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Printed in U.S.A. 981−0149
9−97
HDKAG
Safety Precautions
Thoroughly read the OPERATOR’S MANUAL beforeoperating the genset. Safe operation and top perfor-mance can be obtained only with proper operationand maintenance.
The following symbols in this Manual alert you to poten-tial hazards to the operator, service person and equip-ment.
Alerts you to an immediate hazardwhich will result in severe personal injury or death.
WARNING Alerts you to a hazard or unsafe prac-tice which can result in severe personal injury ordeath.
CAUTION Alerts you to a hazard or unsafe prac-tice which can result in personal injury or equipmentdamage.
Electricity, fuel, exhaust, moving parts and batteriespresent hazards which can result in severe personal inju-ry or death.
GENERAL PRECAUTIONS
• Keep ABC fire extinguishers handy.
• Make sure all fasteners are secure and torquedproperly.
• Keep the genset and its compartment clean. Ex-cess oil and oily rags can catch fire. Dirt and gearstowed in the compartment can restrict cooling air.
• Before working on the genset, disconnect the nega-tive (- ) battery cable at the battery to prevent start-ing.
• Use caution when making adjustments while thegenset is running—hot, moving or electrically liveparts can cause severe personal injury or death.
• Used engine oil has been identified by some stateand federal agencies as causing cancer or repro-ductive toxicity. Do not ingest, inhale, or contactused oil or its vapors.
• Benzene and lead in some gasolines have beenidentified by some state and federal agencies ascausing cancer or reproductive toxicity. Do not to in-gest, inhale or contact gasoline or its vapors.
• Do not work on the genset when mentally or physi-cally fatigued or after consuming alcohol or drugs.
• Carefully follow all applicable local, state and feder-al codes.
GENERATOR VOLTAGE IS DEADLY!
• Generator output connections must be made by aqualified electrician in accordance with applicablecodes.
• The genset must not be connected to the public util-ity or any other source of electrical power. Connec-tion could lead to electrocution of utility workers,damage to equipment and fire. An approved switch-
ing device must be used to prevent interconnec-tions.
• Use caution when working on live electrical equip-ment. Remove jewelry, make sure clothing andshoes are dry and stand on a dry wooden platformon the ground or floor.
FUEL IS FLAMMABLE AND EXPLOSIVE
• Keep flames, cigarettes, sparks, pilot lights, electri-cal arc-producing equipment and switches and allother sources of ignition well away from areaswhere fuel fumes are present and areas sharingventilation.
• Fuel lines must be secured, free of leaks and sepa-rated or shielded from electrical wiring.
• Use approved non-conductive flexible fuel hose forfuel connections at the genset.
ENGINE EXHAUST IS DEADLY!
• Learn the symptoms of carbon monoxide poisoningin this Manual.
• Never sleep in the vehicle while the genset is run-ning unless the vehicle has a working carbon mon-oxide detector.
• The exhaust system must be installed in accor-dance with the genset Installation Manual.
• Do not use engine cooling air to heat the vehicle in-terior.
• Make sure there is ample fresh air when operatingthe genset in a confined area.
MOVING PARTS CAN CAUSE SEVERE PERSONALINJURY OR DEATH
• Do not wear loose clothing or jewelry near movingparts such as PTO shafts, fans, belts and pulleys.
• Keep hands away from moving parts.
• Keep guards in place over fans, belts, pulleys, etc.
BATTERY GAS IS EXPLOSIVE
• WEAR SAFETY GLASSES and DO NOT SMOKEwhile servicing batteries.
• When disconnecting or reconnecting batterycables, always disconnect the negative (- ) batterycable first and reconnect it last to reduce arcing.
i
Table of Contents
SAFETY PRECAUTIONS Inside Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About This Manual 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model Identification 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feature And Component Locations 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRE-START CHECKS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Check 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Check 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Inspection 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING AND STOPPING 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATTAGE REQUIREMENTS 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Wattage Capacity 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Power 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING RECOMMENDATIONS 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Break-in Procedure 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No-load Operation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exercise Period 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Temperature/High Altitude Operation 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Extremely Dusty Or Dirty Conditions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SCHEDULE 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE PROCEDURES 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Set Inspection 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil And Filter Change 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Belt 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Care 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Breather 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Generator 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning The Generator Set 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Muffler/Spark Arrester 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERATOR SET STORAGE 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Out-of-Service Protection 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Control 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Control 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INFORMATION FOR CALIFORNIA GENSET USERS 25. . . . . . . . . . . . . . . . . . . . . . . . . . . HOW TO OBTAIN SERVICE 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE RECORD 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
California
Proposition 65 WarningDiesel engine exhaust and some of its constituents are knownto the State of California to cause cancer, birth defects, andother reproductive harm.
1
Introduction
ABOUT THIS MANUAL
This manual covers the operation and maintenanceof the generator set models listed on the front cover.Study this manual carefully and observe all of its in-structions and precautions.
Control Panel, Pre-Start Checks, Starting and Stop-ping, Wattage Requirements and Operating Rec-ommendations cover basic operation of the genset.
Maintenance Schedule, Maintenance Procedures,Generator Set Storage and Troubleshooting coverthe maintenance and care necessary for top perfor-mance. The owner is responsible for maintainingthe genset according to the maintenance schedule(Page 11).
Information for California Genset Users providesimportant information for California genset users.
Each operator of the genset should become thor-oughly familiar with the information in this manual.Keep this manual and the genset Installation Manu-al with the other vehicle manuals.
This genset is not a life support sys-tem. It can stop without warning. Children, per-sons with physical or mental limitations, andpets could suffer personal injury or death. Apersonal attendant, redundant power or a warn-ing system must be used if genset operation iscritical.
