Caution: This document contains mixed page sizes (8.

5 x 11 or 11 x
17), which may affect printing. Please adjust your printer settings
according to the size of each page you wish to print.
 HDKBA, HDKBB

Printed in U.S.A. 981-0535

10-02
 California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.

diesel warnings

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

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

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

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

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

PRESSURE CAP
AND SYSTEM FILL
OPENING

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

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Table of Contents
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Fuel Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Engine Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Starting Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator’s Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Remote Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Starting the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Stopping the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
3. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Conducting General Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Changing Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Maintaining the Battery and Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Replacing the Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Cleaning the Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Changing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
4. PREPARING FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Removing / Installing Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Removing / Installing Genset Housing Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
5. CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Controller A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Control Switch S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Line Circuit Breakers CB1, CB2, CB3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Hour Meter M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Glow Plug Relay K3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
3-Phase Voltage Sense Transformer T15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Battery Charge Regulator AVR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
DC Control Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Oil Pressure Switch S2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Coolant Temperature Sender E4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Fuel Pump E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Starter Motor B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

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6. GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Servicing the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Servicing Brushes and Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Testing Field Flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Testing Generator Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Reconnecting the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Adjusting Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Adjusting Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
7. DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Inspecting Drive and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
8. ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Major Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Fuel Injection Timing Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Adjusting Valve Lash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Governor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Coolant Temperature Sender E4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Low Oil Pressure Switch S2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
Coolant Pump Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
Engine-Generator Adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
9. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
10. SERVICE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
11. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
12. TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

DC WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

GENERATOR CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
DC WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

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

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

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

Mobile-6

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by any means, is strictly prohibited.
iv
1. Introduction
ABOUT THIS MANUAL
This is the service manual for the generator sets
(gensets) listed on the front cover. Read and care-
fully observe all of the instructions and precautions 5.5HDKBA-2732A
in this manual. F000 123456

WARNING Improper service or replacement of

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.
[The engine family designation, engine displacement, state-
WARNING Unauthorized modifications or re- ment of compliance with applicable EPA and / or California
placement of fuel, exhaust, air intake or speed emissions regulations appear in this block on the actual name-
control system components that affect engine plate on the genset.]

emissions are prohibited by law in the State of

California.
See the Installation Manual for important recom-
mendations concerning the installation and for a list
of the installation codes and standards for safety
which may be applicable.

See the Parts Manual for part identification numbers

and required quantities and for exploded views of
the genset subassemblies. Genuine Onan re-
placement parts are recommended for best results.

When contacting Onan for parts and product infor-

mation, be ready to provide the model and serial
numbers on the genset nameplate. Figure 1-1 illus-
trates the nameplate and its location. The numbers
in the gray boxes are typical model and serial num-
bers. Every character in these numbers is signifi-
cant. (The last character of the model number is the
specification letter, which is important for obtaining
the right parts.) FIGURE 1-1. TYPICAL NAMEPLATE

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1-1 by any means, is strictly prohibited.
 FUEL RECOMMENDATIONS
WARNING Diesel fuel is combustible and can
cause severe personal injury or death. Do not
smoke near fuel tanks or fuel-burning equip-
ment or in areas sharing ventilation with such
equipment. Keep flames, sparks, pilot flames,
electrical arcs and switches and all other
sources of ignition well away. Keep a multi-
class ABC fire extinguisher handy.
Use clean, fresh No. 2 diesel fuel (ASTM 2-D) when
the outdoor ambient temperature is above freezing, FIGURE 1-2. OIL VISCOSITY VS. TEMPERATURE
and No. 1 diesel fuel (ASTM 1-D) when below freez-
ing. The fuel should have a Cetane number of at
least 45 for reliable starting.
ENGINE OIL RECOMMENDATIONS
Use API (American Petroleum Institute) perfor-
mance Class CH-4 engine oil or better. Also look for
the SAE (Society of Automotive Engineers) viscos-
ity grade. Referring to Figure 1-2, choose the vis-
cosity grade appropriate for the ambient tempera-
tures expected until the next scheduled oil change.
Multi-grade oils such as SAE 15W-40 are recom-
mended for year-round use.
STARTING BATTERIES
The genset requires a 12 volt battery to power its
control and starting circuits. Reliable genset starting
and starter service life depend upon adequate bat-
tery system capacity and maintenance. See Sec-
tion 11. Specifications for battery requirements and
Section 3. Periodic Maintenance for battery care.

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2. Operation
OPERATOR’S CONSOLE
ACCESS TO OIL FILL ACCESS TO
The console (Figure 2-1) has the following features: COOLANT CAP & COOLANT
Control Switch - This switch is used to start and PRESSURE DIPSTICK RECOVERY
CAP TANK
stop the genset, prime the engine fuel system and
restore the fault code (blinking status light).
Status Light - This is an LED (light emitting diode)
in the control switch which blinks rapidly during pre-
heat and cranking. After the genset starts up, this
light stays on continuously, indicating that the gen-
set is running and that the starter has disconnected.
If the genset shuts down, this light blinks in coded
fashion to indicate the nature of the fault shutdown
(see Section 9. Troubleshooting).
(Rapid blinking before cranking starts indicates that
the glow plugs are preheating the combustion
chambers. The controller automatically varies the
time based on engine temperature.)
Line Circuit Breakers - The line circuit breakers
protect the AC power leads connected to the gen-
set.
Coolant Pressure Cap - The coolant pressure cap
is under the access plate. Fill coolant here when re-
filling the system. COOLANT
LINE CIRCUIT CONTROL SWITCH LEVEL SIGHT
Coolant Recovery Tank - The recovery tank is BREAKERS & STATUS LIGHT HOLE
mounted inside the genset and provides for coolant
expansion. The coolant level is visible through the FIGURE 2-1. OPERATOR’S CONSOLE
sight hole on the front of the genset. The fill cap is
under the access cover. Replenish the normal loss
of coolant here.
Oil Fill Cap and Dipstick - Check and fill engine oil.
REMOTE CONTROL PANEL
The vehicle probably has a control panel inside the
vehicle for remote control of the genset, which may
have an hour meter or DC voltmeter.

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 WARNING EXHAUST GAS IS DEADLY! STARTING THE GENSET

All engine exhaust contains carbon monoxide; Start the genset from the genset control panel or re-
an odorless, colorless, poisonous gas that can mote control panel inside the vehicle.
cause unconsciousness and death. Symptoms 1. Push and hold the switch at START until the
of carbon monoxide poisoning include: genset starts. The status indicator light on the
switch flashes during preheat and cranking. It
• Dizziness • Headache will come on solid when the starter disconnects,
• Nausea • Weakness and Sleepiness indicating that the genset is running. (Depend-
• Vomiting • Inability to Think Coherently ing on how cold it is, preheat can take up to
15 seconds, extending the time that the light
IF YOU EXPERIENCE ANY OF THESE SYMP-
blinks.)
TOMS, GET INTO FRESH AIR IMMEDIATELY. If
symptoms persist, seek medical attention. Shut CAUTION Excessive cranking can over-
down the genset and do not operate it until it has heat and damage the starter motor. Do not
been inspected and repaired. crank for more than 30 seconds at a time.
Wait at least 2 minutes before trying again.
Never sleep in the vehicle while the genset is
2. See Section 9. Troubleshooting if the genset
running unless the vehicle has a working car-
does not start after several tries.
bon monoxide detector. The exhaust system
must be installed in accordance with the genset 3. For top performance and engine life, especially
Installation Manual. Make sure there is ample in colder weather, let the engine warm up for
fresh air when operating the genset in a con- two minutes before connecting appliances.
fined area. 4. Check for fuel, exhaust and coolant leaks. Stop
the genset immediately if there is a fuel, ex-
PRIMING THE FUEL SYSTEM haust or coolant leak and have it repaired.
The fuel system should be primed after replacing STOPPING THE GENSET
the fuel filter or running the genset out of fuel. To
prime the fuel system hold the control switch down Turn off air conditioners and other large appliances
in its Stop position for at least 1 minute (starts in and let the genset run for two minutes to cool down.
2 seconds). Then push the switch to STOP.

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3. Periodic Maintenance
Periodic maintenance is essential for good perfor- Maintenance, replacement or repair of emission
mance and long genset life. Use Table 3-1 as a control devices and systems may be performed by
guide for normal periodic maintenance. In hot and any engine repair establishment or individual. How-
dusty environments some maintenance procedures ever, warranty work must be completed by an au-
should be performed more frequently, as indicated thorized Onan dealer.
by the footnotes in the table.

TABLE 3-1. PERIODIC MAINTENANCE SCHEDULE

MAINTENANCE FREQUENCY

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

General Inspection • 3-2

Check Engine Oil Level • 3-3
Check Engine Coolant Level • 3-9
Clean and Check Battery •2 3-5
Clean Spark Arrestor •3 3-6
Change Engine Oil and Oil Filter • •1, 2, 3 3-4
Replace Engine Air Filter •1, 3 3-5
Replace Fuel Filter •3 3-7
Check Coolant Anti-freeze Protection •3 3-8
Flush Coolant System •4 3-8
Replace Coolant Pressure Cap •4 3-8
Replace Engine V-belt (Coolant Pump) •5, 6 8-11
Replace Coolant Hoses and Thermostat •5, 6 8-10
Adjust Engine Valve Lash •5, 6 8-1
Service Fuel Injectors •5, 6 8-1
Check Generator Bearings, Drive Belt, Belt
•5, 6 7-1
Tensioner & Drive Coupling
1 - Perform more often when operating in dusty conditions.
2 - Perform more often when operating in hot weather.
3 - Perform at least once a year.
4 - Perform at least once every two years.
5 - Perform at least once every five years.
6 - Must be performed by a trained and experienced mechanic (authorized Onan dealer).

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3-1 by any means, is strictly prohibited.
 CONDUCTING GENERAL INSPECTIONS WARNING Do not park the vehicle in high grass
or brush. Contact with the exhaust system can
Inspect the genset before the first start of the day cause a fire.
and after every eight hours of operation.
Park the vehicle so that the genset exhaust gases
can disperse away from the vehicle. Barriers such
Oil Level
as walls, snow banks, high grass and brush and oth-
er vehicles can cause exhaust gases to accumulate
Check engine oil level (Page 3-3). in and around the vehicle.
Engine Coolant System Do not operate power ventilators or exhaust fans
while the vehicle is standing with the genset run-
CAUTION Operating the genset when coolant ning. The ventilator or fan can draw exhaust gases
level is low can cause serious engine damage. into the vehicle.

Check the coolant level and look for coolant leaks Fuel System
around the bottom of the genset and on the ground
below. Minor leaks that can be replenished by daily Check for leaks at hose, tube and pipe fittings in the
additions of coolant to the recovery tank should be fuel supply system while the genset is running and
repaired by a qualified service technician as soon as while it is stopped. Check flexible fuel hose sections
possible. Larger leaks are cause for shutting down for cuts, cracks, and abrasions. Make sure the fuel
the genset until it can be repaired. line is not rubbing against other parts. Replace worn
or damaged fuel line parts before leaks occur.
Exhaust System WARNING Diesel fuel leaks can lead to fire. Do
not operate the genset if operation causes fuel
WARNING EXHAUST GAS IS DEADLY! Do not to leak.
operate the genset if there is an exhaust leak or
any danger of exhaust gases entering or being Prime the fuel system if the genset ran out of fuel.
drawn into the vehicle.
Battery Connections
Look and listen for exhaust system leaks while the
genset is running. Shut down the genset if a leak is Check the battery terminals for clean, tight connec-
found and have it repaired before operating the gen- tions. Loose or corroded connections have high
set again. electrical resistance which makes starting harder.
See MAINTAINING THE BATTERY AND BATTERY
Look for openings or holes between the genset CONNECTIONS (Page 3-5).
compartment and vehicle cab or living space if the
genset engine sounds louder than usual. Have all
Mechanical
such openings or holes closed off or sealed to pre- Look for mechanical damage and listen for unusual
vent exhaust gases from entering the vehicle. noises. Check the genset mounting bolts.
Replace dented, bent or severely rusted sections of To prevent overheating and to reduce fouling with
the tailpipe and make sure the tailpipe extends at dust and debris, make sure the genset’s normal
least 1 inch (25.4 mm) beyond the perimeter of the ground clearance is not being reduced by sloping
vehicle. ground, curbs, logs or other objects. Repark the ve-
hicle if necessary and/or remove any objects block-
Check all CO monitors to assure proper operation. ing the air inlet or air outlet.

