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 Service Manual

HDKCA, HDKCB, HDKCC, HDKCD

Printed in U.S.A. 10-06 981-0540B

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

diesel warnings
Table of Contents

SECTION PAGE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Typical Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Recommended Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Recommended Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Recommended Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Starting Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Remote Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Manual Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Manual Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Automatic Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Loading the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Resetting Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Connecting to Utility Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operating in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operating in Hot Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operating at High Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operating in Dusty Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Breaking In a New Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Exercising the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Storing the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

i
SECTION PAGE

3. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Changing Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Maintaining the Battery and Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Replacing the Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cleaning the Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Maintaining the Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
4. PREPARATIONS FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Removing / Installing Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Test Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Disassembling / Reassembling Housing and Mounting System . . . . . . . . . . . . . 4-4
5. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
6. AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
7. EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
8. ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Thermostat and Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Fan Belt (Beginning Spec B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Fan Belt (Spec A only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

ii
SECTION PAGE

9. ENGINE AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Battery Charging Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Governor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
High-Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
10. GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Generator Winding Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Generator Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Adjusting Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
11. CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Control Board (Controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Local and Remote Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Line Circuit Breakers CB1, CB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Relays K1, K2, K3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Voltage Sense Transformer TX1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
12. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Troubleshooting With Table 12-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Fault Code Blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Restoring Fault Code Blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
13. BOLT TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
14. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
15. SERVICE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

CONTROL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

CONTROL WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
AC WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

iii
SAFETY PRECAUTIONS
Thoroughly read the OPERATOR’S MANUAL GENERATOR VOLTAGE IS DEADLY
before operating the genset. Safe operation and
• Disable the automatic genset starting feature
top performance can only be obtained when
(AGS) of an inverter-charger or other automat-
equipment is properly operated and main-
ic starting device before servicing the genset.
tained.
• Generator electrical output connections must
The following symbols in this manual alert you to be made by a trained and experienced electri-
potential hazards to the operator, service person cian in accordance with applicable codes.
and equipment. • The genset must not be connected to shore
power (utility). Back-feed to shore power can
DANGER alerts you to an immediate hazard cause electrocution and damage to equip-
that will result in severe personal injury or ment. An approved switching device must be
death. used to prevent interconnections.
• Use caution when working on live electrical
WARNING alerts you to a hazard or unsafe equipment. Remove jewelry, make sure cloth-
practice that can result in severe personal inju- ing and shoes are dry, stand on a dry wooden
ry or death. platform or rubber insulating mat and use tools
with insulated handles.
CAUTION alerts you to a hazard or unsafe DIESEL FUEL IS COMBUSTIBLE
practice that can result in personal injury or
equipment damage. • Do not smoke or turn electrical switches ON or
OFF where fuel fumes are present or in areas
Electricity, fuel, exhaust, moving parts and batter- sharing ventilation with fuel tanks or equip-
ies present hazards which can result in severe per- ment. Keep flames, sparks, pilot lights, arc-
sonal injury or death. producing equipment and all other sources of
ignition well away.
ENGINE EXHAUST IS DEADLY • Fuel lines must be secured, free of leaks and
separated or shielded from electrical wiring.
• Inspect for exhaust leaks at every startup and
after every eight hours of running. MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
• Learn the symptoms of carbon monoxide poi-
soning in the genset Operator’s Manual. • Disable the automatic genset starting feature
(AGS) of an inverter-charger or other automat-
• Never sleep in the vehicle while the genset is ic starting device before servicing the genset.
running unless the vehicle is equipped with a
working carbon monoxide detector. • Do not wear loose clothing or jewelry near
moving parts such as PTO shafts, fans, belts
• Do not operate the genset when the vehicle is and pulleys.
parked in a confined space, such as a garage. • Keep hands away from moving parts.
• Disable the automatic genset starting feature • Keep guards in place over fans, belts, pulleys,
(AGS) of an inverter-charger or other automat- and other moving parts.
ic starting device before storing the vehicle or
parking it in a garage or other confined space. BATTERY GAS IS EXPLOSIVE
• The exhaust system must be installed in accor- • Wear safety glasses.
dance with the genset Installation Manual. • Do not smoke.
• Engine cooling air must not be used for heating • To reduce arcing when disconnecting or recon-
the vehicle. necting battery cables, always disconnect the

iv
 negative (−) battery cable first and reconnect gear stowed in the compartment can restrict
it last. cooling air.
• Make sure all fasteners are secure and
FLAMMABLE VAPOR CAN CAUSE A torqued properly.
DIESEL ENGINE TO OVERSPEED • Do not work on the genset when mentally or
physically fatigued or after consuming alcohol
Flammable vapor can cause a diesel engine to or drugs.
overspeed and become difficult to stop, resulting in
possible fire, explosion, severe personal injury and • You must be trained and experienced to make
death. Do not operate a diesel-powered genset adjustments while the genset is running—hot,
where a flammable vapor environment can be moving or electrically live parts can cause se-
created by fuel spill, leak, etc. The owners and vere personal injury or death.
operators of the genset are solely responsible for • Used engine oil has been identified by some
operating the genset safely. U. S. state and federal agencies as causing
cancer or reproductive toxicity. Do not ingest,
GENERAL PRECAUTIONS inhale, or contact used oil or its vapors.

• Keep children away from the genset. • Ethylene glycol, used as engine antifreeze, is
toxic to humans and animals. Clean up spills
• Do not use evaporative starting fluids. They and dispose of used engine coolant in accor-
are highly explosive. dance with local environmental regulations.
• To prevent accidental or remote starting while • Keep multi-class ABC fire extinguishers readi-
working on the genset, disconnect the nega- ly at hand. Class A fires involve ordinary com-
tive (−) battery cable at the battery. bustible materials such as wood and cloth.
Class B fires involve combustible and flam-
• Let the engine cool down before removing the mable liquids and gaseous fuels. Class C fires
coolant pressure cap or opening the coolant involve live electrical equipment. (ref. NFPA
drain. Hot coolant under pressure can spray No. 10)
out and cause severe burns.
• Genset installation and operation must comply
• Keep the genset and its compartment clean. with all applicable local, state and federal
Excess oil and oily rags can catch fire. Dirt and codes and regulations.

Mobile-8

v
1. Introduction
ABOUT THIS MANUAL

This is the Service Manual for the generator sets

(gensets) listed on the front cover.

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 alarm sys-
tem must be used if genset operation is critical.
[The engine family designation, engine displacement, state-
ment of compliance with applicable EPA and / or California
emissions regulations appear in this block on the actual name-
WARNING Improper service or replacement of plate on the genset.]
parts can lead to severe personal injury or death
and to damage to equipment and property. Ser-
vice personnel must be qualified to perform
electrical and mechanical service.

Unauthorized modifications or replacement of

fuel, exhaust, air intake or speed control system
components that affect engine emissions are
prohibited by law in the State of California.

NAMEPLATE

Be ready to provide the genset model and serial

numbers on the nameplate when contacting Onan
for parts, service or information. Figure 1-1 illus-
trates the nameplate and its location. The gray
boxes illustrate where to look for the model and seri- FIGURE 1-1. TYPICAL NAMEPLATE
al numbers.

1-1
 TYPICAL GENSET cooling and ventilating air and the maintenance and
service access panels of a typical genset. Not
Figure 1-2 illustrates the fuel, battery, remote con- shown are the combustion air inlet and oil drain
trol and AC output connection points, the flow of openings in the base.

AC OUTPUT AND REMOTE MAINTENANCE FUEL EXHAUST

CONTROL CONNECTIONS ACCESS CONNECTIONS CONNECTIONS

CONTROL BATTERY
PANEL CONNECTIONS

COOLING & VENTILATING AIR IN HOT AIR OUT

FIGURE 1-2. TYPICAL GENSET

1-2
2. Operation
RECOMMENDED FUEL RECOMMENDED ENGINE OIL

WARNING Diesel fuel is combustible and can Use API (American Petroleum Institute) perfor-
cause severe personal injury or death. Do not mance Class CH-4 engine oil or better. Also look for
smoke near fuel tanks or fuel-burning equip- the SAE (Society of Automotive Engineers) viscos-
ment or in areas sharing ventilation with such ity grade. Referring to Figure 2-1, choose the vis-
equipment. Keep flames, sparks, pilot flames, cosity grade appropriate for the ambient tempera-
electrical arcs and switches and all other tures expected until the next scheduled oil change.
sources of ignition well away. Keep a multi- Multi-grade oils such as SAE 15W-40 are recom-
class ABC fire extinguisher handy. mended for year-round use.

Use clean, fresh No. 2 diesel fuel (ASTM 2-D) when See Section 14. Specifications for oil capacity.
the outdoor ambient temperature is above freezing,
and No. 1 diesel fuel (ASTM 1-D) when below freez- STARTING BATTERIES
ing. The fuel should have a Cetane number of at The genset requires a 12 volt battery to power its
least 45 for reliable starting. control and starting circuits. Reliable genset starting
Note: Ultra Low Sulfur Diesel (ULSD) fuel that meets and starter service life depend upon adequate bat-
the ASTM D975 standard for lubricity is suitable for tery system capacity and maintenance.
use with this genset. The 1 to 2 percent less energy
content of the fuel can have a slight effect on maxi- See MAINTAINING THE BATTERY AND BATTERY
mum engine power. CONNECTIONS (p. 3-4) and Section 14. Specifi-
cations for minimum required battery ratings.
Note: B5 Bio-Diesel fuel that meets industry specifi-
cations and quality is suitable for use with this gen-
set.

RECOMMENDED COOLANT

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.

See Section 14. Specifications for coolant capacity. FIGURE 2-1. OIL VISCOSITY VS. TEMPERATURE

2-1
 CONTROL PANEL (Rapid blinking before cranking starts indicates that
the glow plugs are preheating the combustion
The control panel (Figure 2-2) has the following fea- chambers. The genset controller automatically var-
tures: ies the time based on engine temperature.)
Control Switch − This switch is used to start and Line Circuit Breaker(s) − The line circuit breakers
stop the genset, prime the engine fuel system and protect the AC power leads connected to the gen-
restore the fault code (blinking status light). set.
Status Lamp − This is a lamp in the control switch Coolant Recovery Tank Fill Cap − The recovery
that blinks rapidly during preheat and cranking. It tank provides for coolant expansion. Replenish the
stays on continuously while the genset is running. If normal loss of coolant by filling here.
the genset shuts down, it will blink a numerical code
to indicate the nature of the fault shutdown (see Hour Meter − The hour meter records the total run-
Section 12. Troubleshooting). ning time of the genset. It cannot be reset.

LINE CIRCUIT COOLANT RECOVERY

BREAKER(S) TANK FILL CAP

COOLANT RECOVERY
TANK FLUID LEVEL

CONTROL SWITCH
&STATUS LAMP

HOUR METER

FIGURE 2-2. CONTROL PANEL

2-2
 REMOTE CONTROL PANELS
There probably is a remote genset control panel in-
side the vehicle. Onan offers three remote control
kits as follows:
• Remote switch / status lamp (Figure 2-3).
• Remote switch / status lamp and hour meter
(Figure 2-4).
• Remote switch / status lamp and DC voltmeter FIGURE 2-3. REMOTE SWITCH
(Figure 2-5).
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 (p. 3-4).

FIGURE 2-4. REMOTE SWITCH / HOUR METER

FIGURE 2-5. REMOTE SWITCH / DC VOLTMETER

2-3
 WARNING EXHAUST GAS is deadly. All en- PRIMING THE FUEL SYSTEM
gine exhaust contains carbon monoxide; an
odorless, colorless, poisonous gas that can The fuel system should be primed after replacing
cause unconsciousness and death. Symptoms the fuel filter or running the genset out of fuel. To
of carbon monoxide poisoning include: prime the fuel system, hold the control switch down
• Dizziness • Headache in its Stop position for at least half a minute. (Shut-
• Nausea • Weakness and Sleepiness down Code No. 57, Overprime, occurs after 3 min-
• Vomiting • Inability to Think Coherently utes of holding the switch down. See Section 12.
Troubleshooting.)
IF YOU EXPERIENCE ANY OF THESE SYMP-
TOMS, GET INTO FRESH AIR IMMEDIATELY. If MANUAL STARTING
symptoms persist, seek medical attention. Shut
down the genset and do not operate it until it has The genset can be started and stopped from the
been inspected and repaired. genset control panel or from a remote panel.
Never sleep in the vehicle while the genset is 1. Perform the PRE-START CHECKS, prime the
running unless the vehicle has a working car- fuel system if necessary, and turn off the air
bon monoxide detector. The exhaust system conditioners and other large electrical loads.
must be installed in accordance with the genset
Installation Manual. Make sure there is ample 2. Push and hold Start until the genset starts. The
fresh air when operating the genset in a con- status lamp will come on when the genset starts
fined area. and will stay on while it runs. While starting it will
blink rapidly indicating preheating and crank-
PRE-START CHECKS ing. (Depending on how cold it is, preheating
can take up to 15 seconds, extending the time
Before the first start of the day and after every eight that the lamp blinks.)
hours of operation, inspect the genset as instructed
under GENERAL INSPECTION (p. 3-2). Keep a log CAUTION Excessive cranking can over-
of maintenance and the hours run and perform any heat and damage the starter motor. Do not
maintenance that may be due. See Returning the crank for more than 30 seconds at a time.
Genset to Service (p. 2-7) if the vehicle has been in Wait at least 2 minutes before trying again.
storage.
3. See Section 12. Troubleshooting if the genset
Before each start: does not start after several tries.
1. Make sure all vehicle carbon monoxide (CO) 4. Let the genset warm up a few minutes until it is
detectors are working. running smoothly before connecting the ve-
2. Check for signs of fuel and exhaust leaks and hicle electrical loads (appliances).
damage to the exhaust system.
5. Check for fuel, exhaust and coolant leaks. Stop
3. To prevent overheating and to reduce fouling the genset immediately if there is a fuel, ex-
with dust and debris, make sure the genset’s haust or coolant leak and have it repaired.
normal ground clearance is not being reduced
by sloping ground, curbs, logs or other objects. MANUAL STOPPING
Repark the vehicle if necessary and/or remove
any objects blocking the air inlet or air outlet. Run the genset under no load for a few minutes to
4. Turn off air conditioners and other large ap- allow the engine to cool down and then push and re-
pliances. lease Stop.