MODEL IDENTIFICATION
When contacting an Onan dealer or distributor forparts, service or product information, be ready toprovide the model and serial numbers on the gensetnameplate (Figure 1). Every character in thesenumbers is significant. (The last character of themodel number is the specification letter, which is im-portant for obtaining the right parts.)
To make the model and serial numbers easy to findwhen you need them, record them in the boxes pro-vided in Figure 1.
FEATURE AND COMPONENT LOCATIONS
The standard control panel and the routine mainte-nance items are shown in Figure 2.
RECORD NUMBERS HERE
MODEL NUMBER:
SERIAL NUMBER:
SKB1.5U6D2RA 1335 cc
A95312345610HDKAG11435C
FIGURE 1. TYPICAL NAMEPLATE
2
G1250s
START-STOP-PREHEATSWITCH
FIGURE 2. TYPICAL GENERATOR SET
OIL DIP-STICK FUEL FILTER
ASSY.
LIFTINGBRACKET
STOPSOLENOID
ASSY.
AIRCLEANER
ASSY.
FUELPUMP
COOLANT DRAIN(AT LOWER
REAR EDGE OFRADIATOR)
COOLANTFILL RADIATOR
VOLTAGEREGULATOR
DCCONTROL
BOX
OIL FILL (BEHINDFUEL LINES)
FAULT RESETBREAKER
DC CONTROLBREAKER
OIL FILTER
AC OUTPUT BOX (BEHINDAIR CLEANER ASSEMBLY)
DC ALTERNATOR(BEHIND RADIATOR)
FAULT SENSORS(AT REAR OF SET)
3
Control Panel
This section describes the features of the standardcontrol panel. The set controls and breakers are lo-cated on the front of the DC control box. The line cir-cuit breaker is located on the side of the AC controlbox. See Figure 3.
Controls and Breakers
Start-Stop-Preheat Switch: Starts and stops thegenerator set. Operates the engine cylinder pre-heaters.
DC Control Breaker: A 15 ampere DC breaker thatprotects the control box and remote wiring from
short circuits or overload. Also serves as an emer-gency stop switch.
Fault Reset Breaker: A manual reset breaker thatshuts down the engine for:
• Low oil pressure• High coolant temperature• Overspeed
Line Circuit Breaker: A circuit breaker that pro-tects the set from a short circuit or other overload. Itis mounted on the side of the AC control box. Thesingle phase genset uses a dual 45-amp breaker.The three-phase set uses a three-pole 35-ampbreaker.
AC OUTPUT BOX (PARTIALLY HIDDENBEHIND AIR CLEANER ASSEMBLY)
FIGURE 3. GENERATOR SET CONTROLS AND BREAKERS
START-STOP-PREHEATSWITCH
DC CONTROLBREAKER
FAULT RESETBREAKER
LINE CIRCUITBREAKER(S)
4
Pre−Start Checks
ENGINE OIL
Check the engine oil level before each start. Whenthe generator set is new, the engine must be filledwith oil before the initial start. The engine oil capac-ity is 4.7 liters (5 quarts).
If adding oil between changes, use the same brandbecause different brands might not be compatiblewhen mixed. Be careful not to overfill the crankcasebecause the oil will foam, resulting in engine shut-down.
Oil Recommendations
Use oils with the American Petroleum Institute (API)classification CD and later (CD, CE) in viscositiesshown below in Table 1.
Select the oil viscosity that is right for the lowesttemperature expected. Oil that is too thick may notlubricate when the engine is started. Use a lowerviscosity oil as the ambient temperature gets colder.
Do not use synthetic oil or non-detergent oil. Do notmix different brands of oil.
Checking Engine Oil Level
Do not operate the engine with theoil below the ADD mark or above the FULL mark.Overfilling can cause foaming or aeration of theoil, while operation below the ADD mark mightcause loss of oil pressure.
Check the engine oil level at the intervals shown inTable 4. The oil dipstick and fill are located on theside of the engine (see Figure 4). The dipstick is
stamped with FULL and ADD to indicate the oil levelin the crankcase. For an accurate reading, shut offthe engine and wait 10 minutes before checking thelevel. This lets oil in the upper part of the enginedrain into the crankcase.
Keep the oil level near as possible to the FULL markon the dipstick. Remove the oil fill cap and add thesame type of oil when necessary.
Do not operate the engine with theoil level below the ADD mark or above the FULLmark. Overfilling can cause foaming or aerationof the oil, while operation below the ADD markcan cause loss of oil pressure.
FIGURE 4. ENGINE OIL DIPSTICK AND FILL
OIL FILL
OIL DIPSTICK
ALTERNATE OIL FILL AT TOPOF VALVE COVER (HIDDEN)
Anticipated Ambient Temperature
TABLE 1. OIL VISCOSITY VS. TEMPERATURE
5
EXHAUST CHECK
Thoroughly inspect the exhaust system for leaks orcorrosion. Have any problems repaired before op-erating the generator set.
Exhaust gas presents the hazard ofsevere personal injury or death. Make certainthat all exhaust components are operationaland that there are no exhaust leaks.
Do not start the set if exhaust gases will not effec-tively expel away from the vehicle. Be aware thatany vent, window or opening that is not permanentlysealed from the vehicle living space can be an ave-nue for carbon monoxide.
Exhaust gases can cause severepersonal injury or death. Never operate the gen-erator set unless the exhaust outlet is clear ofwalls, snow banks, or any obstructions that canprevent exhaust gases from dissipating. Neveroperate any exhaust fan in the vehicle when thegenerator set is running: an exhaust fan candraw exhaust gas into the vehicle.
FUEL CHECK
Carefully inspect the fuel system for leaks or corro-sion. Have any problems repaired immediately.
Fuel presents the hazard of fire orexplosion which can cause severe personal in-jury or death. Do not permit any flame, spark, pi-lot light, cigarette, or other ignition source nearthe fuel system.