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

WARNING Crankcase pressure can blow hot

engine oil out the fill opening causing severe
burns. Always stop the genset before removing
the oil fill plug.
1. Pull the plug and dipstick out of the oil fill neck
(Figure 3-1). The plug may be difficult to pull
straight out. It is easier if you tilt the plug in its
socket while pulling out. Wipe off the dipstick
and thread it back into the fill neck and seat the
plug, which snaps into its socket. Remove the
plug and dipstick again and check the oil level FRONT ACCESS
on the dip stick. DOOR ON SOME
MODELS
2. Add or drain oil as necessary. See ENGINE OIL
RECOMMENDATIONS (Page 1-2). Keep the KEEP OIL LEVEL
oil level between the high and low beads on the BETWEEN THESE TWO
end of the dipstick, as shown. It is not neces- BEADS ON DIPSTICK
sary to add oil between oil changes if the oil has
not dropped more than 1/3 of the way between
the high and low beads. A full quart (0.9 liter)
can be added if the oil level is at the lower bead.
CAUTION Too much oil can cause high oil
consumption. Too little oil can cause severe
engine damage. Keep the oil level between
the high and low beads on the dipstick. FIGURE 3-1. OIL FILL NECK AND DIPSTICK

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

socket.

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CHANGING ENGINE OIL AND OIL FILTER
WARNING State and federal agencies have de- OIL DRAIN PLUG OIL FILTER
OR VALVE
termined that contact with used engine oil can
cause cancer or reproductive toxicity. Avoid
skin contact and breathing of vapors. Use rub-
ber gloves and wash exposed skin.

See Table 3-1 for scheduled engine oil change.

Change oil more often in hot and dusty environ-
ments.

1. Run the genset until warm and shut it off.

2. Pull the oil fill plug and dipstick (Page 3-3) out
a couple of inches (50 mm) so that the oil will
drain faster.
3. Depending on the installation, remove the bot-
tom maintenance access cover (Figure 3-2) or
front access door (Figure 3-1) and place a pan
under the oil drain outlet.
4. Open the drain valve or remove the plug and
drain all the oil from the engine.
5. Close the drain valve or secure the plug.
6. Spin off the oil filter canister and clean the filter
mounting surface on the engine block. Remove
the old gasket if it remains.
7. Make sure the gasket is in place on the new fil-
ter and apply a thin film of clean oil to the gas-
ket. Spin the new filter on until the gasket just FIGURE 3-2. OIL DRAIN PLUG AND OIL FILTER
touches the block. Turn it an additional 1/2 to
3/4 turn. Do not over tighten.
8. Refill with 2 quarts (1.9 liters) of oil and check
the level (Page 3-3).
9. Secure the maintenance access cover.
10. Dispose of the used oil and oil filter according
to local environmental regulations.

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 MAINTAINING THE BATTERY AND
BATTERY CONNECTIONS

WARNING Arcing at battery terminals or in

light switches or other equipment, and flames or
sparks, can ignite battery gas causing severe
personal injury—Ventilate battery area before
working on or near battery—Wear safety
glasses—Do not smoke—Switch work light ON
or OFF away from battery—Stop genset and dis- AIR FILTER ELEMENT
connect charger before disconnecting battery
cables—Disconnect negative (-) cable first and
reconnect last.
See Table 3-1 for scheduled maintenance. Follow
the battery manufacturer’s instructions. Have the
battery charging system serviced if DC system volt-
FILTER HOUSING
age is consistently low or high. Always:
1. Keep the battery case and terminals clean and
dry and the terminals tight.
2. Remove battery cables with a battery terminal
puller.
3. Make sure which terminal is positive (+) and
which is negative (- ) before making battery
connections. Always remove the negative (- ) HOUSING SUPPORT FRAME
cable first and reconnecting it last to reduce
arcing.

REPLACING THE AIR FILTER ELEMENT

FIGURE 3-3. AIR FILTER
Refer to Table 3-1 for scheduled air filter element re-
placement. In dusty environments the filter element
should be inspected and changed more frequently.

Depending on the installation, remove the protec-

tive grille below the air filter (Figure 3-3) or the front
access door (Figure 3-1). Then unscrew the two (2)
wingnuts and pull away the housing support frame,
housing and filter element.
Turn the wingnuts hand tight when installing the new
filter element.
Note: The filter housing and its support frame fit only
one way (one corner has been trimmed). Turn the as-
sembly all the way around if it does not fit and try
again.

Replace the bottom protective grille or the access

door.

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 CLEANING THE SPARK ARRESTOR
Refer to Table 3-1 for scheduled cleaning of the
spark arrestor muffler (which meets U.S. Forest
Service requirements). Cleaning is required for
maximum genset performance.
WARNING A hot muffler can cause severe
burns. Let the muffler cool down before remov-
ing or installing the cleanout plug.

The muffler is mounted inside the genset housing.

The spark arrestor cleanout plug is located on the
side of the muffler and is accessible through the bot-
tom (Figure 3-4). Clean out the muffler as follows:

1. Remove the cleanout plug (7/16 inch square

head) from the muffler.
2. Start the genset and load it nearly to full power.
Let the genset run for about five minutes to ex-
pel the soot.
3. Stop the genset, allow the muffler to cool down
and reinstall the cleanout plug.

FIGURE 3-4. SPARK ARRESTOR CLEANOUT PLUG

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 REPLACING THE FUEL FILTER the fuel line. Close any shut off valve in the fuel line.
Wipe dirt off the fuel hose fittings at the filter.
WARNING Diesel fuel is combustible and can
cause severe personal injury or death. Do not To remove the filter, disconnect the two fittings at the
smoke near diesel fuel tanks or equipment. filter. Use two flarenut wrenches on each fitting so
Keep flames, sparks, pilot lights, electrical as not to round the corners or stress the fittings.
switches, arc-producing equipment and all oth- Then remove the filter mounting nut and two (2)
er sources of ignition well away. Keep a type bracket mounting screws. Dispose of the fuel filter
ABC fire extinguisher in the vehicle. according to local regulations.

Close any fuel line shutoff valve before discon- Installing the Fuel Filter: Secure the bracket to the
necting the fuel line from the filter. new filter. The filter and its bracket fit properly only
one way.
See Table 3-1 for scheduled fuel filter replacement.
A dirty fuel filter may be the cause of a failure to start.
Depending on the installation, the fuel filter is acces- Loosely secure the filter and bracket to the base
sible through the bottom maintenance access cover with the two mounting screws and re-connect the
(Figure 3-5) or front access door (Figure 3-1) and fuel fittings. Take care not to crossthread the fuel fit-
inner cover. tings. Thread them in by hand and tighten one flat
past seating. Finally, tighten the bracket and bracket
CAUTION Wipe dirt off the fuel hose fittings at mounting screws and replace the access cover(s).
the fuel filter before disconnecting the hoses so
as to keep dirt out of the fuel system. Prime the fuel system by holding the control switch
down in its Stop position for at least 1 minute after
Removing the Fuel Filter: Take care to spill as little replacing the fuel filter. Priming is necessary to dis-
fuel as possible when disconnecting the filter from place the air in the new filter and fill it with fuel.

FILTER DISCONNECT FUEL FILTER MOUNTING DISCONNECT FUEL

LINE TO ENGINE NUT LINE FROM PUMP

FILTER BRACKET
FILTER BRACKET MOUNTING SCREWS

FIGURE 3-5. FUEL FILTER

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 CHANGING COOLANT
RADIATOR DRAIN COCK
Refer to Table 3-1 for scheduled maintenance. The
engine cooling system is filled with a 50/50 mixture
of ethylene glycol anti-freeze and water when the
genset leaves the factory, which is suitable for tem-
peratures down to -34° F (-37° C).
Recommended Coolant Mixture
Use the best quality ethylene glycol antifreeze solu-
tion available. It should be fully formulated with rust
inhibitors and coolant stabilizers. Use fresh water
that is low in minerals and corrosive chemicals. Dis-
tilled water is best. The cooling system has a
3.1 quart (2.9 L) capacity.
Pressure Cap
Replace the pressure cap (Figure 3-8) every two
years (seals deteriorate and leak). Proper cooling
system pressure (14 psi) is essential for optimal en-
gine cooling and minimal coolant loss.
Draining the Cooling System
WARNING Hot coolant spray can cause severe
burns. Let the engine cool before releasing the
pressure cap or removing the drain cap.
Let the engine cool before removing the pressure
cap. Relieve any remaining pressure by turning the
pressure cap slowly, without pushing down. When
the pressure has been relieved, push down on the
cap, turn it the rest of the way and withdraw it. Then FIGURE 3-7. ENGINE COOLING SYSTEM
open the radiator drain cock which is accessible
through the bottom access cover (Figure 3-6) and
drain the coolant into a suitable container.
WARNING Ethylene glycol antifreeze is con-
sidered toxic. Dispose of it according to local
regulations for hazardous substances.
Clean and flush the cooling system before refilling.
Radiator cleaning chemicals are available at local
auto parts stores. Follow the instructions for clean-
ing and flushing that come with the cleaning solu-
tion.

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Refilling the Cooling System Fill the recovery tank with coolant mixture to the
COLD mark.
Close the radiator drain cock and fill the system with
coolant through the fill opening. Pull the hose con-
nected to the pressure cap assembly out as far as it Coolant Level Check
will go. When the coolant level reaches the fill open-
ing, start and operate the genset for a few minutes Check coolant level in the recovery tank (Fig-
and shut it down. Add more coolant if necessary and ure 3-8) before the first startup of each day and fill to
secure the pressure cap. the COLD mark if necessary.

PRESSURE CAP AND

SYSTEM FILL OPENING

COOLANT RECOVERY
TANK FILL CAP RECOVERY TANK
FLUID LEVEL

FIGURE 3-8. ENGINE COOLING SYSTEM PRESSURE CAP AND RECOVERY TANK

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This page is intended to be blank.

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4. Preparing 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
Hazards and Their Sources • Leaking or spilled fuel
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-
guards and ways of avoiding hazards: • Hot exhaust pipes
Burns
• Hot engine and generator sur-
• Use personal protection: Wear appropriate faces
protective safety equipment, such as safety • Electrical shorts
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 in • Improper generator connec-
equipment or conduct electricity. tions
Electrical • Faulty wiring
• Reduce the hazard: A safe, orderly workshop Shock (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 guards not in place
in good working condition. Store flammable liq- Machinery
uids in approved containers; away from fire, Slippery • Leaking or spilled oil
flame, spark, pilot light, switches, arc-produc- Surfaces
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.