2-4
 AUTOMATIC STARTING AND STOPPING To avoid overloading the genset and causing shut-
downs, compare the sum of the loads of the ap-
The vehicle may be equipped with an inverter-char- pliances that are likely to be used at the same time to
ger or other automatic genset starting device the power rating of the genset. It may be neces-
(AGS). Always follow the instructions and safety sary to run fewer appliances at the same time—
precautions provided by the manufacturer of the au- the sum of the loads must not be greater than
tomatic starting device when enabling automatic genset rating.
genset starting.
The genset may shut down due to overload when a
WARNING EXHAUST GAS is deadly. MOV- large motor or air conditioner is started or cycles off
ING PARTS and ELECTRICITY can cause severe and then on again, even though the sum of the loads
personal injury or death. To reduce exposure to is less than genset rating. The reason for this is that
these hazards, always disable automatic genset a motor’s startup load is much larger than its running
starting before: load. It may be necessary to run fewer ap-
S Sleeping in vehicle, unless vehicle has a pliances when large motors and air condition-
working CARBON MONOXIDE detector ers are cycling on and off.
S Parking vehicle in garage or confined space Maximum power decreases as altitude increases
S Parking vehicle for storage because air density decreases. For every 1000-foot
(305 m) increase in elevation you can expect power
S Servicing genset
to decrease approximately 3.5 percent. Table 2-1
S Servicing batteries shows the results of typical calculations. It may be
S Servicing electrical appliances necessary to run fewer appliances at higher alti-
tudes.
S Fueling vehicle
TABLE 2-1. POWER VS. ALTITUDE
LOADING THE GENSET
Elevation above Sea
Maximum Power
Level
The genset can power AC motors, air conditioners,
AC/DC converters, battery chargers and other ap- at/below 500 ft (152 m) 12,000 W (rated)
pliances. How much appliance load* can be pow- at 2500 ft (762 m) 11,280 W
ered depends upon the genset power rating. The
at 5500 ft (1676 m) 10,200 W
genset will shut down or its circuit breakers will trip if
the sum of the loads exceeds genset power. See 10,200 W minus 360 W
above 5500 ft (1676 m)
Section 12. Troubleshooting. 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).

2-5
 RESETTING CIRCUIT BREAKERS OPERATING IN COLD WEATHER
If a circuit breaker in the main power distribution
Make sure the engine oil viscosity is appropriate for
panel of the vehicle or on the genset (Figure 2-2)
the cold weather temperatures. See ENGINE OIL
trips, either a circuit shorted or too many appliances
RECOMMENDATIONS (Page 2-1). Be sure to
were running. Note that the genset will continue to
change the oil if a sudden drop in temperature oc-
run after a circuit breaker trips.
curs.
If a circuit breaker trips, disconnect or turn off as
many loads as possible and reset the circuit break- OPERATING IN HOT WEATHER
er. (Push the circuit breaker to OFF to reset it and
then to ON to reconnect the circuit.) If the circuit Pay particular attention to the following items when
breaker trips right away, either the electrical dis- operating the genset in hot weather:
tribution system has a short or the circuit breaker is
faulty. Call a qualified electrician. 1. Make sure nothing blocks airflow to and from
the genset.
If the circuit breaker does not trip, reconnect the ap-
pliances, one by one, up to a total load that does not 2. Make sure engine oil viscosity is appropriate for
overload the genset or cause the circuit breaker to the ambient temperatures. See ENGINE OIL
trip. If a circuit breaker trips right away when an ap- RECOMMENDATIONS (Page 2-1).
pliance is connected, the appliance probably has a
short. 3. Keep the genset clean.
4. Perform maintenance due. See PERIODIC
Electrical appliances and tools must be used and
MAINTENANCE SCHEDULE (Page 3-1).
maintained properly and be properly grounded to
cause the line circuit breakers to trip when short cir-
cuits occur. OPERATING AT HIGH ALTITUDE

WARNING Short circuits in electrical ap- For the effect of altitude on maximum power, see
pliances and tools can cause fire and electrical LOADING THE GENSET (Page 2-5).
shock leading to severe personal injury or
death. Read and follow the equipment and tool
manufacturer’s instructions and warnings re- OPERATING IN DUSTY ENVIRONMENTS
garding use, maintenance and proper ground-
ing. Pay particular attention to the following items when
operating the genset in dusty environments:
CONNECTING TO UTILITY POWER
1. Do not let dirt and debris accumulate inside the
A vehicle with provisions for connecting utility power genset compartment. Keep the genset clean.
must have an approved device to keep the genset
and utility from being interconnected. See the gen- 2. Perform air cleaner maintenance more often.
set Installation Manual for more information. See PERIODIC MAINTENANCE SCHEDULE
(Page 3-1).
WARNING Interconnecting the genset and the 3. Change engine oil more often. See PERIODIC
public utility (or any other power source) can MAINTENANCE SCHEDULE (Page 3-1).
lead to electrocution of utility line workers,
equipment damage and fire. Use an approved 4. Keep containers of engine oil that have been
switching device to prevent interconnections. opened tightly closed to keep out dust.

2-6
 BREAKING IN A NEW ENGINE WARNING CARBON MONOXIDE is deadly
and can accumulate to dangerous levels in
Proper engine break-in on a new genset or on one garages and other confined spaces. Dis-
with a rebuilt engine is essential for top engine per- able the automatic genset starting feature
formance and acceptable oil consumption. Run the of an inverter-charger or other automatic
genset at approximately 1/2 rated power for the first starting device before storing the vehicle.
2 hours and then at 3/4 rated power for 2 more 2. Push the genset line circuit breaker OFF
hours. See LOADING THE GENSET (Page 2-5). (Page 2-6).
3. Change the engine oil and attach a tag indicat-
Proper engine oil and oil level are especially critical ing oil viscosity. See ENGINE OIL REC-
during break-in because of the higher engine tem- OMMENDATIONS (Page 2-1).
peratures that can be expected. Change the oil if not
appropriate for the ambient temperatures during 4. Disconnect the battery cables (negative [−]
break-in. See ENGINE OIL RECOMMENDATIONS cable first) from the starting battery and store
(Page 2-1). Check oil level twice a day or every the battery according to the battery manufac-
4 hours during the first 24 hours of operation and turer’s recommendations. See MAINTAINING
change the oil and oil filter after the first 50 hours of THE BATTERY AND BATTERY CONNEC-
operation. TIONS (Page 3-4).
5. Plug the exhaust tail pipe to keep out dirt, mois-
EXERCISING THE GENSET ture, bugs, etc.
6. Close the fuel supply valve (if so equipped).
Exercise the genset at least 2 hours each month if
use is infrequent. Run the genset at approximately Returning the Genset to Service
1/2 rated power. See LOADING THE GENSET 1. Check the oil tag on the genset and change the
(Page 2-5). A single two hour exercise period is oil if the viscosity indicated is not appropriate for
better than several shorter periods. the temperatures expected. See ENGINE OIL
RECOMMENDATIONS (Page 2-1).
Exercising a genset drives off moisture, re-lubri- 2. Reconnect the starting battery (negative [−]
cates the engine, replaces stale fuel and removes cable last). See MAINTAINING THE BATTERY
oxides from electrical contacts. The result is better AND BATTERY CONNECTIONS (Page 3-4).
starting, more reliable operation and longer engine
life. 3. Remove the plug from the exhaust tailpipe.
4. Change the air filter element if it is dirty
STORING THE GENSET (Page 3-4).
5. Open the fuel supply valve (if so equipped).
Proper storage is essential for preserving top gen- 6. Inspect the genset. See GENERAL INSPEC-
set performance and reliability when the genset TION (Page 3-2).
cannot be exercised regularly and will be idle for
more than 120 days. 7. Push the genset line circuit breaker ON
(Page 2-6) when the genset is ready to power
appliances.
Storing the Genset
8. Enable the automatic genset starting feature of
1. Disable the automatic genset starting feature of an inverter-charger or other automatic starting
an inverter-charger or other automatic starting device following the device manufacturer’s in-
device. structions and safety precautions.

2-7
3. Periodic Maintenance
Periodic maintenance is essential for top perfor- any engine repair establishment or individual. How-
mance and long genset life. Use Table 3-1 as a ever, warranty work must be completed by an au-
guide for normal periodic maintenance. In hot and thorized Onan dealer.
dusty environments some maintenance procedures
should be performed more frequently, as indicated
by the footnotes in the table. WARNING Accidental or remote starting can
cause severe personal injury or death. Discon-
Maintenance, replacement or repair of emission nect the negative (−) cable at the battery to pre-
control devices and systems may be performed by vent starting while working on the genset.
TABLE 3-1. PERIODIC MAINTENANCE SCHEDULE
FREQUENCY

MAINTENANCE TASK After Every Every Every Every Every

Every Every
First 50 250 500 800 1500 3000 Page
Day Month
Hrs Hrs Hrs Hrs Hrs Hrs
General Inspection • 3-2
Check Engine Oil Level • 3-2
Check Engine Coolant Level • 3-7
Check Battery & Battery Connections1 • 3-4
Change Engine Oil & Oil Filter1, 2, 3 • • 3-3
Clean Spark Arrestor3 • 3-5
Replace Engine Air Filter2, 3 • 3-4
Replace Fuel Filter3 • 3-6
Adjust Engine Valve Lash6 • 9-1
Flush Coolant System4 • 3-7
Replace Coolant Pressure Cap4 • 3-7
Replace V-Belt & Coolant Hoses5, 6 • 8-1
Check Fuel Injector Pressure6, 7 • 9-1
Check Generator Slip Rings /
• 10-4
Brushes2,6

Replace Generator Bearing6 • 10-5

1. Perform more often when operating in hot weather.
2. Perform more often when operating in dusty conditions.
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 trained and experienced personnel (authorized Onan service representatives).
7. EPA requirement.

3-1
 GENERAL INSPECTION Do not operate power ventilators or exhaust fans
while the vehicle is standing with the genset run-
Inspect the genset before the first start of the day ning. The ventilator or fan can draw exhaust gases
and after every eight hours of operation. into the vehicle.

Oil Level Fuel System

Check engine oil level (Figure 3-1). Check for leaks at hose, tube and pipe fittings in the
fuel supply system while the genset is running and
Engine Coolant System while it is stopped. Check flexible fuel hose sections
for cuts, cracks, and abrasions. Make sure the fuel
CAUTION Operating the genset when coolant line is not rubbing against other parts. Replace worn
level is low can cause serious engine damage. or damaged fuel line parts before leaks occur.

Check the engine coolant level and look for coolant WARNING Diesel fuel leaks can lead to fire. Do
leaks around the bottom of the genset and on the not operate the genset if operation causes fuel
ground below. Minor leaks that can be replenished to leak.
by daily additions of coolant to the recovery tank
should be repaired by a qualified service technician Prime the fuel system if the genset ran out of fuel.
as soon as possible. Larger leaks are cause for
shutting down the genset until it can be repaired. Battery Connections
Exhaust System Check the battery terminals for clean, tight connec-
tions. Loose or corroded connections have high
WARNING EXHAUST GAS IS DEADLY! Do not electrical resistance which makes starting harder.
operate the genset if there is an exhaust leak or See MAINTAINING THE BATTERY AND BATTERY
any danger of exhaust gases entering or being CONNECTIONS (p. 3-4).
drawn into the vehicle.
Mechanical
Look and listen for exhaust system leaks while the
genset is running. Shut down the genset if a leak is
Look for mechanical damage and listen for unusual
found and have it repaired before operating the gen-
noises. Check the genset mounting bolts.
set again.

Look for openings or holes between the genset To prevent overheating and to reduce fouling with
compartment and vehicle cab or living space if the dust and debris, make sure the genset’s normal
genset engine sounds louder than usual. Have all ground clearance is not being reduced by sloping
such openings or holes closed off or sealed to pre- ground, curbs, logs or other objects. Repark the ve-
vent exhaust gases from entering the vehicle. hicle if necessary and/or remove any objects block-
ing the air inlet or air outlet.
Replace dented, bent or severely rusted sections of
the tailpipe and make sure the tailpipe extends at CHECKING ENGINE OIL LEVEL
least 1 inch (25.4 mm) beyond the perimeter of the
vehicle. WARNING State and federal agencies have de-
termined that contact with used engine oil can
WARNING Do not park the vehicle in high grass cause cancer or reproductive toxicity. Avoid
or brush. Contact with the exhaust system can skin contact and breathing of vapors. Use rub-
cause a fire. ber gloves and wash exposed skin.
1. Park the vehicle on level ground, shut down the
Park the vehicle so that the genset exhaust gases
genset and remove the front access door.
can disperse away from the vehicle. Barriers such
as walls, snow banks, high grass and brush and oth- 2. Pull out the oil dip stick, wipe it clean, reinsert
er vehicles can cause exhaust gases to accumulate it and pull it out again to check the oil level (Fig-
in and around the vehicle. ure 3-1).