Use the best fuel available. Fuel quality is importantfor dependable performance and satisfactory en-gine life.
Ignition of fuel can cause seriouspersonal injury or death by fire or explosion. Donot permit any flame, cigarette, pilot light, sparkor other igniter near the fuel system.
Fuel Recommendation
Use ASTM 2-D (No. 2 Diesel) or ASTM 1-D (No. 1Diesel) fuel with a minimum Cetane number of 45.Number 2 diesel fuel gives the best economy andperformance under most conditions. Use number 1diesel fuel when ambient temperatures are below32° F (0° C) and during long periods of light engineload.
Use low sulfur content fuel which has a cloud pointat least 10 degrees below the lowest expected fueltemperature. (Cloud point is the temperature atwhich wax crystals begin to form in diesel fuel.)
GENERAL INSPECTION
Check the generator set for damaged or looseparts. Make sure the air inlet and outlet areas arenot blocked. Investigate any abnormal operatingnoises. Make sure that the generator set is securelymounted in its compartment or under-floor housing.
Check to see that the vehicle is not parked in highgrass or brush.
Do not operate the generator setwhen the vehicle is parked in high grass orbrush. Engine exhaust could ignite the grass,and the resulting fire could cause severe per-sonal injury or death, and/or property damage.
6
Starting and Stopping
EXHAUST GAS IS DEADLY!All engine exhaust contains contain carbon monoxide, an odorless, colorless, poisonous gas thatcan cause unconsciousness and death. Symptoms of carbon monoxide poisoning include:
• Dizziness • Nausea• Headache • Vomiting• Weakness and Sleepiness • Inability to Think Coherently
IF YOU EXPERIENCE ANY OF THESE SYMPTOMS, GET INTO FRESH AIR IMMEDIATELY. If symptomspersist, seek medical attention. Shut down the genset and do not operate it until it has been inspectedand repaired.Never sleep in the vehicle while the genset is running unless the vehicle has a working carbon monox-ide detector. The exhaust system must be installed in accordance with the genset Installation Manual.Make sure there is ample fresh air when operating the genset in a confined area.
STARTING
Starting at Set
1. Press the Start/Stop/Preheat switch to Stop/Preheat . Hold for 10 to 30 seconds, dependingon the temperature (see Table 2).
Preheat time longer than 30 sec-onds may damage glow plugs.
TABLE 2. PREHEAT TIME vs. TEMPERATURE
Below 32° F (0° C)
Ambient Temperature Preheat Time
Above 86° F (30° C)
Between 32° to 50° F
(0° to 10° C)
10 seconds
15 seconds
20 seconds
30 seconds
Between 50° to 86° F
(10° to 30° C)
2. Press the Start/Stop/Preheat switch to Start .Release the switch when the engine starts.
3. If the engine does not start after cranking 30seconds, release the switch. Wait two minutes,then repeat Step 1 (preheat).
Excessive cranking can over-heat the starter, damaging it. Do not engagethe starter longer than 30 seconds withoutallowing two minutes for cooling.
4. If the engine does not start on the second try:
• Check the fuel supply.• Make sure the fuel system has been primed.
With an empty tank, the fuel system may needpriming before the set can start. See Fuel Sys-tem in the Maintenance Section.
Starting at Remote Panel
The same procedures and cautions for normalstarting apply to remote starting.
7
Start-up Checks (Remote Panel)
Check the gauges on the control box after the en-gine starts. Check the oil pressure gauge immedi-ately.
Oil Pressure Gauge: Oil pressure should be 40 to60 psi (276 to 414 kPa) when the engine is at oper-ating temperature.
DC Voltmeter: Battery voltage during operationshould be 14 to 15 volts, depending on the state ofbattery charge.
Water Temperature Gauge: Water temperatureshould be 165° to 195° F (74° to 91° C) dependingon load and ambient temperature.
STOPPING
Before Stopping
Run the genset at no load three to five minutes be-fore stopping. This lets the lubricating oil and enginecoolant carry heat away from the combustion cham-ber and bearings.
Failure to allow running time for en-gine cooling without load can cause enginedamage. Make sure the generator set runs un-loaded at least three minutes.
To Stop: Press the Start/Stop/Preheat switch toStop . Failure to hold the stop button down longenough may allow the genset to slow, but begin run-ning again, if AC voltage to the control does not fallbelow the minimum operating level.
8
Wattage Requirements
AC WATTAGE CAPACITY
The AC power output from the generator will powerappliances and other equipment. (The wattage re-quirement of appliances and electrical equipmentmay be referred to as “electrical load”.)
On the single-phase set, a 45-amp dual circuitbreaker (two 45-amp circuits) mounted on the setprotects the generator from an overloaded output,which occurs when too much load is applied atonce. On the three-phase set, a three-pole 35-ampbreaker is used.
Connecting a Load
To determine the maximum amount of electricalload that can be applied, follow these steps:
1. Determine the maximum load (wattage) sup-plied by the genset/vehicle circuit, by multiply-ing the circuit breaker size by the AC outputvoltage:
2 x 45 (amps) x 120 (volts) = 10800 wattsor
2 x 22.5 (amps) x 240 (volts) = 10800 watts
2. Check the wattage requirement of each deviceto be connected (see Table 3). The appliancenameplate should list the wattage of each item.
3. Add the wattages of all the items to be poweredat the same time. Make sure that the total watt-age does not exceed the limit of the circuitbreaker.
Example:
Air Conditioner 1800 wattsConverter 500 wattsCoffee Percolator 600 wattsTelevision 300 wattsTotal 3200 watts
4. Start the generator set and let it warm up a fewminutes before applying electrical load.
Make sure that each appliance and tool is properlygrounded and in good working condition before us-ing it.