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 REMOVING / INSTALLING GENSET WARNING Gensets are heavy and can cause
severe personal injury if dropped during remov-
See Section 9. Troubleshooting to determine the al. Use adequate lifting devices. Keep hands
probable cause of the problem before removing the and feet clear while lifting.
genset for service. The genset is normally mounted
in a special compartment on the floor of the vehicle Installation in Vehicle
or on a supporting frame. Contact the vehicle
manufacturer or installer if the best way to remove Generally, installation is the reverse of removal and
the genset is not obvious. disconnection. Before installing the genset, repair
any damage to and seal all hoes in the vapor-tight,
Disconnections fire-resistive barrier between the genset and coach
interior. Make sure all mounting screws, and brack-
1. Disconnect the negative (-) battery cable from ets are secure and that all battery, AC output, con-
the battery and then disconnect the battery trol, exhaust and fuel connections are proper and in
cables from the genset. good repair. Perform the service checklist before
placing the genset in service (Section 10. Service
WARNING Sparks and high current could
Checklist).
cause fire and other damage to the battery,
battery cables and vehicle if the loose ends
of cables connected to the battery touch. Use four Grade 5 screws (3/8-16 UNC) to secure
Always disconnect the negative (-) battery the genset to the floor or frame. The screws must
cable from the battery before disconnecting protrude at least 1/2 inch (10 mm) but not more than
the battery cables from the genset. 1 inch (25 mm) into the base, as measured from the
bottom surface of the base. Torque the screws to
2. Disconnect the remote control wiring harness 35 lb-ft (41 N-m).
connector at the genset.
3. Disconnect the AC output leads at the genset
REMOVING / INSTALLING GENSET
terminals. HOUSING PANELS

4. Disconnect the exhaust tailpipe from the muf- WARNING Do not operate the genset without
fler flange. the housing panels secure in place. The panels
5. Disconnect the supply and return fuel lines from guard against rotating parts and bare live elec-
the genset. trical parts that can cause severe personal inju-
ry or death. The housing is also required for
WARNING Diesel fuel is combustible and proper genset cooling.
can cause severe personal injury or death.
Do not smoke if you are near fuel tanks or See Figure 4-1. The housing consists of five remov-
fuel-burning equipment or are in an area able panels. The front (service) panel may also in-
sharing ventilation with such equipment. clude a removable service door secured by latches.
Keep flames, sparks, pilot lights, electrical
arcs and arc-producing equipment and all Note the fan inlet baffles (Figure 4-1). To line up the
other sources of ignition well away. baffle screw holes with the holes in the front panel,
remove the air inlet grille on the bottom side of the
Removal from Vehicle base and reach in by hand to move the baffles into
alignment with the screw holes.
Make sure that the genset is firmly supported before
loosening any mounting bolts. There are four bolt CAUTION Make sure to reinstall the fan inlet
holes in the skid-base for securing the genset to the baffles, which are necessary for proper genset
floor or supporting frame. The two lifting eyes are cooling.
accessible through the access opening in the top
panel of the genset. Lift the genset with both lifting When reassembling, torque the panel screws to
eyes when using a hoist. 8 lb-ft (11 N-m).

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ACCESS COVER FOR CONTROLLER
A1 AND GENERATOR BRUSHES

FAN INLET
BAFFLES

GENSETS WITHOUT FRONT

SERVICE ACCESS DOOR

GENSETS WITH FRONT

SERVICE ACCESS DOOR

FIGURE 4-1. THE GENSET HOUSING PANELS AND THEIR MOUNTING SCREWS

Redistribution or publication of this document,

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This page is intended to be blank.

Redistribution or publication of this document,

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5. Control System
OVERVIEW functions required to operate the genset. All con-
nections to the controller are through connector J1.
Controller A1 is an integrated microcontroller-
Refer to the wiring diagram (Page A-1) and wiring
based engine and generator control (Figure 5-1). It
harness drawing (Page A-3).
provides all the control, monitoring and diagnostic

INTAKE
RESONATOR

CONTROLLER A1

GLOW PLUG
RELAY K3

3−PH VOLTAGE SENSE

TRANSFORMER T15

CONNECTOR J1

FIGURE 5-1. CONTROLLER A1

Redistribution or publication of this document,

5-1 by any means, is strictly prohibited.
 CONTROLLER A1 Stop: Touch the control switch to STOP (Prime).
The controller:
Major Functions
1. Disables output voltage.
Figure 5-2 is a block diagram of controller functions.
2. Deenergizes the fuel lift pump and governor ac-
Initialization: Control initialization consists of tuator.
checking memory (RAM, ROM, EEPROM) and
genset configuration. 3. Turns off the status lamp.

Fuel Prime: Press and hold the control switch at 4. Writes session data (number of cranks, min-
STOP (Prime) for more than 3 seconds to cause utes of operation, last fault, etc.) to non-volatile
fuel pump E5 to prime the fuel system. memory (NVM).

5. Removes processor power when idle 5 min-

Startup: Press and hold the control switch at
utes.
START (Preheat) until the genset starts. The con-
troller: Note: Stop takes precedence over Start if both pres-
1. Energizes fuel lift pump E5. ent due to a faulty switch or other cause.

2. Energizes the glow plugs (two) during pre-heat

and cranking. The duration of pre-heat prior to Voltage Control: The controller maintains nominal
cranking is engine temperature dependent, but AC output voltage during steady state operation by
does not exceed 15 seconds. varying field current as load varies. In response to
transient loads it lowers the voltage setpoint to allow
3. Enables the status lamp to blink rapidly. engine recovery. Field power is supplied by the
4. Enables some fault detection. quadrature windings (Q1-Q2).
5. Enables cranking. The maximum allowed dura-
tion of cranking is engine temperature depen- Fuel Control: The controller maintains nominal fre-
dent and varies between 20 and 30 seconds. quency as load varies by modulating the pulse width
6. Enables field flash (F1-F2). of the current energizing governor actuator A12,
which moves the fuel rack.
7. Energizes governor actuator A12 (full rack).
8. Disconnects the starter (B1) at 800 rpm. Voltage Adjustments: See ADJUSTING VOLT-
9. When operating speed is reached: AGE (Page 6-5).
A. Enables output voltage.
B. Turns off field flash. Frequency Adjustments: See ADJUSTING FRE-
QUENCY (Page 6-5).
C. Turns on status lamp.
D. Enables Switched B+ (J1-8). Fault Monitoring, Shutdown and Diagnostics:
E. Enables complete fault detection. See Section 9. Troubleshooting.

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 COOLANT TEMPERATURE SENDER
LOCAL
CONTROL

OIL PRESSURE SWITCH

FUEL LIFT PUMP

ENGINE

REMOTE STARTER
CONTROL

GLOW PLUGS

CONTROLLER

GOVERNOR ACTUATOR

RS-232
(FACTORY ONLY)

QUADRATURE

FIELD

GENERATOR
AC SENSE

BATTERY
BATTERY CHARGING

AC OUTPUT

FIGURE 5-2. CONTROLLER A1 BLOCK DIAGRAM

Redistribution or publication of this document,

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Controller A1 Removal / Replacement

WARNING Accidental or remote starting can

cause severe personal injury or death. Before
removing a panel or access door, disconnect
the negative (-) cable at the battery to prevent
the engine from starting.

The controller is mounted on the intake resonator

and is accessible through the access panel on the
left end of the enclosure. Use a small flat-bladed
screwdriver to lever out the catch on connector FIGURE 5-3. DISCONNECTING P1 / J1
P1/J1 and pull the connector apart (Figure 5-3).
CONTROL
CONTROL SWITCH S1 SWITCH S1
HOUR
The switch is mounted on the control panel (Fig- METER
ure 5-4). Unsnap connector P9, which is accessible M1
through the access panel on the left end of the en-
closure, from the back of the switch for access to its
terminals. Replace the switch if it does not close
across terminals 2 and 3 when the switch is held in
the Start position or close across terminals 1 and 2
when held in the Stop position, or the status indica- LINE CIRCUIT
tor light does light when 12 VDC is connected BREAKERS
across terminals 7 (- ) and 8 (+). See Figure 5-5. CB1, CB2, CB3

LINE CIRCUIT BREAKERS CB1, CB2, CB3

The line circuit breakers are mounted on the control

panel and are accessible through the access panel
on the left end of the enclosure (Figure 5-4). Discon-
nect all wiring and check electrical resistance
across the terminals of each circuit breaker. Re-
place a circuit breaker that does not reset or that
does not close or open as the handle is turned ON
and OFF.

HOUR METER M1 FIGURE 5-4. CONTROL SWITCH, LINE CIRCUIT

BREAKERS, HOUR METER
The hour meter (when the genset is so equipped) is
mounted on the control panel and is accessible
through the access panel on the left end of the en-
closure (Figure 5-4).

GLOW PLUG RELAY K3

The glow plug relay is mounted in its wiring socket

on the intake resonator (Figure 5-1). Pull the relay
out to test it. Apply 12 VDC across terminals 85-86.
Replace the relay if the contacts across terminals
30-87 (NO) do not open and close. FIGURE 5-5. CONTROL SWITCH S1

Redistribution or publication of this document,

5-4 by any means, is strictly prohibited.
 3-PHASE VOLTAGE SENSE
TRANSFORMER T15
Mounting: The voltage sense transformer for (P1-34)
3-phase generators is mounted on the intake reso-
nator (Figure 5-1). It is connected as shown on
Page A-2 to sense output voltage in L1.

Testing: Replace the transformer if resistance in ei-

ther winding is not as specified in the schematic (P1-33)
(Figure 5-6).

BATTERY CHARGE REGULATOR AVR1

Mounting: The regulator and heat sink are
mounted as shown on the engine-generator adap- FIGURE 5-6. 3-PHASE VOLTAGE SENSE
tor and are accessible when the top or back panel is TRANSFORMER T15
removed (Figure 5-7).

Testing: See Page 6-4 to test battery charge wind-

ing B1-B2. To test the regulator, remove the lead
from terminal B+. If B1-B2 output is 15 to 20 VAC,
but regulator output is less than 12.8 VDC, replace
regulator VR.

DC CONTROL FUSE F1
AVR1
This is a 30 amp mini-bayonet fuse in the wiring har-
ness near the starter solenoid (Page A-3). It is ac-
cessible from below through the access panel in the
HEAT
base. SINK

OIL PRESSURE SWITCH S2

See Page 8-5.

COOLANT TEMPERATURE SENDER E4

See Page 8-5.

FUEL PUMP E2
See Page 8-8.

STARTER MOTOR B1
See Page 8-11.

FIGURE 5-7. BATTERY CHARGE REGULATOR

AVR1

Redistribution or publication of this document,

5-5 by any means, is strictly prohibited.
This page is intended to be blank.

Redistribution or publication of this document,

5-6 by any means, is strictly prohibited.
6. Generator
OVERVIEW the rotor windings through the brush block assem-
bly. The rotor shaft is supported on both ends by
These are belt-driven, 2-bearing, 2-pole (3600 sealed ball bearings. The drive belt pulley and fans
rpm), revolving-field generators with brushes and are center-bolted to the tapered rotor ends.
slip rings (Figure 6-1). Output voltage is regulated
by microcontroller-based genset controller A1 Brush Block: Field current passes through the
(Page 5-1). brush block which has two spring-loaded carbon
brushes that make contact with the rotor slip rings.
Stator: The stator consists of steel laminations with
two or three sets of windings in the lamination slots.
The main windings (T1-T2, etc.) are for powering Principle of Operation: During startup genset con-
the connected loads. The quadrature windings troller A1 flashes the field with battery current for
(Q1-Q2) are for field excitation. Some models have fast buildup of generator voltage as the engine ac-
battery charge windings (B1-B2). celerates to operating speed. During operation the
controller maintains nominal AC output voltage by
Rotor: The rotor consists of a shaft with steel lami- varying field current in response to load. In re-
nations wrapped with field windings. A molded slip sponse to transient loads it lowers the voltage set-
ring assembly is pressed on to supply field current to point to allow for engine recovery.