3-2
 3. Add or drain oil as necessary. See REC- 2. Remove the front access door and the oil fill
OMMENDED ENGINE OIL (p. 2-1). Keep the cap, unscrew the oil drain plug and drain all the
oil level between the FULL and ADD marks. oil from the engine. Reinstall the oil drain
plug securely.
CAUTION Too much oil can cause high oil
consumption. Too little oil can cause severe 3. Spin off the oil filter canister and clean the filter
engine damage. Keep the oil level between mounting surface on the engine block. Remove
the FULL and ADD marks. the old gasket if it remains.
4. Reinsert the dipstick and secure the oil fill cap 4. Make sure the gasket is in place on the new fil-
and front access door. ter and apply a thin film of clean oil to the gas-
ket. Spin the new filter on until the gasket just
CHANGING ENGINE OIL AND OIL FILTER touches the block. Turn it an additional 1/2 to
3/4 turn. Do not overtighten.
Refer to Table 3-1 for scheduled engine oil change.
Change oil more often in hot and dusty environ- 5. Refill with 5.9 quarts (5.6 liters) of oil, check oil
ments. level (Figure 3-1) and secure the front access
door.
1. Place a pan under the oil drain plug (Fig-
ure 3-1), run the genset until warm and shut it 6. Dispose of the used oil and oil filter according
off. to local environmental regulations.

FILTER

DIP STICK

FILL CAP

DRAIN PLUG
(22 MM HEX HEAD)

FIGURE 3-1. ENGINE OIL MAINTENANCE

3-3
 MAINTAINING THE BATTERY AND 2. Remove battery cables with a battery terminal
BATTERY CONNECTIONS puller.
3. Make sure which terminal is positive (+) and
WARNING Arcing at battery terminals or in which is negative (−) before making battery
light switches or other equipment, and flames or connections, always removing the negative (−)
sparks, can ignite battery gas causing severe cable first and reconnecting it last to reduce
personal injury—Ventilate battery area before arcing.
working on or near battery—Wear safety
glasses—Do not smoke—Switch work light ON REPLACING THE AIR FILTER ELEMENT
or OFF away from battery—Stop genset and dis-
connect charger before disconnecting battery Refer to Table 3-1 for scheduled air filter replace-
cables—Disconnect negative (−) cable first and ment. Replace it more often in dusty environments.
reconnect last. The air filter is accessible through the front access
door (Figure 3-2). Loosen the three screws that se-
Refer to Table 3-1 for scheduled battery mainte- cure the coolant recovery tank to the housing top
nance, and follow the battery manufacturer’s in- panel and move it out of the way. Loosen the two
structions. Have the battery charging system ser- screws that secure the air filter housing to the hous-
viced if DC system voltage is consistently low or ing top panel so that the spring clips that secure the
high. Always: filter housing end cap can be unlatched. Remove
1. Keep the battery case and terminals clean and the end cap and replace the filter element. Secure
dry and the terminals tight. the filter housing, coolant tank and access door.

COOLANT
RECOVERY TANK AIR FILTER HOUSING
(SHOWN CUT AWAY) END CAP

FIGURE 3-2. REPLACING THE AIR FILTER ELEMENT

3-4
 CLEANING THE SPARK ARRESTOR 1. Remove the top enclosure panel.

Refer to Table 3-1 for scheduled cleaning of the 2. Remove the cleanout plug from the muffler. Se-
spark arrestor muffler (which meets U.S. Forest cure the top enclosure panel before running the
Service requirements). Cleaning is required for genset. With the cover in place there will be
maximum genset performance. enough air flow to cool the engine properly and
WARNING A hot muffler can cause severe carry the soot out of the compartment.
burns. Let the muffler cool down before remov-
ing or installing the cleanout plug. 3. Start the genset and load it nearly to full power.
Let the genset run for about five minutes to ex-
The muffler is mounted inside the genset housing pel the soot.
(Figure 3-3). The spark arrestor cleanout plug is lo-
cated on the side of the muffler and is accessible by 4. Stop the genset, allow the muffler to cool down,
removing the top enclosure panel. Clean out the reinstall the cleanout plug and secure the top
muffler as follows: panel.

CLEANOUT PLUG
(11/16 INCH HEX HEAD)

REMOVE THIS PANEL

FOR ACCESS

MUFFLER

FIGURE 3-3. SPARK ARRESTOR CLEANOUT PLUG

3-5
 REPLACING THE FUEL FILTER as well as on the flare nut so as not to stress the fit-
ting. Flare nut wrenches should be used on the flare
See Table 3-1 for scheduled fuel filter replacement. nuts so as not to round the corners on the nuts. Dis-
A dirty fuel filter may be the cause of a failure to start. pose of the fuel filter according to local regulations.
The fuel filter is accessible through the front access (Note: Filter removal will be easier if the filter mount-
door (Figure 3-4). ing bracket screws are removed.)

WARNING Diesel fuel is combustible and can CAUTION Wipe dirt off the fuel hose fittings at
cause severe personal injury or death. Do not the fuel filter before disconnecting the hoses so
smoke near diesel fuel tanks or equipment. as to keep dirt out of the fuel system.
Keep flames, sparks, pilot lights, electrical
switches, arc-producing equipment and all oth-
Installing the Fuel Filter
er sources of ignition well away. Keep a type
ABC fire extinguisher in the vehicle.
Rotate the filter half a turn around its mounting stud
if the fittings interfere with the bracket. It only fits one
Close any fuel line shutoff valve before discon-
way.
necting the fuel line from the filter.

Accidental or remote starting can cause severe Connect the fuel fittings before tightening the filter
personal injury or death. Disconnect the nega- mounting nut. Take care not to crossthread the fuel
tive (−) cable at the battery to prevent starting fittings. Thread them in by hand and tighten one flat
while working on the genset. past seating with two wrenches.

Removing the Fuel Filter Prime the fuel system for half a minute to fill the new
filter with fuel.
Disconnect the two fittings at the filter and remove
the mounting nut. Apply a wrench on the filter fitting Secure the access door.

HOSE TO FUEL
ENGINE FILTER

FILTER
MOUNTING NUT

BRACKET
HOSE FROM MOUNTING
FUEL PUMP SCREWS

FIGURE 3-4. FUEL FILTER

3-6
 MAINTAINING THE COOLANT SYSTEM cap, turn it the rest of the way and withdraw it. Then
remove the coolant drain plug (Figure 3-5) and
Refer to Table 3-1 for scheduled maintenance. The drain the coolant into a suitable container.
engine cooling system is filled with a 50/50 mixture
of ethylene glycol anti-freeze and water when the WARNING Ethylene glycol antifreeze is con-
genset leaves the factory, which is suitable for tem- sidered toxic. Dispose of it according to local
peratures down to -34° F (-37° C). regulations for hazardous substances.

Recommended Coolant Flush and clean the cooling system before refilling.
Radiator cleaning chemicals are available at local
See RECOMMENDED COOLANT (p. 2-1). auto parts stores. Follow the instructions for clean-
ing and flushing that come with the cleaning solu-
Pressure Cap tion.
Replace the pressure cap (Figure 3-5) every two Refilling Cooling System
years (seals deteriorate and leak). Proper cooling
system pressure (14 psi) is essential for optimal en- Install the coolant drain plug using pipe thread seal-
gine cooling and minimal coolant loss. ant. Tighten it just enough so that it does not leak
when the genset is running and has warmed up. Pull
Draining and Cleaning Cooling System the hose connected to the pressure cap assembly
out as far and as high as it will go and fill the system
WARNING Hot coolant spray can cause severe with coolant. When the coolant level reaches the fill
burns. Let the engine cool before releasing the opening, start and operate the genset for a few min-
pressure cap or removing the drain cap. utes and shut it down. Add more coolant if neces-
sary and secure the pressure cap.
Accidental or remote starting can cause severe
personal injury or death. Disconnect the nega- Fill the recovery tank with coolant mixture to the
tive (−) cable at the battery to prevent starting COLD mark.
while working on the genset.
Coolant Level Check
Let the engine cool before removing the pressure
cap. Relieve any remaining pressure by turning the Check coolant level in the recovery tank (Fig-
pressure cap slowly, without pushing down. When ure 3-5) before the first startup of each day and fill to
the pressure has been relieved, push down on the the COLD mark if necessary.

3-7
 PRESSURE CAP
COOLANT RECOVERY AND SYSTEM
TANK FILL OPENING

RECOVERY TANK
FILL CAP (BLUE)

COOLANT
LEVEL

COOLANT DRAIN PLUG

(1/4 INCH HEX SOCKET)

FIGURE 3-5. ENGINE COOLING SYSTEM

3-8
4. Preparations for Service
SPECIAL TOOLS • Be prepared for an accident: Keep fire extin-
guishers and safety equipment nearby. Agen-
The following tools are necessary for servicing the cies such as the Red Cross and public safety
genset: departments offer courses in first aid, CPR and
Torque wrench: 0-75 lbs-ft (0-100 N-m) fire control. Take advantage of this information
to be ready to respond to an accident. Learn to
Tachometer be safety-conscious and make safety proce-
Digital multi-meter: AC and DC Voltage, Ohms dures part of the work routine.
Load test panel and leads
TABLE 4-1. HAZARDS AND THEIR SOURCES
SAFETY
• Leaking or spilled fuel
Hazards and Their Sources Fire and
• Hydrogen gas from battery
Explosion • Oily rags improperly stored
There are hazards in servicing gensets. Study Safe- • Flammable liquids improperly
ty Precautions and become familiar with the haz- stored
ards listed in Table 4-1. Note the following safe- • Hot exhaust pipes
guards and ways of avoiding hazards: • Hot engine and generator sur-
Burns
faces
• Use personal protection: Wear appropriate • Electrical shorts
protective safety equipment, such as safety
shoes and safety glasses. Poisonous • Operating genset where ex-
Gas haust gases can accumulate
Do not wear rings or jewelry and do not wear
loose or damp clothing that might get caught • Improper generator connec-
in equipment or conduct electricity. tions
Electrical Shock • Faulty wiring
• Reduce the hazard: A safe, orderly workshop (AC) • Working in damp conditions
area and well-maintained equipment reduce • Jewelry touching electrical
the hazard potential. Keep guards and shields components
in place on machinery and maintain equipment Rotating • Fan or belt guards not in place
Machinery
in good working condition. Store flammable liq-
uids in approved containers; away from fire, Slippery • Leaking or spilled oil
Surfaces
flame, spark, pilot light, switches, arc-produc-
ing equipment and other ignition sources. Keep Heavy • Removing genset from vehicle
the workshop clean and well-lighted and pro- Objects • Removing heavy components
vide adequate ventilation.
• Develop safe work habits: Unsafe actions Testing the Genset Inside a Building
cause accidents with tools and machines. Be
familiar with the equipment and know how to Make sure there is ample fresh air when operating
use it safely. Use the correct tool for the job and the genset inside a building to prevent carbon mon-
check its condition before starting. Comply with oxide asphyxiation.
the warnings in this manual and take special
precautions when working around electrical WARNING EXHAUST GAS IS DEADLY! Engine
equipment. Do not work alone if possible and exhaust must be vented outside if the genset is
take no risks. operated inside a building.

4-1
 REMOVING / INSTALLING GENSET WARNING Diesel fuel is combustible and
can cause severe personal injury or death.
See Section 12 . Troubleshooting to determine the Do not smoke if you are near fuel tanks or
probable cause of the problem before removing the fuel-burning equipment or are in an area
genset for service. The genset is normally mounted sharing ventilation with such equipment.
in a special compartment on the floor of the vehicle Keep flames, sparks, pilot lights, electrical
or on a supporting frame. Contact the vehicle arcs and arc-producing equipment and all
manufacturer or installer if the best way to remove other sources of ignition well away.
the genset is not obvious.
Removal from Vehicle
Disconnections
1. Disable the automatic genset starting feature of Make sure that the genset is firmly supported before
an inverter-charger or other automatic starting loosening any mounting bolts. There are four bolt
device and disconnect the negative (-) battery holes in the skid-base for securing the genset to the
cable from the battery to keep the genset from floor or supporting frame. The lifting eye is accessi-
starting while working on it. Then disconnect ble through the access opening in the top panel of
the battery cables from the genset. the genset.
WARNING Accidental or remote starting
WARNING Gensets are heavy and can cause
can cause severe personal injury or death. severe personal injury if dropped during remov-
Disable the automatic starting feature of an al. Use adequate lifting devices. Keep hands
inverter-charger or other automatic starting and feet clear while lifting.
device and disconnect the negative (−)
cable at the battery to prevent starting while
Installation in Vehicle
working on the genset.

Sparks and high current could cause fire Generally, installation is the reverse of removal and
and other damage to the battery, battery disconnection. Before installing the genset, repair
cables and vehicle if the loose ends of any damage to and seal all hoes in the vapor-tight,
cables connected to the battery touch. Al- fire-resistive barrier between the genset and coach
ways disconnect the negative (−) battery interior. Make sure all mounting screws, and brack-
cable from the battery before disconnecting ets are secure and that all battery, AC output, con-
trol, exhaust and fuel connections are proper and in
the battery cables from the genset.
good repair. Perform the service checklist before
2. Disconnect the remote control wiring harness placing the genset in service (Section 15. Service
connector at the genset. Checklist).
3. Disconnect the AC output leads at the genset
terminals. Use four Grade 5 screws (3/8-16 UNC) to secure
the genset to the floor or frame. The screws must
4. Disconnect the exhaust tailpipe from the muf- protrude at least 1/2 inch (10 mm) but not more than
fler flange. 1 inch (25 mm) into the base, as measured from the
5. Disconnect the supply and return fuel lines from bottom surface of the base. Torque the screws to
the genset. 35 lb-ft (41 N-m).

4-2
 TEST STAND WARNING EXHAUST GAS IS DEADLY! Engine
exhaust must be vented outside if the genset is
When testing and servicing the genset on a work- operated inside a building.
bench or test stand make sure the openings in the
skid-base shown in Figure 4-1 (shaded areas) are CAUTION Restricting the air inlet and outlet
free and clear. Also, make sure there is ample fresh openings could lead to damage to the genset
air when operating the genset. due to overheating.

ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ ÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
AIR
IN
ÉÉÉ
ÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉ ÉÉÉ
ÉÉÉÉÉÉÉ
ÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉ ÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉAIR
ÉÉÉÉÉÉÉAIR

ÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉ ÉÉÉÉÉÉÉ

IN OUT

ÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉ ÉÉÉ

ÉÉÉÉÉÉÉ
ÉÉÉÉ
ÉÉÉÉÉÉÉ
FIGURE 4-1. AIR INLET AND OUTLET OPENINGS IN BOTTOM (SHADED AREAS)

4-3
 DISASSEMBLING / REASSEMBLING 2. Remove the two output terminal block mount-
HOUSING AND MOUNTING SYSTEM ing screws to free the output cables from the
panel—preferable to loosening the terminal
Disassembling Housing screws.
3. Loosen the screws that secure the circuit
WARNING Do not operate the genset without breakers to the operator’s console and pull the
the housing panels secured in place. The panels circuit breakers and attached wiring away.
guard against rotating parts and bare live elec- 4. Disconnect the leads at the terminals on the
trical parts that can cause severe personal inju- control switch and hour meter.
ry or death. The housing is also required for
proper genset cooling. 5. Remove the mounting screws to free auxiliary
relays K1, K2 and K3 (p. 11-5)
See Figure 4-2. The housing consists of removable 6. Disconnect the two air intake hoses from the air
panels. The front and top panels include removable intake resonator box.
service doors secured by latches or screws.
7. Remove all attachment screws and pull the
panel away.
Remove all the screws around the perimeter of each
panel and pull the panel away. Note the sets of two Reassembling Housing
and of three screw holes in the top panel which are
circled. These are for the screws that secure the the Reassembly is the reverse of disassembly. To make
air cleaner housing and the coolant recovery tank, sure that all of the panel screw holes will line up, wait
respectively. Remove these screws before lifting to tighten the screws until all of the panels and
the top panel away. screws are in place.

CAUTION The panel screws are all the same When reassembling, torque the panel screws to
length. Do not substitute longer screws to 8 lb-ft (11 N-m).
mount the air cleaner housing or recovery tank.
Note: Note: When securing the side service door
Longer screws can cause damage by bottoming
frame to the panel on its right, the frame and panel
before becoming tight. should touch metal-to-metal. Pull the sound absorb-
ing insulation back a little, if necessary, so that it is
Because of overlapping flanges, the top panel must not pinched between the panel and frame. That way
be removed to remove the side panels and put back the insulation covers the slots in the door frame
last. which would otherwise let some noise out.

To remove the end panel on the generator end of the Reassembling Mounting System
genset:
When reassembling, torque the vibration isolator
1. Cut the wire-tie that secures the wiring har- center and mounting screws according to torque
nesses to the panel. specifications (p. 13-1).

4-4
 AIR CLEANER LIFTING EYE
MOUNTING ACCESS COVER
SCREWS

COOLANT RECOVERY
TANK MOUNTING
SCREWS

AC OUTPUT
TERMINAL
COVER
4-5

BRUSH BLOCK
ACCESS COVER

FIGURE 4-2. HOUSING PANELS

 RADIATOR
ACCESS
COVER

PRIMARY VIBRATION
ISOLATORS (3)
4-6

FUEL PUMP
ACCESS
COVER
SECONDARY VIBRATION
ISOLATORS (4)

FIGURE 4-3. MOUNTING SYSTEM

5. Fuel System
WARNING Accidental or remote starting can FUEL PUMP
cause severe personal injury or death. Before
removing a housing panel or access door, dis- Fuel Flow Test
connect the negative (−) cable at the battery to 1. Disconnect the fuel return hose from the line to
prevent the engine from starting. the supply tank and point the end into a quart
(1 liter) or larger container that has volume
Figure 5-1 shows the components of the fuel system graduations.
up to the connections at the engine.
2. Prime the genset by pushing the Start/Stop
WARNING Diesel fuel is combustible and can switch to STOP and holding it there for the
cause severe personal injury or death. Do not duration of the test. Flow should not be less
smoke near fuel tanks or fuel-burning equip- than 200 ml (0.4 pints) per minute.
ment or are in an area sharing ventilation with 3. If flow is less than specified, replace the fuel fil-
such equipment. Keep flames, sparks, pilot ter. If that does not help, look for other restric-
flames, electrical arcs and switches and other tions in the fuel system. Last, replace the fuel
sources of ignition well away. Keep a type ABC pump. The pump is not serviceable.
fire extinguisher handy.
Removal and Installation
CAUTION Always wipe dirt off fuel fittings be-
fore disconnecting them to keep dirt from enter- The fuel pump is mounted inside the engine mount-
ing the fuel system. ing tower in the base and is accessible by removing
the cover on the side of the base (Figure 4-3).
FUEL INJECTION SYSTEM
Before connecting the fuel lines to the pump, loosen
See Engine Workshop Manual 981-0541 regarding the fuel filter so that there is enough hose length to
fuel injection system service. make connections.

FUEL FILTER Connect the fittings on both ends of the fuel line by
hand before tightening either. Use flare-nut
The fuel filter is mounted on a bracket on the side of wrenches to tighten the fittings so as not to round
the base and is accessible through the front access the corners on the nuts and two wrenches at each
door. See Page 3-6 regarding fuel filter replace- fitting so as not to stress the pump or filter. Tighten
ment. each fitting one flat past seating.

5-1
 INJECTOR PUMP
CONNECTION

FUEL FILTER
FUEL RETURN
CONNECTION
FUEL PUMP

FUEL
RETURN
FITTING FUEL
SUPPLY
FITTING

FIGURE 5-1. FUEL SUPPLY AND RETURN SYSTEM

5-2
6. Air Intake System
WARNING Accidental or remote starting can cess (p. 4-4). To reassemble the air intake system,
cause severe personal injury or death. Before refer to Figure 6-1.
removing a housing panel or access door, dis-
connect the negative (−) cable at the battery to
prevent the engine from starting. CAUTION Do not cut the engine intake air
tubes to make them “fit better.” Their lengths
Remove the top and back housing panels for ac- are critical for proper noise attenuation.

AIR CLEANER HOUSING—SECURED

TO HOUSING TOP PANEL BY THE 2
SCREWS SHOWN

GENERATOR ENGINE INTAKE

INTAKE COVER AIR RESONATOR

AIR INTAKE
TUBE—ENGINE
AND GENERATOR

FIGURE 6-1. AIR INTAKE COMPONENTS

6-1
7. Exhaust System
WARNING Accidental or remote starting can and remove the top and back housing panels
cause severe personal injury or death. Before (p. 4-4).
removing a housing panel or access door, dis- 2. Disconnect the exhaust tail pipe and remove
connect the negative (−) cable at the battery to the flanged tail pipe adaptor.
prevent the engine from starting.
3. Remove the flange screws on both ends of the
The muffler is bolted directly to the outlet flange of flexible tube and withdraw the tube out the end
the engine exhaust manifold and a flexible, corru- of the genset.
gated stainless steel tube is bolted to the muffler
CAUTION The flexible tube is fragile. Take
outlet flange (Figure 7-1). The flange on the other
care not to bend or twist it.
end of the flexible tube is bolted to a bracket on the
base assembly (Figure 8-1). 4. Remove the screws from the 2 muffler support
brackets and the muffler manifold flange and
Flanged tailpipe adaptors are available for tailpipe withdraw the muffler.
connections out the end, back or bottom of the gen-
set. See the Installation Manual for important safety Installation of the muffler is the reverse of removal.
warnings and instructions regarding the routing and Use new flange gaskets for the tail pipe adaptor,
termination of the tailpipe (not supplied by Onan). flexible tube and muffler. Tighten all screws and nuts
according to specifications (p. 13-1).
Always use new flange gaskets when connecting
exhaust system components.
WARNING Exhaust gas is deadly. The exhaust
system must not leak. Liability for injury, death,
damage and warranty expense due to the use of
See Page 3-5 regarding spark arrestor cleaning.
an unapproved muffler or due to modifications
becomes the responsibility of the person instal-
To remove the muffler:
ling the unapproved muffler or performing the
1. Disconnect the negative (-) battery cable from modifications. Use Onan approved exhaust
the battery to prevent the genset from starting system parts.

7-1
FIGURE 7-1. MUFFLER ASSEMBLY

7-2
8. Engine Cooling System
GENERAL 2. Let the genset cool down and then drain the
cooling system (p. 3-7).
WARNING Accidental or remote starting can
cause severe personal injury or death. Before WARNING Hot coolant spray can cause se-
removing a housing panel or access door, dis- vere burns. Let the engine cool before re-
connect the negative (−) cable at the battery to leasing the pressure cap or removing the
prevent the engine from starting. drain cap.
3. Remove the radiator access cover on the back
Refer to Figure 8-1 to reassemble the cooling sys- of the base (Figure 4-3).
tem components.
4. Disconnect the two radiator hoses and with-
The genset has a liquid-cooled engine with integral, draw the radiator out the side opening in the
belt-driven coolant pump. The radiator is mounted base.
horizontally in the base of the genset. The system
drain plug is on the radiator end tank. The coolant Installation of the radiator is the reverse of removal.
recovery tank is mounted on the underside of the Replace the foam sealing strips around the opening
top housing panel. in the base if they are damaged. Tighten all screws
according to specifications (p. 13-1).
Beginning Spec B, the centrifugal blower (fan) is
driven by a flexible coupling on the end of the crank- FAN
shaft (Figure 9-1). Prior to Spec B the fan is driven
by a two-belt, two-stage drive system (Figure 9-2). To Remove Fan
1. Remove the top and end housing panels
The fan pulls cooling air up through the radiator and (p. 4-4).
across all of the components inside the housing.
The warm air is discharged out the bottom opening 2. Remove the four fan hub bolts and withdraw the
in the right end of the base. fan and spacer.

CAUTION The fan (blower wheel) is frag-

See Page 3-7 regarding periodic cooling system
maintenance and Page 9-4 regarding the coolant ile. Do not brace against it when loosening
temperature sender. or tightening the hub bolts.

THERMOSTAT AND PUMP To Replace Fan Coupling

If it is necessary to replace the fan coupling (pulley)
See Engine Workshop Manual 981-0541 for coolant
from the end of the crankshaft, remove the belt or
thermostat and pump service.
belts and use a 1/2 inch socket drive to remove the
coupling.
RADIATOR
Beginning Spec B, if it is necessary to replace the
To remove the radiator:
flexible member of the fan coupling (Figure 9-1),
1. Disconnect the negative (-) battery cable from torque the eight (8) flange nuts according to specifi-
the battery to prevent the genset from starting. cations (p. 13-1).

8-1
 FAN BELT (BEGINNING SPEC B) Belt Replacement

Belt Tension When Equipped With Battery Remove the fan and then install the new belt and ad-
just tension.
Charging Alternator
FAN BELT (SPEC A ONLY)
Remove the top genset housing panel (p. 4-4). Ad-
just tension so that deflection is 8-10 mm Primary Belt Tension
(0.3-0.4 inch) midway between the alternator and
pump pulleys when a force of 10 kg (22 pounds) is Remove the top genset housing panel (p. 4-4). Ad-
applied. See (Figure 9-1). just tension so that deflection is 8-10 mm
(0.3-0.4 inch) midway between the alternator and
Belt Tension When Not Equipped With pump pulleys when a force of 10 kg (22 pounds) is
Battery Charging Alternator applied.

Secondary Belt Tension

There is no means to adjust belt tension. To install a
new belt, run the belt over both pulleys and pull the The secondary belt has a spring tensioner (Fig-
pump pulley up to its hub and push it on. Secure the ure 9-1).
pulley with the 4 bolts and tighten the bolts accord-
ing to specifications (p. 13-1). It is critical that the Belt Replacement
correct replacement belt be used. (Belt tension in-
creases slightly as the engine runs and is sufficient Remove the fan and then install the new belt(s) and
for the relatively light pump load.) See (Figure 9-1). adjust primary belt tension.

8-2
 COOLANT
RECOVERY
OVERFLOW TANK
LINE

VENT PRESSURE CAP

LINE AND SYSTEM FILL

INNER SYSTEM
BLUKHEAD FILL HOSE
RADIATOR
HOSES

FAN
SCROLL
8-3

FAN

EXHAUST
FLANGE SEE SECTION 9. ENGINE AND ACCESSORIES
BRACKET FOR BELT AND PULLEY ARRANGEMENT RADIATOR

FIGURE 8-1. ENGINE COOLING SYSTEM

9. Engine and Accessories
WARNING Accidental or remote starting can 3. Remove the blower (fan) assembly (p. 8-2).
cause severe personal injury or death. Before 4. Remove the radiator (p. 8-1) for access to the
removing a housing panel or access door, dis- bolt head of the generator isolation mount.
connect the negative (−) cable at the battery to
prevent the engine from starting. 5. Disconnect the generator cooling air tube from
the generator (p. 6-1).
ENGINE 6. Disconnect the battery cables and base
grounding strap from the engine.
See Engine Workshop Manual 981-0541 for servic-
ing the engine proper: adjusting valve clearance 7. Disconnect the wiring harness lead to the fuel
(lash), servicing the fuel injection system, replacing pump.
the glow plugs, cleaning the crankcase breather as- 8. Disconnect the supply and return fuel hoses at
sembly, replacing the coolant thermostat and pump the engine (p. 5-2).
and overhauling the engine.
9. Disconnect the flexible connector from the muf-
Removal fler outlet flange (p. 7-2).
10. Attach a hoist of sufficient capacity to the lifting
The engine-generator-muffler assembly and wiring eye, take up the slack and remove the center
harnesses can be removed as an assembly from bolts of the three isolation mounts. Lift the en-
the genset if it is necessary to remove either the en- gine-generator_muffler assembly away.
gine (Figure 9-1) or the generator (Figure 10-1). To
do so: Installation
1. Remove all of the housing panels except the in-
Installation is the reverse of removal. Make sure the
ner bulkhead (p. 4-4), leaving the wiring har- air seal ring is in place around the oil drain hole in the
nesses attached to the engine-generator as- base to keep air from bypassing the radiator. (The
sembly. engine-generator compartment is under a partial
2. Drain the cooling system, disconnect the radia- vacuum.) Tighten all screws to specifications
tor and vent hoses from the engine. (p. 13-1).