Electrical shock can cause severepersonal injury or death. Appliances should bein good working condition and be properlygrounded to provide additional protection fromelectrical shock.
TABLE 3. APPROXIMATE POWER DRAW OFCOMMON APPLIANCES
Appliance or Tool Approximate Running Wattage
Air Conditioner 1400-2000. . . . . . . . . . . . . . . Battery Charger Up to 800. . . . . . . . . . . . . . Coffee Percolator 550-750. . . . . . . . . . . . Converter 300-500. . . . . . . . . . . . . . . . . . . Electric Blanket 50-200. . . . . . . . . . . . . . Electric Broom 200-500. . . . . . . . . . . . . . . Electric Drill 250-750. . . . . . . . . . . . . . . . . Electric Frying Pan or Wok 1000-1500. . . . Electric Iron 500-1200. . . . . . . . . . . . . . . . . Electric Stove (Per Element) 350-1000. . . Electric Water Heater 1000-1500. . . . . . . . . Hair Dryer 800-1500. . . . . . . . . . . . . . . . . . . Microwave Oven 1000-1500. . . . . . . . . . . . . Radio 50-200. . . . . . . . . . . . . . . . . . . . . . . Refrigerator 600-1000. . . . . . . . . . . . . . . . . Space Heater 1000-1500. . . . . . . . . . . . . . . . Television 200-600. . . . . . . . . . . . . . . . . . .
Motorized Devices
Motorized devices consume more power duringstartup than they do when running at normal speed.(Some motors draw as much as three times theiroperating power during startup.) If you plan to use amotorized device, turn it on before starting otherappliances. When the motor is running at normalspeed, more devices may be added.
9
Circuit Breakers
Circuit breakers on the electrical distribution panelor on the genset will open if their current ratings areexceeded. This may be caused either by runningtoo many appliances at once, or by a short circuit.
The genset will continue to run after a breaker trips.Turn off all loads, then reset the breaker. If it tripsagain, a short circuit is indicated. Turn off the setand contact a qualified technician for assistance.
If the breaker does not trip, turn on only as many de-vices as the breaker size allows (see Connecting ALoad in this section). If the breaker trips again, a de-fective load or circuit breaker is indicated.
Connection to Utility Power
Connect the RV or commercial vehicle to utility pow-er (power from an outside source such as a plug-in
outlet) only through an approved device, to protectagainst the possibility of generator power and utilitypower being connected. Consult the InstallationManual for information on isolating the genset fromutility-supplied power.
Connecting the generator set di-rectly to the public utility or any other powersystem can cause electrocution, damage toequipment, or fire. Hazardous voltages can flowfrom the generator set into the utility line. An ap-proved switching device must be used to pre-vent interconnections.
DC POWER
A 30-amp belt-driven alternator on the engine sup-plies DC power to recharge the starting battery forthe set.
10
Operating Recommendations
BREAK-IN PROCEDURE
Drain the crankcase oil after the first 35 hours of op-eration. See the Maintenance section of this manu-al for the procedure.
NO-LOAD OPERATION
Hold no-load operation to a minimum. With noload, combustion chamber temperatures drop solow that fuel does not burn completely. This createscarbon deposits which clog injectors, glaze cylin-ders and cause piston rings and valves to stick. If itis necessary to run the engine for long periods, con-nect an electrical load to the generator output.
EXERCISE PERIOD
Infrequent use can result in difficult starting andmoisture condensation problems. This moisture is aresult of the engine not being run long enough toreach normal operating temperature. In extremecases, water may be deposited in the oil. If this hap-pens, severe engine damage can result. To preventthis possibility, run the generator set under load atleast one hour per week.
Exercising for one long period each week is betterthan several shorter periods of operation. Do NOToperate the set for long periods at no load.
LOW TEMPERATURE/HIGH ALTITUDEOPERATION
1. Use the correct SAE oil rating for the currenttemperature conditions. Change the oil onlywhen it is warm. See Table 1.
2. Use No. 1 diesel fuel for temperatures lowerthan 32° F (0° C) or for all temperatures if alti-tude is above 5000 feet (1500 m). The fuelshould have a cetane rating of at least 45.Shorten the oil change interval by half if the sul-fur content of the fuel is higher than 0.5%.
EXTREMELY DUSTY OR DIRTYCONDITIONS
If running the genset in extremely dusty or dirty en-vironments, do the following:
• Keep genset and radiator cooling surfacesclean.
• Service the air cleaner more frequently (as nec-essary).
• Change crankcase oil every 50 operatinghours.
• Clean the generator as necessary. See Mainte-nance Procedures.
11
Maintenance Schedule
Following the maintenance schedule and using thegenerator set properly will result in longer gensetlife, better performance, and safer operation. Per-form each maintenance procedure at the time peri-od indicated or after the number of operating hoursindicated, whichever comes first. Refer to Mainte-nance Procedures for instructions.
NOTE: Many of these procedures are best performedby an authorized Onan service center. If you are at allin doubt about your ability to perform genset mainte-nance, have the Onan service center nearest youperform these tasks.
Consult an Onan service center if the generator setwill be subjected to extremely hot or dusty condi-tions; a more frequent maintenance schedule maybe necessary. Log all service and maintenance forwarranty support (see Maintenance Record).
Accidental starting of the generatorset during maintenance can cause severe per-sonal injury or death. Disconnect both genera-tor set starting battery cables, before perform-ing maintenance. Remove the negative (-) cablefirst to reduce the risk of arcing.