END BELL SUPPORT

BRACKET

BRUSH BLOCK
ASSEMBLY

SLIP RINGS
RADIATOR
FAN
STATOR
GENERATOR
O−RING FAN

THROUGH
BOLTS (4)

END BELL

O−RING

ROTOR

WAVE WASHER

ENGINE−GENERATOR
ADAPTER

FIGURE 6-1. GENERATOR

Redistribution or publication of this document,

6-1 by any means, is strictly prohibited.
 SERVICING THE GENERATOR Stator Reassembly

WARNING Accidental or remote starting can Reassembly is the reverse of removal. Note the fol-
cause severe personal injury or death. Before lowing:
removing a panel or access door, disconnect 1. Loosen the end bell support bracket bolts, if not
the negative (-) cable at the battery to prevent already removed, so that the bracket does not
the engine from starting. interfere with proper stator and end bell align-
ment.
Stator Removal 2. Align the stator and end bell with the line
1. Disconnect the generator leads inside the AC scribed on them during disassembly.
outlet box and remove all enclosure panels. 3. Relubricate the bearing bore in the end bell with
molybdenum disulfide paste (Onan
2. Remove the brush block (Figure 6-1). PN 524-0118 or equivalent).
CAUTION The brushes can be damaged if 4. Make sure the O-ring is in place in the bearing
the brush block is not removed before re- bore.
moving the end bell.
5. Torque the stator through bolts and end bell
3. Remove the fan hub bolt and fan. (To keep the bracket bolts to 8 lb-ft (11 N-m) and the fan hub
rotor from turning while loosening the fan bolt, bolt to 45 lb-ft (61 N-m). (To keep the rotor from
hold the pulley bolt with a wrench.) To pull the turning while tightening the fan bolt, hold the
fan off the shaft taper, secure a three-point pulley bolt with a wrench.)
wheel puller to the three holes in the fan hub
with M6 or 1/4 inch self-tapping screws. Rotor
4. Remove the end bell support bracket from the To remove the rotor, remove the stator and then the
engine bracket and the end bell (4 bolts). drive pulley (Page 7-2) and pull the rotor straight out
5. Scribe a line across the adapter, stator lamina- to the front. Catch the wave washer so that it can be
tions and end bell to make realignment easier reused. When reassembling, lubricate the bearing
during reassembly. bores in the end bell and adapter with molybdenum
disulfide paste (Onan PN 524-0118 or equivalent).
6. Block the stator so that it does not fall against Make sure the wave washer is in place in the en-
the rotor, and then remove the four generator gine-generator adaptor and that the O-rings are in
through bolts. place in the bearing bore groves in both ends.
7. Pull the generator end bell straight out. Ex- Use an adhesive when installing new bearings on
amine the bearing bore and replace the end bell the rotor shaft. Apply the adhesive to the shaft
if it is scored or otherwise damaged by the bear- (Locktite 680 or equivalent) and primer (activator) to
ing. the bearing (Locktite 747 or equivalent). Press each
8. Pull the stator assembly straight out, taking bearing on up to its shaft shoulder using a bench
care not to damage rotor or stator windings. press.

9. Block the rotor to support its hanging weight to CAUTION Apply force only to the bearing in-
prevent damage to the adapter and bearing. ner race to avoid damage to the bearing.

Redistribution or publication of this document,

6-2 by any means, is strictly prohibited.
 SERVICING BRUSHES AND SLIP RINGS
WARNING Accidental or remote starting can
cause severe personal injury or death. Before
removing a panel or access door, disconnect
the negative (-) cable at the battery to prevent
the engine from starting.
Brush Block
Access: Remove the access panel on the left end
of the enclosure for access to the brush block.
Service: Disconnect the field leads from the brush
block (Figure 6-2), remove the mounting screw and F−
withdraw the brush block from the generator end F+
bell. Replace the brush block assembly if either
brush is shorter than 7/16 inch (11 mm), binds in the
brush block or is damaged in any way. FIGURE 6-2. BRUSH BLOCK
Reconnect the field leads, F- (black) to the outside
terminal, and F+ (red) to the inside terminal.
Slip Rings
Remove the brush block and inspect the slip rings
for grooves, pits, or other damage. Use a Scotch
Brite pad or commutator stone to remove light wear
or corrosion.
TESTING FIELD FLASH
Field flash can be tested by measuring output volt-
age while cranking with the governor actuator leads
(Page 8-2) disconnected to keep the engine from
starting. If output voltage increases at least 1 volt
while cranking, the whole field excitation system—
controller, brushes, slip rings and rotor—are prob-
ably in working order and the problem lies else-
where. See Section 9. Troubleshooting.

Redistribution or publication of this document,

6-3 by any means, is strictly prohibited.
 TESTING GENERATOR WINDINGS TABLE 6-2. STATOR WINDING RESISTANCES
RESISTANCE (OHMS)
Testing the Rotor WINDING
@ 77° F (25° C) ± 10%
Field Resistance Test: Remove the access panel 120/240 VAC, 60 Hz
on the left end of the enclosure for access to the T1-T2, T3-4 0.612
brush block and connector P1 (controller A1). Dis- Q1-Q2 2.42
connect field leads F1 and F2 from controller A1 by
B1-B2 0.124
pulling connector P1 and measure resistance
120 VAC, 60 Hz
across pins 1 and 14. If resistance is not as speci-
fied in Table 6-1: T1-T2, T3-4 0.153
1. Check for and repair faulty field leads. Q1-Q2 2.42
B1-B2 0.124
2. Service brush block and slip rings (Page 6-3).
230 VAC, 50 Hz
3. Check rotor resistance across the slip rings.
Replace the rotor if resistance is not as speci- T1-T2, T3-4 0.692
fied. Q1-Q2 2.89
B1-B2 0.112
Ground Test: Using a megger or the highest scale
3-Ph, 400 VAC, 50 Hz
on a digital ohmmeter, measure resistance between
the rotor and either slip ring. Replace the rotor if its T1-T2, T1-T3, T2-T3 0.35
winding has less than one megohm resistance to Q1-Q2 3.28
ground. B1-B2 0.418
TABLE 6-1. ROTOR WINDING RESISTANCE 3-Ph, 240 VAC, 60 Hz
RESISTANCE (OHMS) @ 77° F (25° C) ± 10% T1-T2, T1-T3, T2-T3 0.97
31.97 Q1-Q2 2.73
B1-B2 0.303
Testing the Stator
Disconnect T1, T2, T3 and T4 from the terminals in
the output box. Disconnect B1 and B2 from charging
regulator AVR1. Disconnect Q1 and Q2 from con-
troller A1 by pulling connector P1 (Pins 3 and 13).
Open Winding Test: Measure resistance across
each winding lead pair (Table 6-2). Replace the sta-
tor if any winding is open (zero ohms).
Winding Resistance Test: Use a meter (Wheat-
stone Bridge) having 0.001 ohm precision to mea-
sure resistance across each winding lead pair
(Table 6-2). Replace the stator if resistance in any
winding is not as specified.
Ground Test: Using a megger or the highest scale
on a digital ohmmeter, measure resistance between
the stack and each stator lead. Replace the stator if
any winding has less than one megohm resistance
to ground.

Redistribution or publication of this document,

6-4 by any means, is strictly prohibited.
 RECONNECTING THE GENERATOR To adjust voltage:
Reconnect the generator properly for the applica- 1. Disconnect all generator loads and connect ac-
tion. See Page A-2. curate meters to measure AC volts and fre-
quency.
ADJUSTING FREQUENCY
WARNING HAZARDOUS VOLTAGE!
If it is necessary to change the output frequency for Touching uninsulated live parts inside the
the application, remove the access cover on the left genset or connected equipment can result
end of the genset. Find the leads marked J8 HZ, in severe personal injury or death. For your
60 HZ and 50 HZ in the wiring harness (Page A-3). protection, stand on a dry wooden platform
Connect 60 HZ or 50 HZ to J8 HZ, as appropriate, or rubber insulating mat, make sure your
and secure the access cover (4 screws). clothing and shoes are dry, remove jewelry
from your hands and use tools with insu-
ADJUSTING VOLTAGE lated handles.
Output voltage may need to be readjusted for the
2. Start the genset and let voltage and frequency
application, especially if it was necessary to change
stabilize for 5 to 10 seconds.
the frequency and/or reconnect the generator
(Page A-2). Recheck generator reconnections and 3. Rapidly press the control switch to START
reconsider whether frequency needs to be changed 6 times within 10 seconds.
before attempting voltage adjustments.
Voltage is adjusted by means of the control switch. 4. To adjust voltage up, press the control switch
Rapidly pressing the switch to START 6 times dur- to START and release quickly. Each time the
ing the first minute after startup puts the genset con- switch is released, voltage will rise approxi-
troller into voltage set mode. The amber status indi- mately 0.6 volt.
cator lamp will begin blinking once every second to
5. To adjust voltage down, press the control
confirm voltage set mode. The green status indica-
switch to START and release in 1 second.
tor lamp will remain on. The controller resumes nor-
Each time the switch is released, voltage will
mal operating mode 20 seconds after the last ad-
drop approximately 0.6 volt.
justment.
Note: If a fault shutdown occurs or the control switch 6. Normal operation will resume in 20 seconds af-
is pressed to STOP during voltage set mode, voltage ter the last adjustment. The last adjustment will
adjustments will not be stored in controller memory. be retained by the controller.

Redistribution or publication of this document,

6-5 by any means, is strictly prohibited.
This page is intended to be blank.

Redistribution or publication of this document,

6-6 by any means, is strictly prohibited.
7. Drive System
OVERVIEW ible coupling. The generator pulley is center-bolted
to the tapered end of the rotor shaft. The pulley must
The engine drives the generator by means of a 6-rib
be removed to remove the generator rotor from the
“Poly-Vee” belt (Figure 7-1). The drive pulley is
engine-generator adapter.
mounted on the engine flywheel by means of a flex-

ENGINE
CRANKSHAFT

ENGINE−GENERATOR
ADAPTER

ENGINE FLYWHEEL

FLEXIBLE COUPLING
AND HUB

DRIVE
PULLEY
GENERATOR
ROTOR

BELT TENSIONER
ASSEMBLY

GENERATOR
PULLEY

DRIVE BELT

FIGURE 7-1. GENERATOR DRIVE

Redistribution or publication of this document,

7-1 by any means, is strictly prohibited.
 INSPECTING DRIVE AND BEARINGS generator shaft taper. (To keep the rotor from turn-
ing while loosening the pulley bolt, hold the fan bolt
WARNING Accidental or remote starting can with a wrench.) Torque the center bolt to 45 lb-ft
cause severe personal injury or death. Before (60 N-m) when reassembling.
removing a panel or access door, disconnect
the negative (-) cable at the battery to prevent Tensioner Pulley Assembly
the engine from starting.
Spin the idler pulley. Replace the bearing if it does
Remove the back panel (Page 4-1) to inspect the not spin smoothly or is noisy. Replace the idler as-
drive and bearings: sembly if it does not pivot smoothly from one end of
1. Pivot the belt tensioner away from the belt with its travel to the other. Torque the center pivot bolt
a 3/8 inch drive and remove the belt. Examine 45 lb-ft (60 N-m).
the belt for cracks, worn spots and other signs
of deterioration. Replace the belt if necessary Drive Pulley and Coupling
or if it has been in service 5 years or 2000
hours. Remove the drive pulley and coupling as an assem-
2. Remove the drive pulley and coupling as an as- bly from the flywheel. Then, if necessary, remove
sembly from the flywheel and then the pulley the 4 coupling nuts on each end to disassemble the
from the coupling. Examine the coupling for coupling from the hub and the pulley. Examine the
wear and deterioration and replace it if neces- coupling for wear and deterioration and replace it if
sary. Examine the two split-sleeve bearings in necessary. Examine the two split-sleeve bearings in
the pulley hub for wear and scoring and replace the pulley hub for wear and scoring and replace
them if necessary. them if necessary.