9-1
 LIFTING EYE COOLANT BATTERY CHARGING
FLYWHEEL
TEMPERATURE ALTERNATOR
SENDER HDKCC, HDKCD
OIL PRESSURE
SWITCH
(NOT SHOWN)
OIL
FILTER

ENGINE TIMING
9-2

MARKS AND PIN

STARTER
MOTOR AND
SOLENOID

FLEXIBLE FAN
COUPLING
OIL HOSES

OIL FILL
ASSEMBLY

GOVERNOR BELT & PULLEYS—NO ALTERNATOR

ACTUATOR HDKCA, HDKCB

FIGURE 9-1. ENGINE AND ACCESSORIES—BEGINNING SPEC B

 LIFTING EYE STARTER COOLANT VENT HOSE
FLYWHEEL MOTOR AND TEMPERATURE FITTING
SOLENOID SENDER

OIL FILTER OIL PRESSURE BATTERY

SWITCH CHARGING
(NOT SHOWN) ALTERNATOR

ENGINE TIMING SECONDARY

9-3

MARKS AND PIN BELT TENSIONER

ASSEMBLY

FLYWHEEL
HOUSING

OIL HOSES

OIL FILL
ASSEMBLY
GOVERNOR FREE-SPINNING FAN COUPLING
ACTUATOR (PULLEY) ON CRANKSHAFT

FIGURE 9-2. ENGINE AND ACCESSORIES—SPEC A ONLY

 WARNING Accidental or remote starting can minal) when the engine is not running or if the switch
cause severe personal injury or death. Before does not open when oil pressure rises to 14 psi
removing a housing panel or access door, dis- (96 kPa).
connect the negative (−) cable at the battery to
prevent the engine from starting. BATTERY CHARGING ALTERNATOR

ENGINE SENSORS The battery charging alternator is accessible for ser-

vice by removing the top housing panel (p. 4-4). Ad-
The engine is equipped with a coolant temperature just fan belt tension and tighten the mounting bolts
sender and low oil pressure cutout switch (Fig- according specifications (p. 13-1) when reassem-
ure 9-1). The associated fault codes (Sec- bling.
tion 12. Troubleshooting) are as follows:
• No. 1 - Engine Over Temperature STARTER MOTOR
• No. 2 - Low Oil Pressure The starter motor is accessible for service by re-
• No. 24 - Faulty Engine Temperature Sender moving the top housing panel (p. 4-4). Tighten the
mounting bolts according specifications (p. 13-1)
Coolant Temperature Sender when reassembling.

The sender is accessible for replacement by remov- GLOW PLUGS

ing the top housing panel (p. 4-4). Replace the
sender if resistance is not approximately 1300 ohms Refer to engine Workshop Manual 981-0541 when
in ice water, 700 ohms at room temperature or 57 replacing the glow plugs, which are accessible for
ohms in boiling water. Use thread sealant and en- service by removing the top housing panel.
gage at least two threads when reassembling.
Note: Note: If a glow plug does not come out after
Oil Pressure Switch unscrewing it, or the end has broken off, it will
be necessary to remove the engine head. Glow
The switch is accessible for replacement by remov- plugs can swell if preheat voltage is greater than
ing the top housing panel (p. 4-4). Replace the 14 volts, such as when a battery booster is used
switch if it is not closed (ground continuity at the ter- for starting.

9-4
 WARNING Accidental or remote starting can
cause severe personal injury or death. Before
removing a housing panel or access door, dis-
connect the negative (−) cable at the battery to
prevent the engine from starting. HIGH-IDLE
SPEED STOP
SCREWS
GOVERNOR ACTUATOR

The governor actuator (Figure 9-3) is removeable

by removing the housing end panel (Figure 4-2) and
the fan and inner bulkhead (Figure 8-1). Remove
the actuator from the engine block (2 screws). When
reassembling, make sure the O-ring seal is in place
and that the push rod goes through the internal
guide hole. Replace the actuator if:
• Electrical resistance across its terminals is not
2 to 4 ohms.
• The plunger does not pull in smoothly when B+
(12 VDC) is applied across its leads. GOVERNOR
• The plunger does not move in and out smoothly ACTUATOR
when pushed in by hand.

HIGH-IDLE SPEED

Reset high-idle speed if the stop screw seals have

been broken or internal governor parts have been FIGURE 9-3. GOVERNOR ACTUATOR AND HIGH-
IDLE SPEED STOP SCREW
replaced or are worn. To reset high-idle speed:
1. Remove the governor actuator to allow opera-
tion at full fuel rack, but leave it connected to
keep Fault No. 19 from preventing Start. Plug
the opening to keep oil from splashing out.
2. Disconnect the fuel pump and power it directly
with a 12 volt battery to keep the engine run-
ning when Fault No. 12 or 14 occurs.

WARNING These adjusting screws are in

close proximity to rotating belts and pulleys
that can cause severe personal injury. Be
very careful not to get your hands near the
pulleys and belts while making the adjust-
ments.
3. Disconnect all loads from the genset to protect
them from overfrequency and start the genset.
Adjust the stop screws (Figure 9-3) to obtain
67.3-68.3 Hertz (2019-2049 rpm). TO STOP
THE ENGINE, disconnect the fuel pump from
the battery.
4. Seal the adjusting threads with paint.
5. Re-install all of the components that were re-
moved or disconnected.

9-5
10. Generator
WARNING Accidental or remote starting can Stator Winding insulation resistance. Disconnect T2
cause severe personal injury or death. Before and T3 from the grounding screw on the engine
removing a housing panel or access door, dis- mounting bracket (p. A-3) to isolate the windings
connect the negative (−) cable at the battery to from ground, and separate the two parts of genera-
prevent the engine from starting. tor connector P3/J3 to isolate the control board from
the DC test voltage. Apply one side of the DC test
GENERATOR WINDING TESTS voltage to both windings (connect to either end) and
the other side to a good generator ground (stator
Testing Winding Insulation Resistance laminations) for 10 minutes and record resistance
values at one minute and at 10 minutes.
Testing for Winding-to-Winding and Winding-
to-Ground Shorts: A digital ohmmeter can be used A resistance value of at least 5 megohms should be
(highest scale) as a preliminary check for a obtained for a new stator with dry windings. The po-
grounded Stator, Quadrature or Field Winding or for larization index (the ratio of the resistance reading
a short between Stator (Main) and Quadrature at 10 minutes to the reading at one minute) should
windings. The meter should indicate infinite resist- also be at least 2. For a genset that has been in ser-
ance. vice, the resistance value should not be less than
1 megohm, nor the polarization index less than 2.
A 500 VDC megger is recommended for finding
winding-to-winding or winding-to-ground shorts. If the readings are low, or the genset has been in
Resistance between windings or to ground should storage for a long time in a high-humidity environ-
be not be less than 1 megohm. See Table 10-1. ment, the test should be repeated after the windings
have been dried. The most effective way of drying
Testing Stator Winding Insulation with a Meg- the stator windings, if the genset is operable, is to
ger: A 500 VDC megger is recommended for testing run it under full load for at least one hour.

10-1
Testing Winding Resistance Field and Quadrature Windings: Separate the
two parts of generator connector P3/J3 for access
Use a Digital Ohmmeter to check for open or to the field windings (P3-7—P3-8) and quadrature
shorted Main (Stator), Quadrature or Field Wind- windings (P3-3—P3-6/P3-5). Resistance must
ings. Use a Wheatstone Bridge having a precision within Table 10-1 tolerances. If field resistance is
of at least 0.001 ohm to measure Stator Winding re- high, first service the brushes and slip rings
sistance. (p. 10-4) and repeat the test. Then, if necessary,
service the rotor.
Replace a rotor or stator that has winding
resistances outside Table 10-1 tolerances. TABLE 10-1. WINDING, WINDING-TO-WINDING &
WINDING-TO-GROUND RESISTANCES
Stator Windings: Check Stator Winding resistance RESISTANCE (OHMS) @ 705 F (215 C)
WINDING
across the AC output terminal block: TB2-1—TB2-3 HDKCA, HDKCC HDKCB, HDKCD
and TB2-2—TB2-3. Make sure circuit breaker T1-T2, T3-T4 0.197-0.241 0.178-0.218
CB1/CB2 is ON. Q1-Q60
2.0-2.4 2.0-2.4
(P3-3 to P3-6)
If resistance is within Table 10-1 tolerances, the Q1-Q50
whole AC output circuit is probably sound. 2.4-2.9 −
(P3-3 to P3-5)
Rotor
If resistance is high, check resistance directly 19.4 22.5
(P3-7 to P3-8)
across the winding leads, which are connected at T1-T3, T2-T4,
1 megohm 1 megohm
CB1/CB2 and at the grounding screw on the gener- T1-Q1, T3-Q1
ator mounting bracket (p. A-3). Service as neces- T1, T3 & Q1 to
1 megohm 1 megohm
sary by tightening connections or servicing the gen- GROUND
erator, AC harness (p. A-3) or circuit breakers Rotor (P3-7) to
1 megohm 1 megohm
(p. 11-5). GROUND

10-2
 CONTROL BOARD

GENERATOR
INTAKE
COVER
O-RING

END BELL

THROUGH BOLTS (4)

(thread the ends with
shorter lengths of thread
into the adaptor)

STATOR
ASSEMBLY
10-3

ROTOR
BEARING
GENERATOR
LEAD EXIT AND
BRUSH BLOCK ROTOR
ACCESS ASSEMBLY

DRIVE DISC
(assemble with
GUARD chamfered
SCREEN edge out)

ADAPTOR
CASTING

SLIP RINGS
BRUSH BLOCK ASSEMBLY
FAN

FIGURE 10-1. GENERATOR

 GENERATOR SERVICE
BRUSH LEAD
WARNING Accidental or remote starting can TERMINAL
cause severe personal injury or death. Before
removing a housing panel or access door, dis-
connect the negative (−) cable at the battery to
prevent the engine from starting.
Brushes and Slip Rings
Access: Remove the brush block access cover
(Figure 4-2) for access to the brush block assembly
and slip rings.
Checking for Wear: Check brush wear by marking
off a piece of wire at 1 inch (25 mm) and inserting it
into each of the two holes in the top of the brush
block from which the pig tails exit. Replace the brush
if the wire can be inserted more than 1 inch (25 mm).
FIGURE 10-2. BRUSH BLOCK ASSEMBLY
(Make sure the wire rests on top of the brush and not
on part of the spring.)
Cleaning Up Slip Rings: If the slip rings are
grooved or pitted, try cleaning them up with a com-
mutator stone while cranking the engine. (Connect
the starter motor directly to a battery and the starter
solenoid to a remote start switch.) The rotor will
have to be removed if the slip ring assembly has to
be replaced.
Replacing Brush Block: When replacing the brush
block assembly, center the brushes on the slip rings
before tightening the two mounting screws. Make
sure to reconnect the lead marked F1 to the out-
board brush and the lead marked F2 to the inboard
brush.

10-4
 WARNING Accidental or remote starting can 1. Make sure the chamfered edge of the drive disc
cause severe personal injury or death. Before faces the flywheel.
removing a housing panel or access door, dis- 2. Make sure the ends of the through bolts with the
connect the negative (−) cable at the battery to shorter lengths of thread are threaded into the
prevent the engine from starting. adaptor casting.
Removing the Generator 3. Make sure the O-ring is in place in the bearing
bore of the end bell. Grease the bore lightly to
Remove the engine-generator assembly as an as- make assembly easier.
sembly from the genset (p. 9-1) and then remove
the generator from the engine, as follows: 4. Before securing the the air inlet adaptor assem-
bly, make sure the brush block assembly is in
1. Remove the air inlet assembly (Figure 10-1). place (Brushes and Slip Rings) and that the
2. Disconnect the generator leads attached to the wire holding up the brushes has been removed.
grounding screw on the generator mounting
bracket (Page A-3) and separate the two parts Replacing the Rotor Bearing
of generator connector P3/J3.
Use a gear puller if it is necessary to remove the ro-
3. Remove the brush block assembly or lift the
tor bearing. If the slip ring assembly is being re-
brushes and insert a wire to keep the brushes
placed, install the new assembly before pressing on
up and out of the way while disassembling and
the bearing. Press a new rotor bearing on flush with
reassembling the generator.
the end of the rotor. Apply Loctite #680 adhesive to
4. Loosen the four through bolt nuts and remove the shaft and Loctite #747 activator to the bearing
the end bell and stator assemblies. mating surface.
5. Remove the adaptor casting from the flywheel
housing and then the rotor from the flywheel. Replacing the Slip Ring Assembly

Installing the Generator Remove the rotor bearing and unsolder the two field
leads if it is necessary to remove the slip ring as-
Installation is the reverse of removal. Tighten all sembly. Press a new slip ring assembly on making
nuts and bolts according to specifications (p. 13-1) sure the key is in place and soldered the field leads
and note the following: to the slip ring assembly.