TABLE 4. PERIODIC MAINTENANCE SCHEDULE
SERVICE TIMEDaily Weekly Monthly 6 Months Yearly
or or or or orafter after after after after
SERVICE THESE ITEMS 8 hours 50 hours 100 hours 250 hours 500 hoursInspect set x1
Check oil level xCheck coolant level xCheck fuel level xCheck air cleaner dust cap (clean if required) x3 xCheck battery charging system xCheck drive belt tension x4
Clean out spark arrester xCheck battery specific gravity xChange crankcase oil and filter x2
Drain water/sediment from fuel filter xCheck anti-freeze xClean generator assembly xDrain sediment from fuel tank x5
Clean crankcase breather x3
Check fuel shut-off linkage xChange fuel filter element xCheck genset brushes x6
Change air cleaner element x3
Clean cooling system x
1 - Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visuallywith genset running and repair any leaks immediately.
2 - Perform after first 35 hours of operation on new genset.3 - Perform more often in extremely dusty conditions.4 - Visually check belts for evidence of slippage.5 - Drain one cup of fuel to remove water and sediment.6 - To be performed by authorized service technician.
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Maintenance Procedures
GENERATOR SET INSPECTION
Inspect the generator set daily or after every eighthours of operation, whichever comes first. Checkthe exhaust, fuel, and DC electrical systems as de-scribed below. Also check the mechanical conditionof the set.
Engine Gauges (Remote Installation)
Check these gauges while the set is running.
Oil Pressure Gauge: Oil pressure should be 40 to60 psi (276 to 414 kPa) when the engine is at oper-ating temperature.
Coolant Temperature Gauge: Coolant tempera-ture should be 165° to 195° F (74° to 91° C), de-pending on load and ambient temperature.
DC Voltmeter: Battery voltage during operationshould be 14 to 15 volts.
Exhaust System
With the set running, inspect the entire exhaust sys-tem including the exhaust manifold, exhaust elbow,muffler and exhaust pipe. Visually and audiblycheck for leaks at all connections, welds, gaskets,and joints. If any leaks are detected, shut down thegenset and do not operate until corrected. Re-place corroded exhaust components before leaksoccur.
Inhalation of exhaust gases can re-sult in severe personal injury or death. Inspectexhaust system audibly and visually for leaksdaily. Repair all leaks immediately.
Fuel System
With the set running, inspect the fuel supply lines,return lines, filters, and fittings for leaks. Check flex-ible sections for cuts, cracks and abrasions. Seethat the fuel lines do not rub against anything thatcould break them. Replace worn fuel line compo-nents before leaks occur.
Fuel leakage will create a fire hazardwhich can result in severe personal injury ordeath if ignited. While checking for leaks, do notsmoke or allow any spark, flame, pilot light orother ignition source in the area. If any leaks aredetected, have them corrected immediately.
DC Electrical System
With the genset off, check the battery terminals forclean and tight connections. Loose or corrodedconnections create resistance which can impedestarting. Clean and reconnect loose battery cables.Always disconnect the negative (- ) battery cablefirst and connect it last, to reduce the possibility ofarcing.
Ignition of explosive battery gasescan cause severe personal injury. Do notsmoke. Wear goggles, protective rubber glovesand apron when servicing batteries.
Mechanical
Check for any signs of mechanical damage. Startthe set and listen for any unusual noises that mayindicate mechanical problems. Have any problemscorrected immediately.
Check the mounting fasteners to make sure the setis secure in its compartment. If an under-floor hous-ing is used, make sure that the set is secured to thehousing. Check the condition of the housing com-ponents and make sure they are secure to the ve-hicle.
Make sure that the generator set air inlet and outletareas are not blocked with debris.
Clean the generator set whenever dust and dirt be-gin to accumulate. Dust and dirt can usually be re-moved with a damp cloth. Steam cleaning may beneeded to remove road contaminants. Do not cleanthe genset while the engine is running. Protect thegenerator, air cleaner, control panel, and electricalconnections from cleaning solvents. Cleaning sol-vents can damage electrical connectors.
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OIL AND FILTER CHANGE
The engine oil was drained from the crankcase be-fore shipment. Before the initial start, fill the lu-brication system with the recommended oil.See Specifications for oil capacity.
Change the oil and filter at the intervals listed inTable 4. Use oil that meets the API classification andSAE viscosity grade indicated in the previous sec-tion.
Engine Oil Change
Run the engine until thoroughly warm. Stop the en-gine, open the drain valve (Figure 5) and drain theoil into a container. When completely drained, closethe valve and refill the crankcase with new oil.
Hot crankcase oil can cause burns ifit is spilled or splashed on skin. Keep fingersand hands clear when removing the oil drainplug and wear protective clothing.
State and federal agencies have de-termined that prolonged contact with used en-gine oil can cause cancer or reproductive toxic-ity. When adding, changing or working withused oil, take care not to breathe, ingest orcome into excessive contact with these sub-stances. Wash hands after use. W ear protectiveclothing and equipment. Provide adequate ven-tilation.
Oil Filter Change
Spin off the oil filter and discard it. Thoroughly cleanthe filter mounting surface. Apply a thin film of oil tothe filter gasket, and spin the filter on until the gasketjust touches the mounting pad. Then turn an addi-tional 3/4 turn. Do not over-tighten the filter.
With oil in the crankcase, start the set and check forleakage around the filter gasket. Tighten the filteronly enough to eliminate leaks.
FIGURE 5. ENGINE OIL
OIL FILL
DRAIN VALVE OIL FILTEROIL DIPSTICK
ALTERNATE OIL FILL AT TOPOF VALVE COVER (HIDDEN)
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COOLING SYSTEM
The cooling system is drained before the set isshipped. It must be refilled before the genset isoperated. Cooling system capacity is listed inSpecifications.
Coolant Requirements
Engine coolant must inhibit corrosion and protectagainst freezing. A 50/50 mixture of ethylene glycolanti-freeze and water is recommended for normaloperation and storage. Use only a reliable brand ofanti-freeze that contains a rust and corrosion inhibi-tor. The anti-freeze should not contain a stop-leak additive.
