminal is positive (+) and
which is negative ( - ) before making battery
connections, always removing the negative (- )
cable first and reconnecting it last to reduce HOUSING SUPPORT FRAME
arcing.

REPLACING THE AIR FILTER ELEMENT

Refer to Table 3 for scheduled air filter element re- FIGURE 11. AIR FILTER
placement. In dusty environments the filter element
should be inspected and changed more frequently.
Remove the protective grille below the air filter (Fig-
ure 11). Then unscrew the two (2) wingnuts and pull
away the housing support frame, housing and filter
element.
Turn the wingnuts hand tight when installing the new
filter element.
Note: The filter housing and its support frame fit only
one way (one corner has been trimmed). Turn the as-
sembly all the way around if it does not fit and try
again.

Replace the bottom protective grille.

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 CLEANING THE SPARK ARRESTOR side of the muffler and is accessible through the bot-
tom (Figure 12). Clean out the muffler as follows:
Refer to Table 3 for scheduled cleaning of the spark
arrestor muffler (which meets U.S. Forest Service
requirements). Cleaning is required for maximum 1. Remove the cleanout plug (7/16 inch square
genset performance. head) from the muffler.

WARNING A hot muffler can cause severe 2. Start the genset and load it nearly to full power.
burns. Let the muffler cool down before remov- Let the genset run for about five minutes to ex-
ing or installing the cleanout plug. pel the soot.

The muffler is mounted inside the genset housing. 3. Stop the genset, allow the muffler to cool down
The spark arrestor cleanout plug is located on the and reinstall the cleanout plug.

CLEANOUT
PLUG

FIGURE 12. SPARK ARRESTOR CLEANOUT PLUG

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 REPLACING THE FUEL FILTER as not to round the corners or stress the fittings.
Then remove the filter mounting nut and two (2)
See Table 3 for scheduled fuel filter replacement. A bracket mounting screws. Dispose of the fuel filter
dirty fuel filter may be the cause of a failure to start. according to local regulations.
The fuel filter is accessible through the bottom main-
tenance access cover (Figure 13). Installing the Fuel Filter: Secure the bracket
loosely to the new filter. The filter and its bracket fit
WARNING Diesel fuel is combustible and can properly only one way.
cause severe personal injury or death. Do not
smoke near diesel fuel tanks or equipment. Loosely secure the filter and bracket to the base
Keep flames, sparks, pilot lights, electrical with the two mounting screws and re-connect the
switches, arc-producing equipment and all oth- fuel fittings. Take care not to cross thread the fuel fit-
er sources of ignition well away. Keep a type tings. Thread them in by hand and tighten one flat
ABC fire extinguisher in the vehicle. past seating. Finally, tighten the bracket and bracket
mounting screws.
WARNING To prevent accidental or remote
Prime the fuel system by holding the control switch
starting while working on the genset, discon-
down in its Stop position for at least 1 minute. Prim-
nect the negative (- ) battery cable at the battery.
ing is necessary to fill the new filter with fuel.
Removing the Fuel Filter: Take care to spill as little Secure the maintenance access cover for proper
fuel as possible when disconnecting the filter from engine cooling and for protection from hazardous
the fuel line. Close any shut off valve in the fuel line. moving parts and hot exhaust manifolds.
Wipe dirt off the fuel hose fittings at the filter to keep
dirt out of the fuel system. WARNING Do not run the genset with the main-
tenance access covers off. Contact with hazard-
To remove the filter, disconnect the two fittings at the ous moving parts and hot exhaust manifolds
filter. Use two flarenut wrenches on each fitting so can cause severe personal injury.

FILTER DISCONNECT FUEL FILTER MOUNTING DISCONNECT FUEL

LINE TO ENGINE NUT LINE FROM PUMP

FILTER BRACKET
FILTER BRACKET MOUNTING SCREWS

FIGURE 13. FUEL FILTER

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 CHANGING COOLANT
RADIATOR DRAIN COCK
Refer to Table 3 for scheduled maintenance. The
engine cooling system is filled with a 50/50 mixture
of ethylene glycol and water at the factory, which is
suitable for temperatures down to -34° F (-37° 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.

WARNING Hot coolant spray can cause severe

burns. Let the engine cool before releasing the
pressure cap or removing the drain cap.

Pressure Cap
Replace the pressure cap (Figure 15) every two
years (seals deteriorate and leak). Proper cooling
system pressure (14 psi) is essential for optimal en-
gine cooling and minimal coolant loss.

Draining the Cooling System

WARNING To prevent accidental or remote
starting while working on the genset, discon-
nect the negative (- ) battery cable at the battery.

Let the engine cool before removing the pressure

cap. Relieve any remaining pressure by turning the FIGURE 14. LOWER RADIATOR HOSE
pressure cap slowly, without pushing down. To re-
move the cap, push down and turn it the rest of the
way. Then remove the bottom access cover (Fig-
ure 14), open the radiator drain cock and drain the
coolant into a suitable container. Approximately 1.6
quarts (1.5 L) will drain.