When reassembling, torque the coupling nuts Torque the coupling nuts to 8 lb-ft (12 N-m) and the
to 8 lb-ft (12 N-m) and the 4 hub-to-flywheel 4 hub-to-flywheel bolts to 21 lb-ft (29 N-m).
bolts to 21 lb-ft (29 N-m).
3. Spin the idler pulley. Replace the bearing if it Flywheel
does not spin smoothly or is noisy. Replace the
idler assembly if it does not pivot smoothly from Remove the drive pulley and coupling as an assem-
one end of its travel to the other. bly for access to the flywheel mounting bolts. Scribe
a line across crankshaft and flywheel to make re-
4. Spin the generator pulley by hand to determine
alignment easier when reassembling. The flywheel
if there is any noise, looseness or grinding.
will only go on one way because the bolts are
Check for side-to-side and up-and-down loose-
not quite evenly spaced. Proper alignment is
ness of the bearing. If necessary, disassemble
necessary to preserve engine balance and tim-
the generator (Page 6-2) to determine the
ing mark.
cause of the looseness or noise. Replace the
rotor assembly if it is evident that either bearing
Torque the 5 mounting bolts to 42 lb-ft (56 N-m)
has spun on the shaft. Replace the end bell or
when remounting the flywheel.
adapter if it is evident that the bearing has spun
in the bore. Replace the bearings if they have
been in service 5 years or 2000 hours.
Engine-Generator Adapter

SERVICE To remove the adapter, first remove the engine-gen-

erator assembly from its mounting on the three
Generator Pulley vibration isolators, the generator (Page 6-2) from
the adapter and the flywheel from the engine.
Remove the belt and pulley center bolt and use a Torque the 6 mounting bolts to 21 lb-ft (29 N-m)
claw-type wheel puller to break the pulley free of the when reassembling.

Redistribution or publication of this document,

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8. Engine

MAJOR ENGINE SERVICE

LINE UP THESE MARKS
WARNING Accidental or remote starting can WHEN SETTING FUEL
cause severe personal injury or death. Before INJECTION TIMING
removing a panel or access door, disconnect
the negative (-) cable at the battery to prevent
the engine from starting.

Refer to engine Workshop Manual 981-0536 for

major engine service, setting fuel injection timing,
replacing glow plugs, cleaning the crankcase
breather assembly and replacing the coolant pump.
Note: To preserve the high-idle speed setting, do not
disturb the lock wires on the governor adjusting
screws (Page 8-4) when removing the actuator base
for engine service.

FUEL INJECTION TIMING MARKS

Remove the back panel for access. Note that the

timing marks (Figure 8-1) line up at 19° BTDC.

ADJUSTING VALVE LASH FIGURE 8-1. FUEL INJECTION TIMING MARKS

Remove the top panel for access. Do not use the
fuel injection timing marks (Figure 8-1) when adjust-
ing valve lash. That could lead to misadjustments.

Adjust valve lash when both valves are closed at

TDC for the power stroke (every other revolution).
To locate this position for either cylinder, rotate the
engine clockwise (looking from the front) until the in-
take valve push rod (Figure 8-2) just stops moving
down (valve closed). Then turn the engine half a
turn more and set lash for both valves (intake and
exhaust) at 0.0059-0.0073 inch (0.145-0.185 mm).
Repeat this procedure for the other cylinder.

GLOW PLUGS

Refer to engine Workshop Manual 981-0536 when

replacing the glow plugs).
PUSH ROD, PUSH ROD,
Note: If a glow plug does not come out after un- CYL #1 INTAKE CYL #2 INTAKE
screwing it, or the end has broken off, it will be VALVE VALVE
necessary to remove the engine head. Glow
plugs can swell if preheat voltage is greater than
14 volts, such as when a battery booster is used
for starting. FIGURE 8-2. ROCKER ARMS AND PUSH RODS

Redistribution or publication of this document,

8-1 by any means, is strictly prohibited.
 GOVERNOR ACTUATOR Stator: Remove the front and top panels for access.
To remove the stator, disconnect the 2 actua-
The position of the rotor in governor actuator A12 tor leads and remove the cover and 4 stator screws.
(Figure 8-3) is determined by the modulated pulse Pry out the leg of the return spring with a screwdriv-
width of the current supplied by controller A1. er. (Be prepared to catch the spring if it flies off.) Lift
off the bearing carrier and stator.
Assembly / Disassembly
WARNING The spring can fly off and cause se-
WARNING Accidental or remote starting can vere eye injury. Wear safety glasses.
cause severe personal injury or death. Before
removing a panel or access door, disconnect Stator reassembly is the reverse of disassembly.
the negative (-) cable at the battery to prevent The bearing carrier must seat squarely in the stator.
the engine from starting. Torque the stator screws to 24 lb-in (2.7 N-m).

SPRING, SHAFT, BEARING ASSEMBLY SNAP-ON COVER

SPRING LEG
MUST CATCH
UNDERNEATH

FUEL RACK
RETURN SPRING
ROTOR
RETAINER
RING

ROTOR

BEARING
SHAFT CARRIER

TERMINALS

BASE STATOR

FIGURE 8-3. GOVERNOR ACTUATOR

Redistribution or publication of this document,

8-2 by any means, is strictly prohibited.
Replace the return spring if it is worn. This spring re-
turns the fuel rack to the no-fuel position. Push the
spring on over the flat on the shaft and pry the leg
into its slot (Figure 8-3). The leg below the knee
must catch underneath and the spring must be
pushed down as far as it will go.
CAUTION The genset may not stop reliably if
the fuel rack return spring is not assembled
properly.
Use wire ties to secure the cover.
Rotor: The rotor can be pried off the shaft after the
bearing carrier has been removed.
Use a new retainer ring when reassembling. Note
that the ring is concave (dished). Push the dished
side up against the rotor to keep it in place on the ACTUATOR SPEED
CONTROL LEVER
shaft. STOP SCREW
Base: See engine Workshop Manual 981-0536 if it
FIGURE 8-4. SPEED CONTROL LEVER STOP
is necessary to remove the actuator base or replace
internal engine governor parts. The stator must be
removed for access to the screws that secure the
base to the engine.
Note: To preserve the existing high-idle speed ad-
justment, do not disturb the lock wires on the adjust-
ing screws on the governor actuator base
(Page 8-4) when removing it from the engine for en-
gine service.
Adjusting Speed Control Lever Stop
The actuator speed control lever stop (Figure 8-4)
must be adjusted whenever a different actuator
base assembly is installed. The stop screw, rather
than the fuel rack control lever, must stop the speed
control linkage when the fuel rack is driven to the no-
fuel position.
Note: To adjust the stop, the rotor need not be on the
shaft, but the end of the shaft must be supported by
the bearing carrier.
1. Remove the front and top panels for access to
the adjusting screw.
2. Loosen the stop screw locknut and back the
screw out a few turns. (Top one in the group of
three.)
3. Turn the stop screw in until it just makes contact
and set the locknut.

Redistribution or publication of this document,

8-3 by any means, is strictly prohibited.
Adjusting High-Idle Speed
WARNING This adjustment involves operating
the genset with enclosure panels removed that
guard against moving parts that can cause se-
vere personal injury or death. Keep your hands
away from the engine belt and pulleys.
High-idle speed (Figure 8-5) must be checked each
time an actuator base is reinstalled or replaced.
For an initial adjustment when installing a new base,
(to make sure the engine stops when the actuator is
deenergized), turn the high-idle speed adjusting
screw in until the head of the screw is 3/4 inch
(19 mm) from the base (Figure 8-5).
Note: Be prepared, if necessary, to clamp off the sup- CLAMPING
ply and the return fuel lines to stop the engine. SCREW
1. Adjust the speed control lever stop (Page 8-4).
2. For this test, measure engine speed with a SPEED
strobe or injector clamp-on type tachometer. ADJUSTING
SCREW
3. Remove the front and top panels for access to
the speed adjusting screw.
4. Disconnect the actuator leads and connect a
12 volt battery to the actuator terminals using a
battery switch. (The battery will hold the gover-
nor mechanism against the high speed stop
and allow the engine to run after shutdown—
probably Code No. 15.)
CAUTION The actuator could overheat if
the battery is left on more than 10 minutes.
5. When ready, switch the battery on, start the
genset, measure engine speed (rpm) and stop
the engine by switching off the battery. 3/4 inch
19 mm
6. Readjust high-idle speed, as follows, if not be-
tween 3300 and 3400 rpm:
A. Loosen the lock nuts on the two bottom FIGURE 8-5. HIGH-IDLE SPEED SCREW
screws and back out the clamping screw.
B. To increase speed, turn the speed adjust-
ing screw in 1 turn (clockwise). To de-
crease speed, turn it out 1 turn (counter-
clockwise).
7. Repeat Steps 5 and 6 until high-idle speed is
between 3300 and 3400 rpm. Set the lock nut.
8. Run the clamping screw in by hand until snug,
back it out 1-1/2 turns and set the lock nut.

Redistribution or publication of this document,

8-4 by any means, is strictly prohibited.
 COOLANT TEMPERATURE SENDER E4 LOW OIL PRESSURE SWITCH S2

Remove the top or back panel for access to the Remove the top or back panel for access to the
sender (Figure 8-6). Use thread sealant and en- switch (Figure 8-6). Use thread sealant and engage
gage at least two threads when reassembling. at least two threads when reassembling.

WARNING Accidental or remote starting can

WARNING Accidental or remote starting can cause severe personal injury or death. Before
cause severe personal injury or death. Before removing a panel or access door, disconnect
removing a panel or access door, disconnect the negative (-) cable at the battery to prevent
the negative (-) cable at the battery to prevent the engine from starting.
the engine from starting.
Replace the sender if it is not open when the engine
Replace the sender if resistance is not approximate- is not running (zero pressure). Replace it if it does
ly 800 ohms at room temperature or does not de- not close when the engine is running and known to
crease rapidly when immersed in boiling water. have normal oil pressure.

COOLANT
TEMPERATURE
SENDER E4

LOW OIL
PRESSURE
SWITCH S2

FIGURE 8-6. ENGINE SENSORS

Redistribution or publication of this document,

8-5 by any means, is strictly prohibited.
 AIR INTAKE SYSTEM Figure 8-7 illustrates the air intake system. Remove
the top and front panels for access. Apply soap solu-
WARNING Accidental or remote starting can
tion to the rubber sleeve on the engine intake man-
cause severe personal injury or death. Before ifold so that the collar of the resonator will slide on
removing a panel or access door, disconnect easily.
the negative (-) cable at the battery to prevent
the engine from starting.

RUBBER SLEEVE FOR ENGINE INTAKE

COLLAR—APPLY SOAP SOLUTION TO
OUTSIDE SO THAT RESONATOR WILL
SLIDE ON EASILY

RESONATOR

AIR FILTER
ASSEMBLY

FIGURE 8-7. AIR INTAKE SYSTEM

Redistribution or publication of this document,

8-6 by any means, is strictly prohibited.
 MUFFLER Figure 8-8 illustrates the muffler assembly. Remove
the top and right end panels for access.
WARNING Accidental or remote starting can
cause severe personal injury or death. Before
removing a panel or access door, disconnect Use new flange gaskets when reassembling.
the negative (-) cable at the battery to prevent Torque all flange nuts to 21 lb-ft (29 N-m). Torque
the engine from starting. the isolator mount nuts to 8 lb-ft (11 N-m).