10-5
 ADJUSTING VOLTAGE 3. Rapidly press START 6 times. The status lamp
will start to blink once a second to confirm that
The controller has a voltage set mode that is en- the controller is in voltage adjust mode.
abled by rapidly pressing START 6 times during the
first minute after startup. To adjust voltage: 4. To adjust voltage up, press START and re-
1. Disconnect all genset loads and connect accu- lease quickly. Each time START is released,
rate meters to measure AC output voltage. voltage will increase approximately 0.6 volt.
5. To adjust voltage down, press the control
WARNING HAZARDOUS VOLTAGE!
switch to START and release in approximately
Touching uninsulated live parts inside the
1 second. Each time START is released, volt-
genset or connected equipment can result
age will decrease approximately 0.6 volt.
in severe personal injury or death. For your
protection, stand on a dry wooden platform 6. Normal operation will resume in 20 seconds af-
or rubber insulating mat, make sure your ter the last adjustment. The last adjustment will
clothing and shoes are dry, remove jewelry be saved by the controller.
from your hands and use tools with insu-
lated handles.
Note: Voltage adjustments will not be saved if a
2. Start the genset and let voltage and frequency fault shutdown occurs or STOP is pressed while
stabilize for 5 to 10 seconds. in voltage set mode.

10-6
11. Control
WARNING Accidental or remote starting can and harness drawings. The control board is acces-
cause severe personal injury or death. Before sible for replacement through the front access door.
removing a housing panel or access door, dis-
connect the negative (−) cable at the battery to Connector: A single connector (P1/J1) is used for
prevent the engine from starting. all connections between the control board and har-
ness. When separating the connector, use a small
CONTROL BOARD (CONTROLLER) flat-bladed screwdriver to lever out the catch.

The Control Board is an integrated microprocessor- CAUTION Makeshift meter test probes used
based engine and generator control that provides all for testing Control Board connections during
the control, monitoring and diagnostic functions re- troubleshooting can damage pin sockets by
quired to operate the genset. spreading or dislodging the contact wiper arms,
resulting in an open or intermittent electrical
Control Board connection. Use a mating pin (PN 323−1605) or a
test probe that is 0.045 inches in diameter. Re-
Location and Mounting: Refer to Figure 11-1 for place damaged pin sockets (PN 323−1614−01).
control board location and mounting and to Make sure the pin sockets are fully seated and
Pages A-1 and A-2 for the control wiring schematic can’t be pulled out.

CONNECTOR
J1

CONTROL
BOARD

GENERATOR
INTAKE COVER

FIGURE. 11-1 CONTROL BOARD

11-1
Major Controller Functions Stopping: Touch the control switch to STOP
(Prime). The Controller:
Figure 11-2 is a block diagram of Controller func-
tions. 1. Disables output voltage.

Initialization: Control initialization consists of 2. Deenergizes the fuel lift pump and governor ac-
checking memory (RAM, ROM, EEPROM) and tuator.
genset configuration.
3. Turns off the status lamp.
Fuel Priming: Press and hold the control switch at
STOP (Prime) for more than 3 seconds to cause 4. Writes session data (number of cranks, min-
fuel pump E2 to prime the fuel system. utes of operation, last fault, etc.) to non-volatile
memory (NVM).
Starting: Press and hold the control switch at
START (Preheat) until the genset starts. The Con- 5. Removes processor power when idle 5 min-
troller: utes.
1. Energizes fuel lift pump E2.
Note: Note: Stop takes precedence over Start if both
2. Energizes the glow plugs (3) during pre-heat present due to a faulty switch or other cause.
and cranking. The duration of pre-heat prior to
cranking is engine temperature dependent, but
does not exceed 15 seconds. Controlling Voltage: The Controller maintains
3. Enables the status lamp to blink rapidly. nominal AC output voltage as load varies by varying
field voltage. In response to transient loads, it low-
4. Enables some fault detection. ers the voltage setpoint to allow engine recovery.
5. Enables cranking for up to 35 seconds. Field power is supplied by the quadrature windings
(Q1-Q2). See ADJUSTING VOLTAGE (p. 10-6).
6. Enables field flash (F1-F2).
7. Energizes governor actuator E1 (full rack).
8. Disconnects the starter at 800 rpm. Controlling Fuel: The Controller positions the fuel
rack to maintain nominal frequency as load varies
9. When operating speed is reached: by sending a pulse-width-modulated square-wave
signal (PWM) to governor actuator E1. It determines
A. Enables output voltage. frequency by sensing the zero crossings of the
quadrature winding output. When the actuator is not
B. Turns off field flash.
energized, its spring-loaded plunger holds the fuel
C. Turns on status lamp. rack in the no-fuel position.

D. Enables Switched B+ (J1-8).

Fault Monitoring, Shutdown and Diagnostics:
E. Enables complete fault detection. See Section 12. Troubleshooting.

11-2
 COOLANT TEMPERATURE SENDER
LOCAL
CONTROL

OIL PRESSURE SWITCH

FUEL LIFT PUMP

ENGINE

REMOTE STARTER
CONTROL

GLOW PLUGS
CONTROL
BOARD

GOVERNOR ACTUATOR

RS-232
(FACTORY ONLY)

QUADRATURE
& FREQUENCY
SENSE

FIELD GENERATOR

AC VOLTAGE
BATTERY SENSE

AC OUTPUT

FIGURE 11-2. CONTROL BLOCK DIAGRAM

11-3
 WARNING Accidental or remote starting can
cause severe personal injury or death. Before CONTROL RELAYS
removing a housing panel or access door, dis- SWITCH S1 K1, K2, K3
connect the negative (−) cable at the battery to
prevent the engine from starting.

LOCAL AND REMOTE CONTROL

SWITCHES
Refer to Pages A-1 and A-2 for the control wiring
schematic and harness drawings.

Control Switch Tests

Local Control Switch S1: Switch S1 is mounted on
the control panel (Figure 11-3). Unsnap connector
P9, which is accessible through the front access
door. Referring to Figure 11-4, replace the switch if:
• The switch does not close across terminals 2
and 3 when held in the Start position LINE CIRCUIT
HOUR BREAKERS
• The switch does not close across terminals 1 METER M1 CB1 & CB2
and 2 when held in the Stop position
• The status indicator light does light when
12 VDC is connected across terminals 7 (−) FIGURE 11-3. CONTROL COMPONENTS
and 8 (+).

Remote Control Switch: Disconnect remote con-

trol connector J8/P8 and test a remote control
switch (customer supplied) in the same manner as
switch S1 and repair as necessary.

Wiring Harness Tests

If the control switches are good but the Start / Stop
circuit still does not work, test the wiring harness be-
tween the control switches and control board.

Disconnect P1 from the control board (p. 11-1). TERMINALS SCHEMATIC

• P1-9 should close to P1−27 when the local or

remote switch is held in its Start position.
FIGURE 11-4. CONTROL SWITCH S1
• P1-32 should close to P1−27 when the local or
remote switch is held in its Stop position.

Replace broken or missing wires and bent or cor-

roded terminals.

HOUR METER
The hour meter (Figure 11-3) is mounted on the
control panel and is accessible for replacement
through the front access door. It cannot be reset.

11-4
 WARNING Accidental or remote starting can
cause severe personal injury or death. Before
removing a housing panel or access door, dis-
connect the negative (−) cable at the battery to
prevent the engine from starting.

LINE CIRCUIT BREAKERS CB1, CB2

The line circuit breakers (Figure 11-3) are mounted
on the control panel and are accessible for replace-
ment through the front door. Disconnect all wiring TERMINALS SCHEMATIC
and check electrical resistance across the terminals
of each circuit breaker. Replace a circuit breaker FIGURE 11-5. RELAYS
that does not reset or that does not close or open as
the handle is turned ON and OFF.

RELAYS K1, K2, K3

These relays are secured in a row above the intake
resonator (Figure 11-3) and are accessible for re-
placement by removing the top enclosure panel. To
test a relay, apply 12 VDC across terminals 85−86
(Figure 11-5). Replace the relay if 30−87a (NO)
does not close or 30−87 (NC) does not open, or ei-
ther does not return to its normal position when pow-
er is removed.

See Page A-1 for relay function.

VOLTAGE SENSE TRANSFORMER TX1

The voltage sense transformer is mounted in the top
of the intake resonator (Figure 11-6) and is accessi-
ble for replacement by removing the top enclosure
panel. Disconnect all four leads and check electrical
resistance across the primary and secondary wind-
ings. Replace the transformer if the resistance of ei-
ther winding is not as specified in the schematic.

FIGURE 11-6. VOLTAGE SENSE TRANSFORMER

11-5
12. Troubleshooting
TROUBLESHOOTING WITH TABLE 12-1 • Three blinks indicate a service fault. Press
Stop once to cause the two-digit, second-level
To aid troubleshooting the genset controller causes shutdown code to blink. (Pressing Stop again
the status indicator light to blink the numeric code will stop the blinking.) The two-digit code con-
assigned to the fault that caused shutdown. For a sists of 1, 2, 3, 4 or 5 blinks, a brief pause, and
brief description of the fault and step-by-step cor- then 1 to 9 blinks. The first set of blinks repre-
rective action, refer to TABLE 12-1. TROUBLE- sents the tens digit and the second set of blinks
SHOOTING, which lists the fault codes in numerical the units digit of the shutdown code number.
order. For example, shutdown code No. 36 appears
as:
Note: Many genset shutdowns can be avoided by blink-blink-blink—pause—blink-blink-blink-blink-blink-blink—
performing periodic maintenance on schedule
long pause—repeat
(TABLE 3-1. PERIODIC MAINTENANCE SCHEDULE)
and by not running the genset out of fuel. Note that • Four blinks indicate that cranking time ex-
when the genset and propulsion engine draw from ceeded 35 seconds.
the same fuel tank, the fuel dip tubes are usually ar-
ranged so that the genset will run out of fuel first. By • To avoid the possibility of anyone misinterpreting
marking the genset empty point on the fuel gauge, it Code Nos. 3 and 4 as Code Nos. 33 and 44, the lat-
will be easier to tell when the genset may run out of ter have not been assigned faults.
fuel.
RESTORING FAULT CODE BLINKING
FAULT CODE BLINKING
Blinking continues for five minutes and stops. To re-
store blinking press the control switch to STOP
At fault shutdown, the status indicator light will re-
(Prime) until the light comes on (3 to 4 seconds).
peatedly blink sets of 1, 2, 3 or 4 blinks.
Then press STOP (Prime) three times to restores
• One blink indicates shutdown due to high en- blinking.
gine coolant temperature.
Note: Note: The last fault logged will blink even
• Two blinks indicate shutdown due to a loss of though the condition that caused the shutdown may
engine oil pressure. have been corrected.

12-1
 TABLE 12-1. 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 AT CONTROL SWITCH

(Faulty switch, poor or missing connections, dead battery)
Corrective Action: Refer to Pages A-1, A-2 and A-3, as appropriate.
1. Try the genset (local) control switch if there is no response at the remote control switch, and vice
versa.
• If there is no response at either remote or local switch, go to Step 2.
• If there is no response at the remote switch but at the local, go to Step 3.
• If there is no response at the local switch but at the remote, go to Step 6.
2. Check for 12 VDC across genset battery cable terminal block TB1. If there is no voltage, service
as necessary by cleaning and tightening battery cable connections, recharging or replacing the bat-
tery or replacing damaged or missing battery cables. If there is voltage across TB1, but no response
at either remote or local switch, go first to Step 3, and then, if necessary, also to Step 6.
3. Disconnect harness connector P8 from the remote circuits. Check for B+ (12 VDC) at P8-C (Start)
and at P8-E (Stop) and for ground continuity at P8-A (Ground). If there is B+ and ground continuity,
service the remote switch and harness (p. 11-4). If not, go to Step 4.
4. Disconnect harness connector P1 from the control board (p. 11-1) and check for B+ at P1-10 and
for ground continuity at P1-27. If there is B+ and ground continuity, go to Step 5. If not, go to Step 9.
5. Check for wiring continuity in the harness between connectors P8-C and P1-9 (Start), P8-E and
P1-32 (Stop), P8-B and P1-7 (Status), P8-F and P1-8 (Run) and P8-A and P1-27 (Ground). Repair
as necessary. Make sure connector pin sockets are not damaged or corroded and that they are fully
seated and can’t be pulled out. Replace the control board (p. 11-1) if the genset still does not start.
6. Disconnect harness connector P9 from control switch S1 (p. 11-4). Check for B+ (12 VDC) at P9-3
(Start) and at P9-1 (Stop) and for ground continuity at P9-2 (Ground). If there is B+ and ground conti-
nuity, test control switch S1 and replace if necessary (p. 11-4). If not, go to Step 7.
7. Disconnect harness connector P1 from the control board (p. 11-1) and check for B+ at P1-10 and
for ground continuity at P1-27. If there is B+ and ground continuity, go to Step 8. If not, go to Step 9.
8. Check for wiring continuity in the harness between connectors P9-3 and P1-9 (Start), P9-1 and
P1-32 (Stop), P9-8 and P1-7 (Status), P9-7 and P1-27 (Status Ground) and P9-2 and P1-27 ( Start/
Stop Ground). Repair as necessary. Make sure connector pin sockets are not damaged or corroded
and that they are fully seated and can’t be pulled out. Replace the control board (p. 11-1) if the genset
still does not start.
9. Remove the top housing panel (p. 4-4) and check that both harness connectors labeled B1−BAT
are secure on the starter solenoid terminal, that GND is secure on the chassis ground and that there
is wiring continuity in the harness between connectors P1-10 and B1−BAT and between connectors
P1-27 and GND. Repair as necessary. Make sure connector pin sockets are not damaged or cor-
roded and that they are fully seated and can’t be pulled out. Replace the control board (p. 11-1) if
the genset still does not start.
10. Remove the top housing panel (p. 4-4) and replace broken or missing cables between TB1 and the
engine. Tighten loose connections.

12-2
 TABLE 12-1. 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.

THE STARTER ENGAGES AND DISENGAGES

(Low cranking voltage)
Corrective Action:
1. Have the vehicle propulsion engine running while trying to start the genset. Its charging alternator
may be able to maintain a high enough battery terminal voltage to start the genset.
2. Service the battery as necessary by cleaning and tightening connections, recharging or replacing
the battery or replacing damaged battery cables.