WARNING Ethylene glycol antifreeze is con-

sidered toxic. Dispose of it according to local
regulations for hazardous substances.

20 Redistribution or publication of this document

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Cleaning the Cooling System Secure the maintenance access covers for proper
engine cooling and for protection from hazardous
Clean and flush the cooling system with radiator moving parts and hot exhaust manifolds.
cleaning chemicals available at auto parts stores.
WARNING Do not run the genset with the main-
Follow the instructions for cleaning and flushing that
come with the cleaning solution. tenance access covers off. Contact with hazard-
ous moving parts and hot exhaust manifolds
can cause severe personal injury.
Refilling the Cooling System
Close the radiator drain cock and fill the system with Fill the recovery tank with coolant mixture to the
coolant through the fill opening. Pull the hose con- COLD mark.
nected to the pressure cap assembly out as far as it
Coolant Level Check
will go. When the coolant level reaches the fill open-
ing, start and operate the genset for a few minutes Check coolant level in the recovery tank (Figure 15)
and shut it down. Add more coolant if necessary and before the first startup of each day and fill to the
secure the pressure cap. COLD mark if necessary.

PRESSURE CAP AND

SYSTEM FILL OPENING

COOLANT RECOVERY
TANK FILL CAP RECOVERY TANK
FLUID LEVEL

FIGURE 15. ENGINE COOLING SYSTEM PRESSURE CAP AND RECOVERY TANK

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Troubleshooting
TABLE 4. TROUBLESHOOTING lists the shutdown • Two blinks indicate shutdown due to a loss of
codes in numerical order along with step-by-step engine oil pressure.
corrective actions. If you are unable to resolve the
• Three blinks indicate a service fault. Press
problem after taking the corrective actions sug-
Stop once to cause the two-digit, second-level
gested, contact an authorized Onan dealer. See
shutdown code to blink. (Pressing Stop again
How to Obtain Service (Page 31).
will stop the blinking.) The two-digit code con-
sists of 1, 2, 3, 4 or 5 blinks, a brief pause, and
First note the following:
then 1 to 9 blinks. The first set of blinks repre-
• Maintaining engine oil and coolant levels, sents the tens digit and the second set of blinks
keeping battery connections clean and tight, the units digit of the shutdown code number.
watching the fuel gauge, not overloading the For example, shutdown code No. 36 appears
genset, keeping the air inlet and outlet open- as:
ings clear, etc. will prevent most shutdowns. blink-blink-blink—pause—blink-blink-blink-blink-blink-blink—
• When the genset and vehicle engine share a long pause—repeat
common fuel tank the fuel dip tubes are usually • Four blinks indicate that cranking exceeded a
arranged so that the genset will run out of fuel preset time (20 seconds if ambient temperature
first. Marking the genset empty point on the fuel is above 32° F[0° C], 30 seconds if below) with-
gauge will make it easier to tell when to stop the out starting.
genset before running it out of fuel.
• Note: shutdown code Nos. 3 and 4 are first level
SHUTDOWN CODES faults. Avoid interpreting them as second-level
shutdown code Nos. 33 and 44, which have not
The genset controller provides extensive diagnos- been assigned as shutdown codes.
tics by causing the status indicator light on the Con-
Restoring Shutdown Code Blinking - The shut-
trol Switch to blink in a coded fashion. Following a
down code stops blinking after five minutes. Press
fault shutdown, the indicator light will repeatedly
Stop three times within three seconds to restore
blink 1, 2, 3 or 4 blinks at a time.
blinking. Note that the last fault logged will blink,
• One blink indicates shut down due to high tem- even after the condition that caused the shut-
perature. down has been corrected.

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 TABLE 4. TROUBLESHOOTING
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 turn 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.

23 Redistribution or publication of this document

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 TABLE 4. TROUBLESHOOTING (CONT.)
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.

HIGH TEMPERATURE FAULT—CODE NO. 1

(First-level fault code—engine coolant temperature exceeded 230° F [110° C])

Corrective Action:
1. Check the engine coolant level and add coolant as necessary (Page 21).
2. Check for and remove any objects blocking the air 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 level 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 table.

OVERCRANK FAULT—CODE NO. 4

(First-level fault code—Cranking without starting exceeded 20 to 30 seconds, depending on 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.
5. Replace the fuel filter (Page 19).

OVERVOLTAGE FAULT—CODE NO. 12

(The controller is not able to regulate to rated voltage)

Corrective Action: See an authorized Onan dealer.

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 TABLE 4. TROUBLESHOOTING (CONT.)
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.

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 not 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 to 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.

25 Redistribution or publication of this document

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 TABLE 4. TROUBLESHOOTING (CONT.)
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.

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 volt batteries serving
the genset are connected in parallel (12 volt) rather than in series (24 volt).
2. Select a lower battery booster charge rate.

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 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.
4. Replace engine oil with oil of proper viscosity for ambient temperatures. (High oil viscosity can slow
down cranking speed.)

26 Redistribution or publication of this document

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 TABLE 4. TROUBLESHOOTING (CONT.)
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.