FLANGE FLEXIBLE
GASKETS EXHAUST
TUBE

MUFFLER ISOLATOR
ASSEMBLY MOUNTS

FIGURE 8-8. MUFFLER SYSTEM

Redistribution or publication of this document,

8-7 by any means, is strictly prohibited.
 FUEL SYSTEM Fuel Lift Pump

Figure 8-9 illustrates the fuel system as assembled Remove the right side panel for access.
for delivering fuel to and from the fuel injection sys-
WARNING Accidental or remote starting can
tem. See the engine Workshop Manual (981-0536)
for fuel injection system service. cause severe personal injury or death. Before
removing a panel or access door, disconnect
the negative (-) cable at the battery to prevent
WARNING Diesel fuel is combustible and can
the engine from starting.
cause severe personal injury or death. Do not
smoke near fuel tanks or fuel-burning equip- Fuel Filter
ment or in areas sharing ventilation with such
equipment. Keep flames, sparks, pilot flames, See REPLACING THE FUEL FILTER (Page 3-7)
electrical arcs and switches and all other
sources of ignition well away. Keep a multi- Internal Fuel Hoses
class ABC fire extinguisher handy.
When replacing the internal fuel hoses (Figure 8-9)
Fuel Delivery Test: make sure they are reclamped and tied as illus-
trated and will not rub on or be pinched by adjacent
1. Disconnect the fuel return hose from the line to components.
the supply tank and point the end into a quart
(1 liter) container or larger. Thread Sealant and Fuel Line Fittings
2. Prime the genset by pushing the Start/Stop The fuel line between the fuel pump and the fuel fil-
switch to STOP (Prime) and holding it there for ter has flare fittings (Figure 8-9). Always use two
exactly 1 (one) minute. Flow should not be less flare nut wrenches when loosening or tightening a
than 0.4 pints (200 ml) per minute. flare fitting. Do not use any type of thread sealant
3. If flow is less than specified:
on a flare fitting.

A. Replace the fuel filter (Page 3-7). The connections for fuel supply and return that ex-
tend through the side of the drip pan are pipe thread
B. Look for other restrictions in the fuel supply fittings. For these fittings use liquid-type pipe thread
system and repair any restrictions to fuel sealant Listed as suitable for diesel fuel. Apply the
flow. sealant sparingly to the male threads only.
C. Look for air bubbles or long gaps when fuel
is not being delivered. This would indicate
CAUTION Excess liquid-type pipe thread seal-
loose fuel fittings or a cracked fuel filter
ant or pieces of Teflon-type pipe thread sealant
body. Repair as necessary.
can plug the engine fuel system. Apply liquid-
type pipe thread sealant sparingly to the male
D. Replace the fuel pump. threads only. Do not use Teflon tape.

Redistribution or publication of this document,

8-8 by any means, is strictly prohibited.
 FUEL FUEL LIFT
FILTER PUMP

FUEL HOSE
CLAMP AND
TIES

FIGURE 8-9. FUEL SYSTEM

Redistribution or publication of this document,

8-9 by any means, is strictly prohibited.
 COOLING SYSTEM WARNING Accidental or remote starting can
cause severe personal injury or death. Before
The genset has a liquid cooled engine. The centrifu- removing a panel or access door, disconnect
gal blower on the end of the generator pulls cooling the negative (-) cable at the battery to prevent
air in through the air inlet in the bottom of the genset the engine from starting.
and pressurizes the enclosure, which is baffled to
force all of the air out through the radiator (Fig-
When reassembling the cooling system:
ure 8-10).
• Make sure the system fill hose is in front of the
See CHANGING COOLANT (Page 3-8) regarding lifting eye so that it can be pulled out far enough
maintenance of the cooling system. See the engine to fill the system.
Workshop Manual (981-0536) regarding coolant
pump and thermostat service. See COOLANT • The vent line is tied to run along the top of the
PUMP BELT (Page 8-11) regarding belt service. air intake hose (Page 8-6) to keep it from sag-
ging and trapping air.
Remove the front and top panels for access to the
radiator, which is mounted by three (3) screws on • The fill hose is tied to the top of the engine
each side to the adjoining panels. bracket.

NOTE: RECOVERY
TANK HOSE MUST BE VENT LINE
CLOSEST TO PRES-
SURE CAP

SYSTEM FILL
HOSE

MAKE SURE HOSE

IS ON THIS SIDE OF
LIFTING BRACKET
TIE FILL HOSE
HERE TO TOP OF
ENGINE BRACKET
PRESSURE
CAP

RADIATOR

COOLANT RECOVERY
TANK HOSE CLAMP LOWER HOSE

FIGURE 8-10. COOLING SYSTEM

Redistribution or publication of this document,

8-10 by any means, is strictly prohibited.
 COOLANT PUMP BELT
WARNING Accidental or remote starting can
cause severe personal injury or death. Before
removing a panel or access door, disconnect
the negative (-) cable at the battery to prevent
the engine from starting.

Since there is no means to adjust belt tension, it is

critical that the correct replacement belt be used.
(Figure 8-11). (Belt tension increases slightly as the
engine runs and is sufficient for the relatively light
pump load.)

CAUTION Using the wrong coolant pump

drive belt can lead to engine overheating.

Remove the top panel for access when replacing

the coolant pump belt. Start the new belt in the grove
of the top pulley and as far a possible (by hand) in
the grove of the bottom pulley. Continue by barring
the engine in the direction that will wind the belt on
all the way.

STARTER
FIGURE 8-11.COOLANT PUMP BELT
WARNING Accidental or remote starting can
cause severe personal injury or death. Before
removing a panel or access door, disconnect
the negative (-) cable at the battery to prevent
the engine from starting.

Starter Removal and Replacement: The starter

motor (Figure 8-12) is accessible for removal and
installation through the access opening in the the
base pan. Parts are available for rebuilding the
starter. Torque the mounting screws to 29 lb-ft
(39 N-m). Make sure starter B+ is connected to gen-
set B+.

FLYWHEEL
See Flywheel on Page 7-2.

ENGINE-GENERATOR ADAPTOR
See Engine-Generator Adaptor on Page 7-2. FIGURE 8-12. STARTER MOTOR

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8-11 by any means, is strictly prohibited.
This page is intended to be blank.

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8-12 by any means, is strictly prohibited.
9. Troubleshooting
TABLE 9-1 lists the shutdown codes in numerical or- • Three blinks indicates a service fault. Press
der along with step-by-step corrective actions. First Stop once to cause the two-digit, second-level
note the following: shutdown code to blink. (Pressing Stop again
will stop the blinking.) The two-digit code con-
• Maintaining engine oil and coolant levels,
sists of 1, 2, 3, 4 or 5 blinks, a brief pause, and
keeping battery connections clean and tight,
then 1 to 9 blinks. The first set of blinks repre-
watching the fuel gauge, not overloading the
sents the tens digit and the second set of blinks
genset, keeping the air inlet and outlet open-
the units digit of the shutdown code number.
ings clear, etc. will prevent most shutdowns.
For example, shutdown code No. 36 appears
• When the genset and vehicle engine share a as:
common fuel tank the fuel dip tubes are usually blink-blink-blink—pause—blink-blink-blink-blink-blink-blink—
arranged so that the genset will run out of fuel long pause—repeat
first. Marking the genset empty point on the fuel
gauge will make it easier to tell when to stop the • Four blinks indicates that cranking exceeded
genset before running it out of fuel. a preset time (20 seconds if ambient tempera-
ture is above 32° F[0° C], 30 seconds if below)
SHUTDOWN CODES without starting.
• Note: shutdown code Nos. 3 and 4 are first level
The genset controller provides extensive diagnos- faults. Avoid interpreting them as second-level
tics by causing the status indicator light on the Con- shutdown code Nos. 33 and 44, which have not
trol Switch to blink in a coded fashion. Following a been assigned as shutdown codes.
fault shutdown, the indicator light will repeatedly
blink 1, 2, 3 or 4 blinks at a time. Restoring shutdown code Blinking - The shut-
• One blink indicates shutdown due to high en- down code stops blinking after five minutes. Press
Stop three times within three seconds to restore
gine temperature.
blinking. Note that the last fault logged will blink,
• Two blinks indicates shutdown due to a loss of even after the condition that caused the shut-
engine oil pressure. down has been corrected.

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9-1 by any means, is strictly prohibited.
 TABLE 9-1 . TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

NO RESPONSE—DEAD STATUS INDICATOR LIGHT

(Poor connections, faulty wiring or dead battery)

Corrective Action: (Refer to Pages A-1 and A-3 when tracing wiring and connectors below.)
1. Try the local genset control switch (S1) if the remote control switch (S11) does not work, and vice
versa. If neither works, go to Step 2. If one switch works but not the other, go to Step 5.
2. Clean and tighten the positive (+) and negative (- ) battery cable terminals at the battery and genset.
3. Remove the access cover on the bottom side (Page 3-4) and replace fuse F1 if blown.
4. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
5. Remove the access cover on the left side and disconnect connector P1 from controller A1
(Page 5-1). Check for B+ at Pins 10 and 11. If there is no B+, check for missing, bent or corroded
pins and faulty wiring and repair as necessary.
6. While P1 is disconnected, check for continuity between Pin 27and B- (ground). If open, check for
missing, bent or corroded pins and faulty wiring and repair as necessary.
7. While P1 is disconnected, check operation of the local and remote control switches (S1, S11). Start
should close Pin 9 to B- (ground). Stop should close Pin 32 to B- (ground). If the circuit does not
close, check for missing, bent or corroded pins and faulty wiring and repair the appropriate circuit
as necessary.
8. Replace controller A1 (Page 5-4).

THE STARTING BATTERIES DO NOT MAINTAIN A CHARGE

(The battery, battery connections or charging system are in marginal condition)

Corrective Action:
1. Clean and tighten the positive (+) and negative (- ) battery cable connections at the battery and at
the genset.
2. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
3. Service the vehicle battery charging system or the genset battery charger (Page 5-5).

THE STARTER ENGAGES AND DISENGAGES

(Cranking voltage dips below 6 volts because of low battery charge or poor connections)

Corrective Action:
1. Have the vehicle propulsion engine running while trying to start the genset. (The battery charging
alternator may be able to maintain starting voltage high enough to get the genset started.)
2. Clean and tighten the positive (+) and negative (- ) battery cable connections at the battery and at
the genset.
3. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.

Redistribution or publication of this document,

9-2 by any means, is strictly prohibited.
 TABLE 9-1 . TROUBLESHOOTING (CONT.)
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

THERE IS NO POWER WHEN THE GENSET IS RUNNING

(A line circuit breaker is OFF, tripped or malfunctioning)

Corrective Action:
1. Reset or turn ON the line circuit breaker on the genset.
2. Reset or turn ON any other circuit breaker in the power supply system.

THE GENSET WILL NOT STOP RUNNING (THE RUN LIGHT IS OFF)
(The governor mechanism is stuck or binding)

Corrective Action:
1. Close the fuel supply valve, if provided, or squeeze off the fuel supply line.
2. Remove the top housing panel (Page 4-3) and the cover on the governor actuator (Page 8-2). Reat-
tach the governor leads and observe the actuator rotor while cranking. The rotor should rotate
smoothly through about 1/2 inch (12 mm). If it does not, push the actuator rotor by hand (clockwise)
to check for binding in the governor mechanism. It should rotate smoothly and return smoothly. If it
binds or catches, remove the bearing carrier and stator and look for signs of physical contact be-
tween rotor and stator and service as necessary. If there are no signs of contact, remove the gover-
nor base. Replace the base or service the internal engine governor mechanism, as necessary
(Page 8-1).

HIGH TEMPERATURE FAULT—CODE NO. 1

(First-level fault code—engine coolant temperature exceeded 230° F [110° C])
Corrective Action:
1. Check the engine coolant level and add coolant as necessary. (Page 3-8).
2. Check for and remove any objects blocking the air inlet or outlet openings in the bottom and sides
of the genset.
3. Flush the coolant system to remove coolant passage fouling (Page 3-8).
4. Replace the engine thermostat, which might not be opening fully (Page 8-10).
5. Test coolant sender E2 (Page 5-5) and replace if necessary.