Do not exceed a 50/50 mixture of ethylene glycoland water. A higher proportion of ethylene glycol willalter the heat transfer properties of the coolant. A50/50 mixture will provide freeze protection to-34° F (-37° C).
Water used for engine coolant should be clean, lowin minerals, and free of corrosive chemicals. Usedistilled or soft water if available. Avoid the use ofwell water, which may contain minerals that canclog the heat exchanger core and reduce cooling ef-ficiency.
Filling the Cooling System
Verify that all drain cocks are closed and all hoseclamps are secure. Remove the cooling systempressure cap and slowly fill the cooling system withthe coolant mixture.
Exceeding the recommended fillrate can cause incomplete filling of the engineblock, leading to engine damage during warm-up. Always follow the recommended fill proce-dure.
Add coolant to the recovery tank (or separate ex-pansion tank if equipped) to the full-cold level.
Start the engine, then remove the pressure cap andmonitor the coolant level. As trapped air is expelledfrom the system, the coolant level will drop. Addcoolant to replace it. Replace the pressure capwhen the coolant level is stable.
Coolant Level
Check the coolant level at the intervals specified inthe Periodic Maintenance Schedule. Check by ob-serving the coolant level in the recovery tank (orseparate expansion tank if equipped) when the sys-tem is cold. See Figure 6 for a typical cooling sys-tem. Engine coolant is at the proper level when therecovery tank level is between FULL and LOWmarks.
Coolant in a warm engine is underpressure and can flash to steam causing severeburns if the radiator cap or drain cock areopened. Let the engine cool down before open-ing the radiator cap or drain cock.
The high engine temperature cutoffwill shut down the engine in an overheat condi-tion only if the coolant level is sufficiently highto physically contact the shutdown switch.Loss of coolant will allow engine to overheatwithout protection of shutdown device, therebycausing severe damage to the engine. It istherefore imperative that adequate engine cool-ant levels be maintained for operational integri-ty of the cooling system and engine coolantoverheat shutdown protection.
Flushing and Cleaning
Once a year, drain, flush and refill the cooling sys-tem with new coolant. To drain the system, open theradiator coolant drain and the cylinder block drainon the the rear (non-service access) side of engine.See Figure 6.
Contact with hot coolant can causesevere burns. Do not bleed hot, pressurizedcoolant from a closed cooling system.
15
Chemical Cleaning: Rust and scale slow heat ab-sorption and can block coolant flow. Clean the cool-ing system if rust and scale have collected on theengine water jacket or in the heat exchanger. Use agood cleaning compound and follow its instructions.
Flushing: After cleaning, or before filling the sys-tem with new coolant, drain the system and fill withclean water. Run the genset for 10 minutes, thendrain the system completely. Refill with the coolantmixture.
Never pour hot water into a cold en-gine or cold water into a hot engine. Doing socan crack the head or the cylinder block. Do notoperate the unit without water for even a fewminutes.
Thermostat
If the engine overheats or does not reach and main-tain a minimum operating temperature, have thethermostat removed and tested. Replace the ther-mostat with the gasket if necessary. See the ServiceManual for instructions.
Pressure Cap
Closed cooling systems use a pressure cap to in-crease the boiling point of the coolant and allowhigher operating temperatures. Replace the pres-sure cap every two years, or sooner if it malfunc-tions.
FIGURE 6. COOLING SYSTEM COMPONENTS
HOSE IS CONNECTED ATRADIATOR CAP
RECOVERYTANK
BRACKET
OVERFLOWHOSE
RADIATOR COOLANT DRAIN(ON LOWER REAR CORNER OF
RADIATOR)
CYLINDER BLOCK COOLANT DRAIN(REAR OF GENSET ENGINE BLOCK SHOWNWITHOUT SHEET METAL, EXHAUST PARTS)
G1250s
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FAN BELT
A loose fan belt can cause the engine to overheat.The belt tension must be correct for the set to runwell.
First, remove the generator set’s starting batterycables (negative [-] cable first).
Accidental starting of the set cancause severe personal injury or death. Stop thegenerator set and disable it by disconnectingthe starting battery cables (negative [-] cablefirst) when maintaining or repairing the engine,controls, or generator.
To reach the fan belt, remove the belt guard from thefront of the set. Do not operate the genset withoutthe belt guard in place.
To adjust the belt, loosen the bolt that passesthrough the long slot in the alternator mountingbracket and slide the alternator until the tension isright. See Figure 7.
Belt tension is correct when a finger pressure of 22pounds (10 kg) at the middle of the belt deflects itabout 0.4 inch (10 mm).
CS-1239
ADJUSTTENSION
HERE
ALTERNATOR
PUMP/FAN
PULLEY
FIGURE 7. FAN BELT ADJUSTMENT
FUEL SYSTEM
Ignition of fuel can cause seriouspersonal injury or death by fire or explosion. Donot permit any flame, cigarette, pilot light, sparkor other igniter near the fuel system.
Fuel Recommendation
Use ASTM 2-D (No. 2 Diesel) or ASTM 1-D (No. 1Diesel) fuel with a minimum Cetane number of 45.Number 2 diesel fuel gives the best economy andperformance under most conditions. Use number 1diesel fuel when ambient temperatures are below32° F (0° C), and during long periods of light engineload.
Use low sulfur content fuel which has a cloud pointat least 10 degrees below the lowest expected fueltemperature. (Cloud point is the temperature atwhich wax crystals begin to form in diesel fuel.)
Fuel Handling Precautions
Prevent dirt, water or other contaminants from en-tering the fuel system. Filter or strain the fuel as thetank is filled.