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 controller)

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.
5. Replace the fuel filter (Page 19).

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.

27 Redistribution or publication of this document

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 TABLE 4. TROUBLESHOOTING (CONT.)
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.

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.

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Specifications
GENSET CONTROLLER: Integrated Microprocessor Based Engine and Generator Controller
GENERATOR: Two-Bearing, Two-Pole Rotating Field, 3600 RPM, “Poly-Vee” Belt Drive
Power (@1.0 power factor) 5500 W
Voltage 120
Frequency 60 Hz
Number of Phases 1
Current 45.8 amps
Line Circuit Breakers (Standard) One 20 amp and One 30 amp
FUEL CONSUMPTION:
No-load 0.25 gph (0.93 lph)
Half-load 0.41 gph (1.57 lph)
Full-load 0.66 gph (2.51 lph)
ENGINE: 2-Cylinder In-Line, Water-Cooled, Indirect-Injection, 2880 RPM, 4-Stroke Cycle Diesel
Bore 2.64 in (67 mm)
Stroke 2.68 in (68 mm)
Displacement 29.23 in3 (479 cc)
Compression Ratio 23 : 1
Fuel Injection Timing (BTDC) 18° - 20°
Injection Order 1-2
Fuel Nozzle Injection Pressure 1991 psi (13.73 mPa)
Valve Lash: Intake & Exhaust (cold) 0.0059 - 0.0073 inch (0.145 - 0.185 mm)
Oil Capacity (with filter) 2 quart (1.9 liter)
Cooling System Capacity 2.5 quart (2.4 liter)
DC SYSTEM:
Nominal Battery 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)
Fuse F1 (control, start and glow plug circuits) 30 amp mini-bayonet
WEIGHT: 400 lbs (181 kg)
SIZE (L x W x H): 34.5 x 22.4 x 20.3 in (846 x 549 x 498 mm)
SOUND LEVEL: 68 dB(A) @ 10 ft (3m) in typical RV installation

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Emissions
The engine has a label on the side of the valve cov- You should carefully review Operator (Owner),
er, facing the maintenance side of the genset, which Installation and other manuals and information you
states compliance with applicable EPA and Califor- receive with your genset. If you are unsure that the
nia emissions regulations. installation, use, maintenance or service of your
genset is authorized, you should seek assistance
California users of these gensets should be aware from an approved Onan dealer.
that unauthorized modifications or replacement of
fuel, exhaust, air intake, or speed control system
components that affect engine emissions are pro- California genset users may use Table 5 as an aid in
hibited. Unauthorized modification, removal or re- locating information related to the California Air Re-
placement of the genset label is prohibited. sources Board requirements for emissions control.

TABLE 5. EMISSIONS CONTROL INFORMATION

The California emissions control warranty statement is located in

Emissions Warranty Information the same packet of information as this manual when the engine is
shipped from the factory.
Engine Valve Clearance (Lash) See Specifications (Page 29).
The engine is certified to operate on diesel fuel. See FUEL REC-
Engine Fuel Requirements
OMMENDATIONS (Page 5).
Engine Lubricating Oil Requirements See ENGINE OIL RECOMMENDATIONS (Page 5).
High Idle Speed. This is a service procedure requiring trained
Engine Adjustments
personnel and proper tools. See the Service Manual.
The engine emission control system consists of engine design
Engine Emission Control System
and precision manufacture. (IFI)

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How to Obtain Service
When you need service, parts, or product literature 4:00 PM, Central Standard Time, Monday through
(such as the Service Manual) for your genset, con- Friday, or fax 1 - 763 - 528 - 7229.
tact the nearest authorized distributor. Onan has
factory-trained representatives to handle your Before calling for service, have the following infor-
needs for genset parts and service. mation available:
Call 1-800-888-ONAN to contact the nearest Cum- 1. The complete genset model number and serial
mins/Onan or Onan-only distributor in the United number. See Model Identification (Page 4).
States or Canada. (This automated service utilizes
2. The date of purchase
touch-tone phones only). Select OPTION 1
(press 1) to be automatically connected to the dis- 3. The nature of the problem. See Troubleshoot-
tributor nearest to you. ing (Page 22).

If you are unable to contact a distributor using the If you have difficulty in arranging service or resolv-
automated service, consult the Yellow Pages. Typi- ing a problem, please contact the Service Manager
cally, our distributors are listed under: at the nearest Cummins/Onan distributor for assis-
tance.
GENERATORS - ELECTRIC,
ENGINES - GASOLINE OR DIESEL, or
RECREATIONAL VEHICLES - EQUIPMENT, WARNING Improper service or replacement of
PARTS AND SERVICE. parts can result in severe personal injury, death,
and/or equipment damage. Service personnel
If you are outside North America, call Onan Corpo- must be trained and experienced in performing
ration at 1 - 763 - 574 - 5000 from 7:30 AM to electrical and/or mechanical service.

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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.

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Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
763-574-5000
Fax: 763-528-7229

Cummins and Onan are registered trademarks of Cummins Inc.

Redistribution or publication of this document

by any means, is strictly prohibited.