Redistribution or publication of this document,

9-3 by any means, is strictly prohibited.
 TABLE 9-1 . TROUBLESHOOTING (CONT.)
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

LOW OIL PRESSURE FAULT—CODE NO. 2

(First-level fault code—the low oil pressure cutoff switch is open)
Corrective Action: (Refer to Pages A-1 and A-3 when tracing wiring and connectors below.)
1. Check the engine oil level and add oil as necessary (Page 3-3).
2. Drain the excess oil if the oil level is above the Full mark on the dipstick. (The oil will foam if the level
is too high and result in possible loss of oil pressure.)
3. Remove the access cover on the bottom side and tighten the terminal on pressure switch S2
(Page 8-5), if loose.
4. Remove the access cover on the left side and disconnect connector P1 from controller A1
(Page 5-1). Check continuity between Pin 6 and the terminal on pressure switch S2. If there is no
continuity, check for missing, bent or corroded pins and faulty wiring and repair as necessary.
5. Replace the switch with a gauge, ground the switch wire (to keep engine running) and start the en-
gine. Shut down the engine immediately if there is no oil pressure.
A. If engine oil pressure is less than 14 psi (98 kPa), service the oil lubricating system (Page 8-1).
B. If engine oil pressure is at least 14 psi (98 kPa), replace oil pressure switch S2.
6. Replace controller A1 (Page 5-4).

SERVICE CHECK—CODE NO. 3

(First-level fault code—a second-level fault occurred)
Corrective Action: Check the second-level fault code by momentarily pressing Stop. The second-lev-
el fault will be one of the following in this table.

Redistribution or publication of this document,

9-4 by any means, is strictly prohibited.
 TABLE 9-1 . TROUBLESHOOTING (CONT.)
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

OVERCRANK FAULT—CODE NO. 4

(First-level fault code—Cranking without starting exceeded 20 to 30 seconds, depending on ambient)
Corrective Action: (Refer to Pages A-1 and A-3 when tracing wiring and connectors below.)
1. Check the fuel level and refill as necessary. (Note: The genset fuel pickup is probably higher than
the vehicle engine fuel pickup.)
2. Check for fuel (air) leaks at all fuel fittings and tighten as necessary. Prime the engine fuel system
by holding the control switch at Stop for one minute.
3. Check the engine air filter (Page 3-5) and remove any blockage.
4. Check for mechanical damage.
5. Replace the fuel filter (Page 3-7).
6. Conduct a fuel pump flow test and service as necessary (Page 8-8).
7. Inspect and service the glow plugs (Page 8-1) as follows:
A. If loose, tighten the glow plug terminals.
B. Check for B+ at the glow plug terminals during cranking. If there is no B+, remove glow plug
relay K3 from its socket and test for proper operation (Page 5-4). Replace if necessary. Also
check for B+ at relay socket terminal 30, for continuity between terminal 87 and the glow plugs
and for continuity between terminal 86 and B- (ground). Clean and tighten connections and re-
place wiring as necessary.
C. Check for B+ at relay socket terminal 85 while cranking. If there is no B+, disconnect connector
P1 from controller A1 (Page 5-1) and check for missing, bent or corroded pins and faulty wiring
and repair as necessary. If the wire and connections are good, replace controller A1.
D. Remove the glow plug bus bar and check for electrical continuity between each glow plug termi-
nal and B- (ground). Replace any open glow plug (Page 8-1).
8. Remove the top housing panel (Page 4-3) and the cover on the governor actuator (Page 8-2). Reat-
tach the governor leads and observe the actuator rotor while cranking. The rotor should rotate
smoothly through about 1/2 inch (12 mm). If it does not, apply 12 VDC to the actuator terminals and
observe whether the rotor rotates smoothly. If it does not, go to Step A. If it does, go to Step C.
A. Check resistance across the actuator terminals with an accurate digital ohmmeter. If resistance
is not between 1.7 and 2.8 ohms, replace the actuator stator.
B. Push the actuator rotor by hand (clockwise) to check for binding in the governor mechanism.
It should rotate smoothly and return smoothly. If it binds or catches, remove the bearing carrier
and stator and look for signs of physical contact between rotor and stator and service as neces-
sary. If there are no signs of contact, remove the governor base. Replace the base or service
the internal engine governor mechanism, as necessary (Page 8-1).
C. Remove the access cover on the left side and disconnect connector P1 from controller A1
(Page 5-1). Measure resistance between Pin 28 and A12+ and between Pin 29 and A12-. If
either lead is open, check for missing, bent or corroded pins or faulty wiring and repair as neces-
sary.
D. Replace controller A1 (Page 5-1).
9. Service the engine (Page 8-1).

Redistribution or publication of this document,

9-5 by any means, is strictly prohibited.
 TABLE 9-1 . TROUBLESHOOTING (CONT.)
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

OVERVOLTAGE FAULT—CODE NO. 12

(The controller is not able to regulate to rated voltage)
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 grounded
field, stator or quadrature windings (Page 6-4). Replace a stator or rotor that has faulty windings.
2. Replace controller A1 (Page 5-1).

UNDERVOLTAGE FAULT—CODE NO. 13

(The controller is not able to regulate to rated voltage)
Corrective Action:
1. Push the line circuit breaker to OFF, start the genset and measure output voltage. If output voltage
is normal, go to Step 2. If output voltage is low, go to Step 3.
2. Reduce the number of connected appliances, especially when air conditioners and battery chargers
are running.
3. Service the brushes and slip rings as necessary (Page 6-3) and test the generator field, stator and
quadrature windings for opens and shorts (Page 6-4). Replace a stator or rotor that has faulty wind-
ings.
4. Replace controller A1 (Page 5-1).

OVERFREQUENCY FAULT—CODE NO. 14

(The controller is not able to regulate to rated frequency)
Corrective Action:
1. Check for a tripped genset circuit breaker, reset it if necessary, and run with fewer connected loads.
(A breaker tripping under load can cause frequency to overshoot.)
2. Check for fuel (air) leaks at all fuel fittings and tighten as necessary. Prime the engine fuel system
by holding the control switch at Stop for one minute. (Air bubbles can disrupt frequency.)
3. Remove the top housing panel (Page 4-3) and the cover on the governor actuator (Page 8-2). Reat-
tach the governor leads and observe the actuator rotor while cranking. The rotor should rotate
smoothly through about 1/2 inch (12 mm). If it does not, apply 12 VDC to the actuator terminals and
observe whether the rotor rotates smoothly. If it does not, go to Step A. If it does, go to Step C.
A. Check resistance across the actuator terminals with an accurate digital ohmmeter. If resistance
is not between 1.7 and 2.8 ohms, replace the actuator stator.
B. Push the actuator rotor by hand (clockwise) to check for binding in the governor mechanism.
It should rotate smoothly and return smoothly. If it binds or catches, remove the bearing carrier
and stator and look for signs of physical contact between rotor and stator and service as neces-
sary. If there are no signs of contact, remove the governor base. Replace the base or service
the internal engine governor mechanism, as necessary (Page 8-1).
C. Replace controller A1 (Page 5-1).

Redistribution or publication of this document,

9-6 by any means, is strictly prohibited.
 TABLE 9-1 . TROUBLESHOOTING (CONT.)
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

UNDERFREQUENCY FAULT—CODE NO. 15

(The controller is not able to regulate to rated frequency)
Corrective Action:
1. Turn OFF the line circuit breaker. If the genset now runs, run it with fewer connected loads, especially
those with high motor starting loads such as air conditioners.
2. Check the fuel level and refill as necessary. (Note: The genset fuel pickup is probably higher than
the vehicle engine fuel pickup.)
3. Check for fuel (air) leaks at all fuel fittings and tighten as necessary. Prime the engine fuel system
by holding the control switch at Stop for one minute. (Air bubbles can disrupt frequency.)
4. Check the engine air filter (Page 3-5) and remove any blockage.
5. Check for mechanical damage.
6. Replace the fuel filter (Page 3-7).
7. Conduct a fuel pump flow test and service as necessary (Page 8-8).
8. Remove the top housing panel (Page 4-3) and the cover on the governor actuator (Page 8-2). Reat-
tach the governor leads and observe the actuator rotor while cranking. The rotor should rotate
smoothly through about 1/2 inch (12 mm). If it does not, apply 12 VDC to the actuator terminals and
observe whether the rotor rotates smoothly. If it does not, go to Step A. If it does, go to Step C.
A. Check resistance across the actuator terminals with an accurate digital ohmmeter. If resistance
is not between 1.7 and 2.8 ohms, replace the actuator stator.
B. Push the actuator rotor by hand (clockwise) to check for binding in the governor mechanism.
It should rotate smoothly and return smoothly. If it binds or catches, remove the bearing carrier
and stator and look for signs of physical contact between rotor and stator and service as neces-
sary. If there are no signs of contact, remove the governor base. Replace the base or service
the internal engine governor mechanism, as necessary (Page 8-1).
C. Replace controller A1 (Page 5-1).
9. Readjust high idle speed (Page 8-4).
10. Service the fuel injectors and injection pump as necessary (Page 8-1).
11. Check fuel injection timing (Page 8-1).

GOVERNOR ACTUATOR FAULT—CODE NO. 19

(The controller sensed that the actuator circuit is either open or shorted)
Corrective Action:
1. Remove the top housing panel (Page 4-3) and reconnect the leads at the governor actuator, if loose.
Polarity does not matter.
2. Check resistance across the actuator terminals with an accurate digital ohmmeter. If resistance is
not between 1.7 and 2.8 ohms, replace the actuator stator.
3. Remove the access cover on the left side and disconnect connector P1 from controller A1
(Page 5-1). Measure resistance between Pin 28 and A12+ and between Pin 29 and A12-. If either
lead is open, check for a missing, bent or corroded pin or faulty wiring and repair as necessary.

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9-7 by any means, is strictly prohibited.
 TABLE 9-1 . TROUBLESHOOTING (CONT.)
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

GOVERNOR OVERLOAD FAULT—CODE NO. 22

(The duration of operation at or near full-duty cycle was beyond the design limit)
Corrective Action:
1. Reduce the number of appliances running at the same time, especially those with high motor starting
loads such as air conditioners.
2. Check for fuel (air) leaks at all fuel fittings and tighten as necessary. Prime the engine fuel system
by holding the control switch at Stop for one minute.
3. Replace the engine air filter (Page 3-5) and clean the spark-arrest muffler (Page 3-6).
4. Replace the fuel filter (Page 3-7).
5. Conduct a fuel pump flow test and service as necessary (Page 8-8).
6. Readjust high idle speed (Page 8-4).
7. Remove the top housing panel (Page 4-3) and the cover on the governor actuator (Page 8-2). Reat-
tach the governor leads and observe the actuator rotor while cranking. The rotor should rotate
smoothly through about 1/2 inch (12 mm). If it does not, apply 12 VDC to the actuator terminals and
observe whether the rotor rotates smoothly. If it does not, go to Step A. If it does, go to Step C.
A. Check resistance across the actuator terminals with an accurate digital ohmmeter. If resistance
is not between 1.7 and 2.8 ohms, replace the actuator stator.
B. Push the actuator rotor by hand (clockwise) to check for binding in the governor mechanism.
It should rotate smoothly and return smoothly. If it binds or catches, remove the bearing carrier
and stator and look for signs of physical contact between rotor and stator and service as neces-
sary. If there are no signs of contact, remove the governor base. Replace the base or service
the internal engine governor mechanism, as necessary (Page 8-1).
C. Replace controller A1 (Page 5-1).
8. Service the fuel injectors and injection pump as necessary (Page 8-1).
9. Check fuel injection timing (Page 8-1).

TEMPERATURE SENDER FAULT—CODE NO. 24

(The controller sensed that the sender circuit is either open or shorted)
Corrective Action: (Refer to Pages A-1 and A-3 when tracing wiring and connectors below.)
1. Remove the access cover on the bottom side and tighten the terminal on coolant temperature sender
E4 (Page 8-5), if loose.
2. Test the resistance of sender E4 at room temperature and in boiling water (Page 8-5). Replace if
faulty.
3. Remove the access cover on the left side and disconnect connector P1 from controller A1
(Page 5-1). Check continuity between Pin 21 and ring terminal E4-1. If there is no continuity, check
for missing, bent or corroded pins or faulty wiring and repair as necessary.