Due to the precise tolerances of die-sel injection systems, dirt or water in the systemwill cause severe damage to both the injectionpump and the injection nozzles. It is extremelyimportant the fuel be kept clean and water free.
Condensation (water) can cause clogging of fuel fil-ters as well as freezing problems. Water mixing withthe sulfur in the fuel forms acid which can corrodeand damage engine parts.
Low fuel in the tank promotes condensation. Inwarm weather, the fuel tank cools at night quickerthan the fuel. If the fuel level is low, the upper portionof the tank will cool more rapidly, forming condensa-tion. In cold weather, the warm fuel returning fromthe injectors heats the fuel in the supply tank. If thefuel is low, condensation may form on the upper partof the tank. To avoid condensation, fill the fueltank every time the genset is used.
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Low Pressure Fuel System
The electric fuel pump, fuel filter and injection pumpinlet comprise the low pressure fuel system. SeeFigure 8. These components are normally primed(purged of trapped air) at set installation. Be sure tocheck the fuel level in the tank and that the shutoffvalve is open.
NOTE: Priming the fuel system and replacing the fuelfilter are procedures that are best performed by anOnan service technician. If you are at all in doubtabout these procedures, consult an authorized Onanservice center.
Fuel Filter
The wrong fuel or dirty fuel will shorten the life of thefuel filter. See Maintenance Schedule for the filterchange interval.
Dirt or water in the system will causesevere damage to both the injection pump andthe injection nozzles. It is extremely importantthat the fuel be kept clean and free of water.
If the engine shows signs of fuel starvation (reducedpower or surging), the fuel filter should be changed.This involves bleeding the fuel system of trappedair.
Bleeding the system means loosening the fittings ofthe low-pressure fuel lines one by one, and crank-ing the electric fuel pump to drive out trapped air.This procedure must be done by an Onan ser-vice center or a professional diesel technician.
High Pressure Fuel System: The injection pump,fuel injection lines and fuel injectors are the highpressure fuel system. See Figure 8. The high-pres-sure system is self-priming; trapped air is forced outthrough the injection nozzles.
FUELINLET
FUELFILTER
FIGURE 8. FUEL SYSTEM
FUELPUMP
FUEL RETURNLINE FITTING
INJECTION LINECONNECTING NUT
INJECTION PUMPFUEL INLET
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AIR CLEANER
The air cleaner element is a dry type and shouldnever have oil applied to it. Avoid touching the ele-ment except when cleaning it. Instructions forcleaning the element are on a label attached to theelement. Change the element yearly, or more oftenin extremely dusty conditions.
FIGURE 9. AIR CLEANER ASSEMBLY
AIR CLEANERBAND W/CUSHION
AIR CLEANERELEMENT
VALVE WINGBOLT
INLETOUTLET
BATTERY CARE
Service the battery at the intervals shown in themaintenance schedule. Check the electrolyte levelmore frequently during hot weather.
Batteries present the hazard of ex-plosion that can result in severe personal inju-ry. Do not smoke or allow any fire, flame, spark,pilot light, arc-producing equipment or otherignition sources around the battery area. Do notdisconnect battery cables while the generatorset is cranking or running because explosivebattery gases could be ignited.
Battery electrolyte can cause se-vere eye damage and burns to the skin. Weargoggles, rubber gloves and a protective apronwhen working with batteries.
1. Keep the battery case clean and dry.
2. Make certain that the battery cable connec-tions are clean and tight. Use a terminal pullertool to remove the battery cables.
Remove corrosion from the battery terminalconnections. Wash the terminals with an am-monia solution or a solution consisting of 1/4pound (about 100 grams) of baking soda in1 quart (about 1 liter) of water. Be sure the ventplugs are tight to prevent cleaning solution fromentering the cells. After cleaning, flush the out-side of the battery and the surrounding areaswith clean water.
3. Identify the cable as positive (+) or negative (-)before making the battery connections. Alwaysconnect the negative (-) cable last, to reducethe risk of arcing.
4. Maintain the electrolyte level by adding distilledwater. Fill each cell to the split-level marker inthe battery. The water component of the elec-trolyte evaporates, but the sulfuric acid compo-nent remains. For this reason, add water, notelectrolyte to the battery.
5. Use a battery hydrometer to check the specificgravity of the electrolyte in each battery cell(Figure 10). Charge the battery if the specificgravity measures less than 1.215. Do not over-charge the battery. Stop charging the batterywhen the electrolyte specific gravity reaches1.260, at approximately 80° F (27° C).
FIGURE 10. BATTERY CHECK
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CRANKCASE BREATHER
Clean the crankcase breather element at thescheduled intervals, using the following procedure(see Figure 11).
1. Remove the cap nuts and gaskets from the topof the valve cover. Carefully remove the cover.Avoid damaging the gasket.
2. From inside the cover, remove two machinescrews securing the breather element, platesand shield.
3. Clean the element in a suitable solvent. Dry theelement, then saturate with engine oil before re-placing.
Many cleaning solvents presenta hazard of severe personal injury or death.Follow the manufacturer’s instructions andproceed with care.
4. If necessary, clean other breather componentsin solvent before reassembling.
CAP NUT ANDGASKET
FIGURE 11. CRANKCASE BREATHER
FILLER CAPAND GASKET
ELEMENT PLATE 1
BREATHER ELEMENT
OIL SHIELD
VALVE COVER
GASKET
BREATHERPIPE JOINT
BREATHERPIPE
ELEMENT PLATE 2
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AC GENERATOR
Generator Brushes
The generator should be inspected for brush wearand cleaning as required per the Periodic Mainte-nance Schedule. This procedure should be per-formed by an authorized Onan service technician.
Accidental starting of the generatorset can cause severe personal injury or death.Stop the generator set and disable by discon-necting the starting battery cables (negative [-]cable first) before inspecting the generator.