THE STARTING BATTERIES DO NOT MAINTAIN A CHARGE

(Marginal battery, battery connections or charging system)
Corrective Action: Refer to Pages A-1, A-2 and A-3, as appropriate.
1. Service the battery as necessary by cleaning and tightening connections, recharging or replacing
the battery or replacing damaged battery cables.
2. Models HDKCA and HDKCB − The genset starting battery is recharged by the vehicle engine or
separate battery charger. Service as required.
3. Models HDKCC and HDKCD − These models have a feature whereby genset battery charging al-
ternator G1 (p. 9-4) can be disabled, via relay K1 (p. 11-5), by connecting B+ to remote connector
pin P8-D. Service the vehicle engine or separate battery charger if depended upon for recharging
the genset starting battery. If genset battery charging alternator G1 is not disabled, continue with
Step 4.
4. Remove the top housing panel (p. 4-4) and check for wiring continuity in the harness between charg-
ing alternator G1 and starter solenoid terminal B+ (BAT). Repair as necessary.
5. Check for proper operation of relay K1 and replace if necessary (p. 11-5).
6. Check for wiring continuity in the harness between connectors G1-VR and K1-87a. Repair as neces-
sary.
7. Disconnect harness connector P1 from the control board (p. 11-1). Check for wiring continuity in the
harness between connectors P1-24 and K1-30. Repair as necessary. Make sure connector pin sock-
ets are not damaged or corroded and that they are fully seated and can’t be pulled out.
8. Replace battery charging alternator G1 (p. 9-4).

NO AC POWER WHEN GENSET IS RUNNING

(A Circuit Breaker is OFF, tripped or malfunctioning or there are poor AC harness connections)
Corrective Action: Refer to Pages A-1, A-2 and A-3, as appropriate.
1. Reset or turn ON genset circuit breaker CB1.
2. Reset or turn ON any other circuit breaker in the AC power supply system.
3. Check voltage at genset AC output terminal block TB2 when the genset is running. If there is approxi-
mately 120 VAC across TB2-1 and TB2-3 and across TB2-2 and TB2-3, repair or reconnect the wir-
ing between the genset and the main vehicle distribution panel. If there is no voltage, go to Step 4.
4. Check for proper AC harness connections and repair as necessary (p. A-3).
5. Test each circuit breaker and replace if necessary (p. 11-5).

12-3
 TABLE 12-1. 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.

PERSISTENT, AUDIBLE ENGINE SURGING—WITHOUT FAULT SHUTDOWN

(Fuel leaks, restrictions or air bubbles, worn slip rings/brushes, misadjusted or faulty governor,
worn generator bearing)
Corrective Action:
1. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime.
2. Replace the fuel filter (p. 3-6).
3. Conduct a fuel flow test and service as necessary (p. 5-1).
4. Service or replace the brush block, slip rings or rotor as necessary (p. 10-4).
5. Remove the governor actuator, test it for proper operation and replace if necessary (p. 9-5).
6. Check high-idle speed and readjust if necessary (p. 9-5).
7. Check generator bearing bore and replace endbell, bearing and O-ring if necessary (p. 10-4).
8. Service the internal engine governor mechanism (p. 9-1).
9. Service the engine (p. 9-1).

ENGINE OVER TEMPERATURE—CODE NO. 1

(During normal operation engine coolant temperature exceeded 239° F [115° C] for 10 seconds)
Corrective Action:
1. Check engine coolant level, add coolant as necessary and repair any leaks.
2. Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset
and clean out dirt fouling the radiator passages.
3. Run fewer appliances at the same time to keep down engine temperature. (Note that high altitude
and high ambient temperature decrease engine cooling capacity.)
4. Look for loose or broken fan belts and readjust or replace as necessary (p. 8-2).
5. Check for air leaks in the housing as a result of missing or loose housing panels and access covers,
including the access cover for the AC terminals (Figure ).
6. If loose, reconnect wiring harness connector E3-1 to engine coolant temperature sender E3 (p. 9-4).
(The Controller interprets a loose lead touching ground as high temperature.)
7. Replace the coolant thermostat, which might not be fully opening. See Engine Workshop Manual
981-0541.
8. Test temperature sender E3 and replace if necessary (p. 9-4).

LOW OIL PRESSURE—CODE NO. 2

(During normal operation engine oil pressure dropped to less than 14 psi for 3 seconds—switch closed)
Corrective Action:
1. Check engine oil level, add oil as necessary and repair any leaks.
2. Drain the excess oil if the level is above Full on the dipstick. If the level is too high the crankshaft can
whip the oil into foam, which the pump can’t pump.)
3. Test low oil pressure cutoff switch S2 and replace if necessary (p. 9-4).
4. Service the engine (p. 9-1).

12-4
 TABLE 12-1. 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.

SERVICE CHECK—CODE NO. 3

(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.

OVER CRANK—CODE NO. 4

(First-level fault code—Cranking time exceeded 35 seconds)
Corrective Action: Refer to Pages A-1, A-2 and A-3, as appropriate.
1. Check fuel level and refill as necessary. (Note: The genset fuel pickup is probably higher than the
vehicle engine fuel pickup.)
2. Prime the engine fuel system for one minute (p. 2-4).If the fuel pump does not operate, check for
loose wiring harness connectors E2-1 and E2-2 and reconnect them to the pump. If they were found
connected, disconnect them and power the pump directly with a 12 volt battery. Replace the fuel
pump if it does not operate. If the pump operates, disconnect P1 from the control board (p. 11-1) and
check for wiring continuity in the harness between connectors P1-24 and E2-1 and for ground conti-
nuity at connector E2-2. Repair as necessary. Make sure connector pin sockets are not damaged
or corroded and that they are fully seated and can’t be pulled out. Replace the control board if the
fuel pump still does not operate.
3. Check the engine air filter and remove any blockage (p. 3-4).
4. Change the engine oil to oil of the proper viscosity for the ambient temperature. High oil viscosity
can slow down cranking speed.
5. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime.
6. Replace the fuel filter (p. 3-6).
7. Conduct a fuel flow test and service as necessary (p. 5-1).
8. If loose, reconnect wiring harness connector HR-1 to the glow plug bus bar. If it was found connected,
check for B+ on the glow plug bus bar while cranking. If there is B+, remove the glow plug bus bar
and check for electrical continuity between each glow plug terminal and ground. Replace all three
glow plugs if any glow plug is open (p. 9-4). If there is no B+, check for proper operation of glow
plug relay K3 (p. 11-5). If the relay functions properly, check for wiring continuity in the harness be-
tween connectors HR1 and K3-87 and for ground continuity at K3-86. If good, disconnect harness
connector P1 from the control board (p. 11-1) and check for wiring continuity in the harness between
connectors P1-23 and K3-85 and between P1-10 and K3-30. Repair as necessary. Make sure con-
nector pin sockets are not damaged or corroded and that they are fully seated and can’t be pulled
out. Replace the control board if there still is no B+ at the glow plug bus bar during cranking.
9. Remove the governor actuator, test it for proper operation and replace if necessary (p. 9-5). (The
engine cannot start if the actuator fails to pull in its spring-loaded plunger.)
10. Service the fuel injectors and injection pump (p. 9-1).
11. Service the internal engine governor mechanism (p. 9-1).
12. Service a worn engine (p. 9-1).

12-5
 TABLE 12-1. 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.

OVER VOLTAGE—CODE NO. 12

(After voltage regulation was enabled Output Voltage jumped to more than 150 VAC
[125% of rated] for 75 milliseconds or to more than 138 VAC [115% of rated] for 3 seconds)
Corrective Action:
1. Push the line circuit breaker to OFF, start the genset and measure output voltage. If output voltage
is normal, the problem is in the circuits external to the genset. If there is no voltage, test for and ser-
vice a grounded or shorted main, field or quadrature windings (p. 10-2) or grounded or shorted volt-
age sense transformer (p. 11-5).
2. Replace the control board (p. 11-1).

UNDER VOLTAGE—CODE NO. 13

(After voltage regulation was enabled Output Voltage fell to less than 108 VAC
[90% of rated] for 5 seconds)
Corrective Action:
1. Push the line circuit breaker to OFF, start the genset and measure output voltage. If output voltage
is normal, the problem is in the circuits external to the genset. If there is no voltage, test for and ser-
vice a grounded or shorted main, field or quadrature windings (p. 10-2) or grounded or shorted volt-
age sense transformer (p. 11-5).
2. Replace the control board (p. 11-1).

OVER FREQUENCY—CODE NO. 14

(After the starter was engaged Frequency jumped to more than 70 Hz
for 40 milliseconds or to more than 66 Hz for 6 seconds)
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 genset frequency to overshoot.)
2. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime. (Air bubbles can
disrupt frequency.)
3. Remove the governor actuator, test it for proper operation and replace if necessary (p. 9-5).
4. Check high-idle speed and readjust if necessary (p. 9-5).
5. Replace the control board (p. 11-1).
6. Service the internal engine governor mechanism (p. 9-1).

12-6
 TABLE 12-1. 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.

UNDER FREQUENCY—CODE NO. 15

(During normal operation Frequency fell to less than 54 Hz for more than 8 seconds)
Corrective Action:
1. Push the line circuit breaker to OFF and restart the genset. If the genset now runs, run it with fewer
connected loads, especially those with high motor starting loads such as air conditioners.
2. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime. (Air bubbles can dis-
rupt frequency.)
3. Replace the engine air filter and clean the spark-arrest muffler (p. 3-4).
4. Replace the fuel filter (p. 3-6).
5. Conduct a fuel flow test and service as necessary (p. 5-1).
6. Remove the governor actuator, test it for proper operation and replace if necessary (p. 9-5).
7. Check high-idle speed and readjust if necessary (p. 9-5).
8. Replace the control board (p. 11-1).
9. Service the fuel injectors and injection pump (p. 9-1).
10. Check fuel injection timing (p. 9-1).
11. Service the internal engine governor mechanism (p. 9-1).
12. Service a worn engine (p. 9-1).

ACTUATOR SHORTED OR OPEN—CODE NO. 19

(At startup the Controller sensed an open or shorted governor actuator/harness)
Corrective Action: Refer to Pages A-1, A-2 and A-3, as appropriate.
1. If loose, reconnect wiring harness connectors E1-1 and E1-2 to the governor actuator. If they were
found connected, disconnect the wiring harness and measure electrical resistance across the actua-
tor leads. Replace the actuator if resistance is not 2.8 to 2.9 ohms.
2. Disconnect harness connector P1 from the control board (p. 11-1) and check for wiring continuity
in the harness between connectors P1-28 and E1-1 and for ground continuity at connector E1-2. Re-
pair as necessary. Make sure connector pin sockets are not damaged or corroded and that they are
fully seated and can’t be pulled out. Replace the control board if the fault still occurs.

12-7
 TABLE 12-1. 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.

ACTUATOR OVERLOAD—CODE NO. 22

(Due to connected overload or low engine performance, the Controller maintained the governor actuator
at full-duty cycle—maximum pulse-width-modulated square-wave signal [PWM]—for
60 consecutive seconds)
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 all fuel fittings for fuel and air leaks and tighten as necessary. Reprime.
3. Replace the engine air filter and clean the spark-arrest muffler (p. 3-4).
4. Replace the fuel filter (p. 3-6).
5. Conduct a fuel flow test and service as necessary (p. 5-1).
6. Remove the governor actuator, test it for proper operation and replace if necessary (p. 9-5).
7. Check high-idle speed and readjust if necessary (p. 9-5).
8. Service the fuel injectors and injection pump (p. 9-1).
9. Check fuel injection timing (p. 9-1).
10. Service the internal engine governor mechanism (p. 9-1).
11. Service a worn engine (p. 9-1).

FAULTY ENGINE TEMPERATURE SENDER—CODE NO. 24

(After 10 minutes of normal operation the Controller checked for and sensed
an open temperature sender/harness)
Corrective Action:
1. If loose, reconnect wiring harness connector E3-1 to engine coolant temperature sender E3 (p. 9-4).
2. Test the temperature sender and replace if necessary (p. 9-4).
3. Disconnect harness connector P1 from the control board (p. 11-1) and check for wiring continuity
in the harness between connectors P1-21 and E3-1. Repair as necessary. Make sure connector pin
sockets are not damaged or corroded and that they are fully seated and can’t be pulled out. Replace
the control board if the fault still occurs.

12-8
 TABLE 12-1. 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.

VAC SENSE LOST—CODE NO. 27

(The Controller lost VAC sensing during normal voltage regulation when the field was functioning nor-
mally and frequency was at least 40 Hz)
Corrective Action: Refer to Pages A-1, A-2 and A-3, as appropriate.
1. Disconnect harness connector P1 from the control board (p. 11-1) and check for electrical resistance
between pins P1-33 and P1-34, which should be approximately 586 ohms (TX1 secondary winding,
p. 11-5). Go to Step 2 if the secondary circuit of voltage sense transformer TX1 is good. If not, discon-
nect the four harness leads from TX1 and test the transformer. Replace the transformer if either wind-
ing is faulty. If the transformer is good, check wiring continuity in harness leads P1-33—TX1-RED
and P1-34—TX1-GRN. Repair or replace components as necessary. Make sure connector pin sock-
ets are not damaged or corroded and that they are fully seated and can’t be pulled out.
2. Make sure the line circuit breaker (CB1/CB2) is OFF, disconnect the four harness leads from TX1
and test the transformer. Replace the transformer if either winding is faulty. If the transformer is good,
check electrical resistance between harness leads TX1-S1 and TX1-S2, which should be approxi-
mately twice the individual winding resistances in Table 10-1 (T1−T2 + T3−T4). If not, check wiring
continuity in harness leads CB1-LINE—TX1-S1 and CB2-LINE—TX1-S2 and for proper connec-
tions of both sense leads and generator leads to the line terminals on CB1 and CB2. Repair, recon-
nect or replace components as necessary.
3. Replace the control board (p. 11-1).