Redistribution or publication of this document,

9-8 by any means, is strictly prohibited.
 TABLE 9-1 . TROUBLESHOOTING (CONT.)
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

AC VOLTAGE SENSE FAULT—CODE NO. 27

(The controller was unable to sense output voltage)
Corrective Action: (Refer to Pages A-1 and A-3 when tracing wiring and connectors below.)
1. Remove the access cover on the left side and disconnect connector P1 from controller A1
(Page 5-1). Check continuity between Pin 33 and Pin 34. If open, check for missing, bent or corroded
pins and faulty wiring and repair as necessary.
2. On 3-phase gensets, test voltage sense transformer T15 (Page 5-5).
3. Service the brushes and slip rings as necessary (Page 6-3) and test the generator field, stator and
quadrature windings for opens and shorts (Page 6-4). Replace a stator or rotor that has faulty wind-
ings.
4. Replace controller A1 (Page 5-1).

HIGH BATTERY VOLTAGE FAULT—CODE NO. 29

(The controller sensed battery system voltage greater than 19 volts)
Corrective Action:
1. Check battery bank connections and reconnect, if necessary, so that the 12 volt batteries serving
the genset are connected in parallel (12 volt) rather than in series (24 volt).
2. Select a lower external battery boost charge rate.

LOW CRANKING SPEED FAULT—CODE NO. 32

(Cranking speed less than 100 rpm [2.5 Hz, generator] for more than 12 seconds)

Corrective Action:
1. Have the vehicle propulsion engine running while trying to start the genset. (The battery charging
alternator may be able to maintain starting voltage high enough to get the genset started.)
2. Clean and tighten the positive (+) and negative (- ) battery cable connections at the battery and at
the genset.
3. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
4. Replace engine oil with oil of proper viscosity for ambient temperatures. (High oil viscosity can slow
down cranking speed.)

CONTROL CARD FAULT—CODE NO. 35

(Microprocessor EEPROM error during self-test)
Corrective Action: Replace controller A1 (Page 5-1).

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9-9 by any means, is strictly prohibited.
 TABLE 9-1 . TROUBLESHOOTING (CONT.)
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

ENGINE STOPPED FAULT—CODE NO. 36

(The genset stopped without a command from the controller)
Corrective Action:
1. Check the fuel level and refill as necessary. (Note: The genset fuel pickup is probably higher than
the vehicle engine fuel pickup.)
2. Check for fuel (air) leaks at all fuel fittings and tighten as necessary. Prime the engine fuel system
by holding the control switch at Stop for one minute.
3. Check the engine air filter (Page 3-5) and remove any blockage.
4. Check for mechanical damage.
5. Replace the fuel filter (Page 3-7).
6. Conduct a fuel pump flow test and service as necessary (Page 8-8).
7. Check for an open field or open or grounded quadrature circuit (Page 6-4) and service as necessary.
8. Remove the top housing panel (Page 4-3) and the cover on the governor actuator (Page 8-2). Reat-
tach the governor leads and observe the actuator rotor while cranking. The rotor should rotate
smoothly through about 1/2 inch (12 mm). If it does not, apply 12 VDC to the actuator terminals and
observe whether the rotor rotates smoothly. If it does not, go to Step A. If it does, go to Step C.
A. Check resistance across the actuator terminals with an accurate digital ohmmeter. If resistance
is not between 1.7 and 2.8 ohms, replace the actuator stator.
B. Push the actuator rotor by hand (clockwise) to check for binding in the governor mechanism.
It should rotate smoothly and return smoothly. If it binds or catches, remove the bearing carrier
and stator and look for signs of physical contact between rotor and stator and service as neces-
sary. If there are no signs of contact, remove the governor base. Replace the base or service
the internal engine governor mechanism, as necessary (Page 8-1).
C. Remove the access cover on the left side and disconnect connector P1 from controller A1
(Page 5-1). Measure resistance between Pin 28 and A12+ and between Pin 29 and A12-. If
either lead is open, check for missing, bent or corroded pins or faulty wiring and repair as neces-
sary.
D. Replace controller A1 (Page 5-1).
9. Service the engine (Page 8-1).

FIELD OVERLOAD FAULT—CODE NO. 38

(Field voltage exceeded 150 VDC)
Corrective Action:
1. Reduce the number of air conditioners running at the same time (and other appliances that cause
low power factor).
2. Have the air conditioners and other appliances checked for proper operation. (A locked compressor
rotor can cause very low power factor.)
3. Service the brushes and slip rings as necessary (Page 6-3) and test the generator field, stator and
quadrature windings for opens and shorts (Page 6-4). Replace a stator or rotor that has faulty wind-
ings.

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 TABLE 9-1 . TROUBLESHOOTING (CONT.)
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

SHORTED ROTOR FAULT—CODE NO. 41

(The rotor circuit is shorted to ground)
Corrective Action: (Refer to Pages A-1 and A-3 when tracing wiring and connectors below.)
1. Remove the access cover on the left side and disconnect connector P1 from controller A1
(Page 5-1). Check for continuity between Pin 1 or 14 and B- (ground). Repair or replace wiring,
brushes and slip rings (Page 6-3) or rotor (Page 6-4), as necessary, if the rotor is shorted to ground.
2. Replace controller A1 (Page 5-1).

PROCESSOR FAULT—CODE NO. 42

(Microprocessor ROM error during self-test)
Corrective Action: Replace controller A1 (Page 5-1).

PROCESSOR FAULT—CODE NO. 43

(Microprocessor RAM error during self-test)
Corrective Action: Replace controller A1 (Page 5-1).

SPEED SENSE FAULT—CODE NO. 45

(Controller unable to sense quadrature frequency)

Corrective Action:
1. Check the fuel level and fill as necessary. Then prime the engine fuel system by holding the control
switch at Stop for one minute and try restarting.
2. Service the brushes and slip rings as necessary (Page 6-3) and test the generator field, stator and
quadrature windings for opens and shorts (Page 6-4). Replace a stator or rotor that has faulty wind-
ings.

OVERPRIME FAULT—CODE NO. 57

(Prime mode exceeded 3 minutes)

Corrective Action: Check for and remove any object that may be holding either control switch (remote
or local) in the prime (stop) position.

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10. Service Checklist
GENERAL joints along the whole length of the exhaust system.
Repair all leaks before putting the genset in service.
Before reinstalling the genset, repair any damage to
and seal all holes in the vapor-tight, fire-resistive FUEL SYSTEM
barrier between the genset and coach interior.
Check flexible sections for cuts, cracks and abra-
After servicing or reinstalling a genset conduct the sions and make sure they do not rub against any-
following checks and tests to determine that the thing that could cause damage.
genset will operate safely and perform as required. WARNING Diesel fuel is combustible and can
cause severe personal injury or death. Do not
MOUNTING smoke near fuel tanks or fuel-burning equip-
ment or in areas sharing ventilation with such
Check for proper mounting and tighten all fasteners equipment. Keep flames, sparks, pilot flames,
securely. Make sure the air inlet and outlet openings electrical arcs and switches and all other
in the bottom of the genset are not restricted in any sources of ignition well away. Keep a multi-
way and that there is access for changing the oil fil- class ABC fire extinguisher handy.
ter and draining oil.
STARTUP
WIRING
WARNING EXHAUST GAS IS DEADLY! Do not
WARNING Batteries give off explosive gases operate the genset when the vehicle is indoors
that can cause severe personal injury — Do not or where exhaust can accumulate.
smoke — Keep flames, sparks, pilot lights,
switches, arc-producing equipment and all oth- Read the Operator’s Manual, perform the mainte-
er ignition sources away. nance and pre-start checks instructed and follow all
of its instructions and safety precautions. Check for
Make sure all AC output, control, ground and battery fuel and exhaust leaks and unusual noises while the
connections are tight and properly installed. Check genset is running under full and intermediate loads.
wiring for cuts, cracks and abrasions and make sure Do not place the genset in service until all fuel and
it does not rub against anything that could cause exhaust leaks have been fixed and operation is sat-
damage. isfactory.

EXHAUST SYSTEM OUTPUT CHECK

Apply a full load to make sure the genset can pro-
Make certain that the exhaust tail pipe terminates duce its full rated output. Use a load test panel to ap-
beyond the perimeter of the vehicle and not near ply a progressively greater load until full load is
vents or openable windows or doors. Test the on- reached.
board CO alarm(s). See the Installation Manual for
important considerations concerning the installa- CONTROL
tion of an exhaust system.
Stop and start the genset several times at the gen-
When the genset is up and running, look and listen set control and remote control (if so equipped) to
for leaks at all connections, welds, gaskets, and verify that it functions properly.

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11. Specifications

60 Hz Models 50 Hz Models
GENSET CONTROLLER: Integrated Microprocessor Based Engine and Generator Controller
GENERATOR: Two-Bearing, Two-Pole Rotating Field, “Poly-Vee” Belt Drive
Power (@1.0 PF) 5500 W 5000 W
RPM 3600 3000
Voltage 120V 1-Ph, 120/240V 1-Ph, or 120/240V 3-Ph 115/230V 1-Ph or 230/400V 3-Ph
Current 45.8A, 22.9A, or 13.2A 23.9A or 7.2A
Circuit Breakers 25A, 25A, or 15A 25A or 8A
FUEL CONSUMPTION:
No-load 0.25 gph (0.93 lph) 0.21 gph (0.78 lph)
Half-load 0.41 gph (1.57 lph) 0.34 gph (1.31 lph)
Full-load 0.66 gph (2.51 lph) 0.55 gph (2.09 lph)
ENGINE: 2-Cylinder In-Line, Water-Cooled, Indirect-Injection, 4-Stroke Cycle Diesel
RPM 2880 2400
Bore 2.64 in (67 mm)
Stroke 2.68 in (68 mm)
Displacement 29.23 in3 (479 cc)
Compression Ratio 23 : 1
Fuel Injection Timing
18°-20 °
(BTDC)
Injection Order 1-2
Fuel Nozzle Injection
1991 psi (13.73 mPa)
Pressure
Valve Lash: Intake & Ex-
0.0059 - 0.0073 inch (0.145 - 0.185 mm)
haust (cold)
Oil Capacity
2 quart (1.9 liter)
(with filter)
Cooling System
2.3 quart (2.2 liter)
Capacity
DC SYSTEM:
Nominal Battery
12 volts
Voltage
Minimum Battery
475 amps down to 0° F (-17° C)
Capacity CCA
650 amps down to -20° F (-29° C)
(Cold Cranking Amps)
Fuse F1 (control, start
30 amp mini-bayonet
and glow plug circuits)
WEIGHT: 400 lbs (181 kg)
SIZE (L x W x H): 34.5 x 22.4 x 20.3 in (846 x 549 x 498 mm)
SOUND LEVEL: 68 dB(A) @ 10 ft (3m)

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12. Torque Specifications

lb-ft* N-m *
Genset Mounting Screws 35 48
Generator Through Bolts 8 11
Belt Tensioner Center Bolt 20 26
Generator Pulley Center Bolt 45 61
Fan Bolts 8 11
Flywheel to Pulley Coupling Nuts 5 6
Flywheel Center Bolt 60 81
Exhaust Manifold Flange Nuts 20 26
Muffler Flange Nuts 10 13
Intake Manifold Bolts 19 26
Engine Mounting Bolts 20 26
Starter Motor Mounting Bolts 20 26
Starter Terminal Nut 6.5 8
* - Use engine oil as a lubricant for all threads except when otherwise specified.

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 630-2298-1

DC WIRING DIAGRAM
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by any means, is strictly prohibited.
A-1
 630-2298-2

GENERATOR CONNECTION DIAGRAM

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by any means, is strictly prohibited.
A-2
 338-4092

DC WIRING HARNESS
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by any means, is strictly prohibited.
A-3
Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
763-574-5000
Fax: 763-528-7229
Redistribution or publication of this document,
Cummins and Onan are registered trademarks of Cummins Inc.
by any means, is strictly prohibited.