HIGH BATTERY VOLTAGE—CODE NO. 29

(During startup the Controller sensed that battery system voltage was greater than 19.2 volts for 5 milli-
seconds or greater than 19.2 volts for 1 second will running)
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.

12-9
 TABLE 12-1. 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.

STARTING FAULT—CODE NO. 32

(The Controller could not detect cranking speed [quadrature zero crossings] for 12 seconds)
Corrective Action:
1. Have the vehicle propulsion engine running while trying to start the genset. Its charging alternator
may be able to maintain a high enough battery terminal voltage to start the genset.
2. Service the battery as necessary by cleaning and tightening connections, recharging or replacing
the battery or replacing damaged battery cables.
3. Change the engine oil to oil of the proper viscosity for the ambient temperature. High oil viscosity
can slow down cranking speed.
4. Remove the top housing panel (p. 4-4) and check for wiring continuity in the harness between con-
nectors SW (starter solenoid) and K2-87 (starter pilot relay) and between K2-30 and B+ (BAT) (start-
er solenoid). Repair as necessary.
5. Check for proper operation of starter pilot relay K2 and replace if necessary (p. 11-5).
6. Disconnect harness connector P1 from the control board (p. 11-1) and check for wiring continuity
in the harness between connectors J1-12 and K2-85 and for ground continuity at connector K2-86.
Repair as necessary. Make sure connector pin sockets are not damaged or corroded and that they
are fully seated and can’t be pulled out.
7. Service or replace the starter motor assembly (p. 9-4).
8. Replace the control board (p. 11-1).

EE CHECKSUM FAULT—CODE NO. 35

(During startup the genset Controller detected an EE memory error)
Corrective Action: Replace the control board (p. 11-1)

MECHANICAL FAULT—CODE NO. 36

(The Controller declared this fault because engine speed fell below 1000 RPM for 0.5 seconds, though
not by Controller action)
Corrective Action:
1. Check fuel level and refill as necessary. (Note: The genset fuel pickup is probably higher than the
vehicle engine fuel pickup.)
2. Prime the engine fuel system for one minute (p. 2-4).
3. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime.
4. Check the engine air filter and remove any blockage (p. 3-4).
5. Replace the fuel filter (p. 3-6).
6. Conduct a fuel flow test and service as necessary (p. 5-1).
7. Remove the governor actuator, test it for proper operation and replace if necessary (p. 9-5).
8. Replace the control board (p. 11-1).
9. Service the engine (p. 9-1).

12-10
 TABLE 12-1. 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.

FIELD OVERLOAD—CODE NO. 38

(During normal voltage regulation Field Voltage exceeded 180 VAC for 10 seconds)
Corrective Action:
1. Reduce the number of air conditioners running at the same time, and other appliances that cause
low power factor. (The lower the power factor of a motor or compressor, the more current it draws
per kilowatt. The genset Controller, in turn, must boost field voltage to meet the higher demand for
current imposed by low power factor.)
2. Have the air conditioners and other appliances checked for proper operation. (A locked compressor
rotor can cause a very low power factor.)
3. Test the generator field and stator windings and service as necessary (p. 10-2).

GENERATOR ROTOR SHORT—CODE NO. 41

(While field flashing during cranking, the Controller sensed that the rotor circuit was shorted to ground)
Corrective Action:
1. Disconnect Generator connector J3/P3 and check for a short to ground at P3-7 and at P3-8 (p. 10-2).
Service or replace brushes, slip rings and rotor as necessary.
2. Replace the control board (p. 11-1).

ROM FAULT—CODE NO. 42

(During startup the genset Controller detected a ROM memory error)
Corrective Action: Replace the control board (p. 11-1)

RAM FAULT—CODE NO. 43

(During startup the genset Controller detected a RAM memory error)
Corrective Action: Replace the control board (p. 11-1)

SPEED SENSE LOST—CODE NO. 45

(After start disconnect the Controller lost speed sense [quadrature zero crossings] for 0.25 seconds)
Corrective Action:
1. Disconnect Generator connector J3/P3 and check for open and shorted field (P3-7—P3-8) and
quadrature (P3-3—P3-6) windings (p. 10-2). Service or replace brush block, slip rings, rotor or stator
as necessary.
2. Spec A only: Check all fuel fittings for fuel and air leaks and fuel lines for kinks, and repair as neces-
sary. Reprime.
3. Replace the control board (p. 11-1).

12-11
 TABLE 12-1. 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.

LOSS OF FIELD SENSE—CODE NO. 48

(The field sense circuit on the Controller circuit board failed during normal voltage regulation)
Corrective Action: Replace the control board (p. 11-1)

OVERPRIME—CODE NO. 57
(The local or remote control switch was held in the Prime position for more than 3 minutes)
Corrective Action: Check for and remove any object that may be holding either control switch (remote
or local) in the prime position.

12-12
13. Bolt Torques

lb-ft N-m
Housing Panel Screws 7-9 10-12
Intake Air Hose Clamp Screws 7-9 10-12
Intake Air Resonator Mounting Screws 6-12 lb-inch 0.7-1.4
Radiator Access Plate Screws 7-9 10-12
Fuel Pump and Fuel Filter Bracket Mounting Screws 7-9 10-12
Fuel Fittings at Pump and Fuel Filter—One Flat passed finger tight. − −
Exhaust Assembly Flange Screws and Nuts 16-20 22-28
Battery Cable Terminal Block Terminal Nuts 6.7-8.3 9-11
Battery Cable Terminal Block Mounting Screws 7-9 10-12
Starter Solenoid Terminal Nuts 4.4-8.7 5.9-11.8
AC Output Terminal Block Terminal Screws 12-14 lb-inch 1.4-1.6
AC Output Terminal Block Mounting Screws 20-22 lb-inch 2.2-2.5
Circuit Breaker Terminal Screws 12-14 lb-inch 1.4-1.6
Circuit Breaker Mounting Screws 12-14 lb-inch 1.4-1.6
Vibration Isolator Mounting Screws 7-9 10-12
Primary Vibration Isolator Center Bolt* 43-53 58-72
Secondary Vibration Isolator Center Bolt* 27-30 37-41
Generator Drive Disc to Flywheel Bolts* 24-32 33-44
Generator Drive Disc to Rotor Bolts* 19-21 25-29
Generator Through Bolt Nuts* 20-25 28-34
Generator to Flywheel Housing Bolts* 39 52
Flywheel Housing Mounting Bolts* 30-40 41-55
Flywheel Mounting Bolts* 65-80 88-108
Starter Mounting Bolts* 18-22 24-30
Engine Mounting Bracket Bolts* 36-43 48-58
Engine Lifting Bracket Bolts* 18-22 24-30
Engine Oil Drain Plug* 32 44
Fan Spacer Bolts* 18-22 24-30
Fan Coupling (Pulley)* 103-118 137-157
Flexible Fan Coupling Nuts (Beginning Spec B)* 7-9.6 10-13
M6 Engine Bolts Except When Otherwise Specified* 5.8-6.9 7.9-9.3
M8 Engine Bolts Except When Otherwise Specified* 13.0-15.2 17.7-20.6
M10 Engine Bolts Except When Otherwise Specified* 28.9-33.3 39.2-45.1
M12 Engine Bolts Except When Otherwise Specified* 46.3-53.5 62.8-72.6
* − Use engine oil as a thread lubricant.

13-1
14. Specifications

MODEL: HDKCA HDKCB

GENSET CONTROL: Integrated Microprocessor-Based Engine and Generator Controller
GENERATOR: Single-Bearing, 4-Pole Rotating Field, 1800 RPM
Power (@1.0 power factor) 10,000 W 12,500 W
Voltage 120 / 240 120 / 240
Frequency 60 Hz 60 Hz
Number of Phases 1 1
Current 41.7 amps per leg 52.1 amps per leg
Line Circuit Breaker 2-pole, 45 amp 2-pole, 50 amp
FUEL CONSUMPTION:
No-load 0.11 gph (0.4 lph) 0.11 gph (0.4 lph)
Half-load 0.48 gph (1.8 lph) 0.48 gph (1.8 lph)
Full-load 1.01 gph (3.8 lph) 1.2 gph (4.5 lph)
ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection (IDI), 4-Stroke Cycle Diesel
Bore 3.43 in (87 mm)
Stroke 3.64 in (92.4 mm)
Displacement 100.5 in3 (1,647 cc)
Compression Ratio 22.6 : 1
Fuel Injection Timing (BTDC) 14.5°
Firing Order 1−3−2
Fuel Nozzle Injection Pressure 1991 psi (13.731 mPa)
Cylinder Compression Test 370 psi (2.55 mPa) minimum
Valve Lash: Intake & Exhaust (cold) 0.0071 to 0.0087 in (0.18 to 0.22 mm)
Oil Capacity (with filter) 5.9 quart (5.6 liter)
Cooling System Capacity 6.6 quart (6.2 liter)
DC SYSTEM:
Nominal Battery Voltage 12 volts
Minimum Battery Capacity 475 amps down to 0° F (−17° C)
CCA (Cold Cranking Amps) 650 amps down to −20° F (−29° C)
Battery Recharging Installer must provide for battery charging
WEIGHT: 775 lbs (351 kg) 794lbs (360 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” @ half load

14-1
 SPECIFICATIONS
MODEL: HDKCC HDKCD
GENSET CONTROL: Integrated Microprocessor-Based Engine and Generator Controller
GENERATOR: Single-Bearing, 4-Pole Rotating Field, 1800 RPM
Power (@1.0 power factor) 10,000 W 8000 W 12,000 W
Voltage 120 / 240 115 / 230 120 / 240
Frequency 60 Hz 50 Hz 60 Hz
Number of Phases 1 1 1
Current 41.7 amps per leg 34.8 amps per leg 50 amps per leg
Line Circuit Breaker 2-pole, 45 amp 2-pole, 35 amp 2-pole, 50 amp
FUEL CONSUMPTION:
No-load 0.11 gph (0.4 lph) 0.11 gph (0.4 lph) 0.11 gph (0.4 lph)
Half-load 0.48 gph (1.8 lph) 0.33 gph (1.2 lph) 0.48 gph (1.8 lph)
Full-load 1.01 gph (3.8 lph) 0.82 gph (3.1 lph) 1.20 gph (4.5 lph)
ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection (IDI), 4-Stroke Cycle Diesel
Bore 3.43 in (87 mm)
Stroke 3.64 in (92.4 mm)
Displacement 100.5 in3 (1,647 cc)
Compression Ratio 22.6 : 1
Fuel Injection Timing (BTDC) 14.5°
Firing Order 1−3−2
Fuel Nozzle Injection Pres-
1991 psi (13.731 mPa)
sure
Cylinder Compression Test 370 psi (2.55 mPa) minimum
Valve Lash: Intake & Exhaust
(cold)
0.0071 to 0.0087 in (0.18 to 0.22 mm)
Oil Capacity (with filter) 5.9 quart (5.6 liter)
Cooling System Capacity 6.6 quart (6.2 liter)
DC SYSTEM:
Nominal Battery Voltage 12 volts
Minimum Battery Capacity 475 amps down to 0° F (−17° C)
CCA (Cold Cranking Amps) 650 amps down to −20° F (−29° C)
Maximum Regulated Charg-
ing Current
20 amps
WEIGHT: 775 lbs (351 kg) 794 lbs (360 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” @ half
60 Hertz Models
load
50 Hertz Models 67 dB(A) @ 10 ft (3m) before installation @ full load

14-2
15. Service Checklist
After servicing, inspect and test the installation to nections, welds, gaskets and joints. Also make sure
confirm that the genset will operate as intended. the exhaust pipe is not overheating adjacent materi-
Check each of the areas described below before als or equipment. Do not run the genset until all ex-
putting the genset into service. haust leaks have been repaired.

Housing WARNING Exhaust gas is deadly. The exhaust

Check to see that all housing panels and access system must not leak and must discharge all ex-
covers are in place and secure. haust away from the vehicle. Do not run the gen-
set until the exhaust leaks have been repaired.
Mounting The exhaust tailpipe must be supported by a
hanger near the vehicle perimeter and terminate
Examine all mounting bolts and supporting mem-
at least 1 inch outside the perimeter and at least
bers to verify that the genset is properly mounted.
1 foot from doors and windows.
All fasteners should be tightened securely to pre-
vent them from working loose when subjected to
vibration. Fuel System

Lubrication While the genset is running, inspect the fuel supply

and return lines, filter and fittings for leaks. Check
If the engine oil was drained, refill as required. flexible sections for cuts, cracks and abrasions and
make sure they are not rubbing against anything
Cooling System that could cause leakage. Repair all fuel leaks im-
mediately.
If the engine coolant was drained, refill as required.

Wiring WARNING Diesel fuel is combustible. Leaking

fuel could lead to fire and to severe personal in-
Verify that all wiring connections are tight and jury or death. Repair fuel leaks immediately.
installed properly. Check each of these connec-
tions: Control
• Load wires
• Control wires Stop and start the genset several times at the con-
trol panel on the genset and at the remote control
• Ground straps board (if provided) to verify that they work properly.
• Battery cables
Mechanical
Output Check
Apply a full load to make sure the genset can pro- Stop the genset and inspect it for leaking gaskets,
duce rated output. Use a load test panel to apply a loose fasteners, damaged components and inter-
progressively greater load until full load is reached. ference with other equipment. Repair as necessary.
Inspect the generator compartment and verify that
Exhaust System there are no breaks or openings in the vapor-proof
wall that separates the compartment from the ve-
While the genset is running inspect the entire ex- hicle interior. Seal openings as necessary. Make
haust system. Look and listen for leaks at all con- sure that all soundproofing material is in place.

15-1
 630-2676

CONTROL SCHEMATIC

A-1
 338-4461

CONTROL WIRING HARNESS

A-2
 AC HARNESS

AC WIRING HARNESS

A-3
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.