Generator Bearing
Inspect the bearing for evidence of outer case rota-tion every 1000 hours of use. The bearing should bereplaced every five years because the bearinggrease gradually deteriorates due to oxidation. Seethe Service Manual for the bearing replacementprocedure. If the generator requires major repair orservice, contact an authorized Onan dealer or dis-tributor.
CLEANING THE GENERATOR SET
Clean the generator set at least once every sixmonths. Dust usually can be removed with a dampcloth. Some road contaminants may require steamcleaning. Do not steam clean the generator setwhile the engine is running. When cleaning, protectthe area so spray is not directed into the generator,
air cleaner, control box, fuel solenoid, or electricalconnections. Do not clean with solvents; they candamage electrical connectors.
MUFFLER/SPARK ARRESTER
The exhaust spark arrester mounted inside the muf-fler is necessary for safe operation . It must be peri-odically cleaned out for maximum efficiency, and tomeet Forest Service requirements (RV use). Seethe maintenance schedule for cleaning intervals.
To clean the spark arrester, remove the 1/8 inchpipe plug from the bottom of the muffler. Run thegenerator set with a full load for five minutes. Stopthe generator set and allow the muffler to cool. Re-place the pipe plug in the muffler. See Figure 12.
FIGURE 12. EXHAUST MUFFLER
PIPEPLUG
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Generator Set Storage
OUT-OF-SERVICE PROTECTION
The lubricating qualities of No. 2 diesel fuel shouldprotect the cylinders of a diesel engine at least 30days when the set is not being run. For storage lon-ger than 30 days, proceed as follows:
1. Exercise the genset (see Operating Recom-mendations) until the engine is at operatingtemperature.
2. Shut down the genset and disconnect the bat-tery cables (negative [-] cable first). Store thebattery in a cool, dry place and connect to atrickle charger once every 30 days to maintainfull charge.
Battery electrolyte can causesevere eye damage and burns to the skin.Wear goggles, rubber gloves and a protec-tive apron when working with batteries.
3. Drain the crankcase oil while still warm. Re-place the oil filter. Refill the crankcase and at-tach a tag indicating oil viscosity.
4. Check the coolant level. Add more coolant iflow. If freezing temperatures are possible, testthe coolant mixture.
5. Plug the exhaust outlet to prevent entrance ofmoisture, bugs, dirt, etc.
6. Clean and wipe the entire genset. Lightly coatparts that may rust with grease or oil.
Returning the Genset to Service
See Maintenance Procedures for specific mainte-nance procedures.
1. Remove the plug from the exhaust outlet.
2. Check the tag on oil base and verify that oil vis-cosity is still correct for existing ambient temper-atures.
3. Clean and check the battery. Measure the elec-trolyte specific gravity with a hydrometer (1.260@ 80° F [27° C]) and verify the proper level. Ifthe specific gravity is low, charge the battery un-til the value is correct. If the level is low, add dis-tilled water and charge until the specific gravityreading is correct. DO NOT OVERCHARGE.
Battery electrolyte can causesevere eye damage and burns to the skin.Wear goggles, rubber gloves and a protec-tive apron when working with batteries.
4. Prime the fuel system.
5. Connect the starting battery, negative (-) cablelast.
6. Remove all loads before starting the genset.
7. After starting, apply load of at least 50 percentrated capacity.
8. Check all gauges for normal readings. Gensetis ready for operation.
22
Troubleshooting
AC CONTROL
The AC control consists of the line circuit breakersconnected between the generator output and theload. On the single-phase genset, two 45-ampbreakers are mounted on the side of the AC controlbox on the set. The three-phase genset uses athree-pole 35-amp breaker.
If the breaker trips, the electrical load is too great forthe generator set. This may be caused either byrunning too many appliances at once, or by a shortcircuit.
Consult Wattage Requirements to determine thewattage needed by typical appliances.
DC CONTROL
The DC control has a number of sensors that con-tinuously monitor the engine for abnormal condi-tions such as low oil pressure and high coolant tem-perature. If any one of these conditions occur, thecontrol stops the engine. See Figure 13. If a majorproblem is indicated, contact an Onan dealer or dis-tributor for help or service.
Fault Reset Breaker
The control panel fault reset breaker will trip for anyone of the fault conditions described separately be-low. The white breaker reset button pops out about1/4 inch (6mm) when a fault occurs. Locate theproblem and make the necessary corrections be-
fore resetting breaker and starting the generatorset. All fault shutdowns except overspeed aredelayed 5 seconds to avoid nuisance tripping.
Low Oil Pressure
Remove dipstick and check oil level. If low, add oil tobring level up to the Full mark. Inspect engine exte-rior for leaks and repair as necessary. The oil pres-sure switch actuates the fault circuit if pressuredrops below 9 psi (62 kPa).
Crankcase pressure can blow outhot oil and cause SEVERE burns. Do NOT checkoil while the generator set is operating.
High Coolant Temperature
If fault occurred during operation, observe CoolantTemperature Gauge (option) for indication of tem-perature over 230° F (110° C). The coolant thermo-stat switch closes at this temperature and actuatesthe fault circuit.
Check coolant level in radiator after allowing engineto cool down. See that the pump belt is OK and hasproper tension. Also check cooling system cleanli-ness (freedom from contaminants, rust, sludgebuildup, etc.).
Contact with hot coolant can resultin SEVERE burns. Allow cooling system to coolbefore releasing pressure and removing radia-tor cap or release of hot coolant can result.
23
OILPRESSURE
SWITCH(LATCH)
OILPRESSURE
SWITCH(SHUTDOWN)
OILPRESSURE SEND−
ER(METER)
COOLANTTEMPERATURE
SWITCH(SHUTDOWN)
REAR OF GENERATOR SET
COOLANTTEMPERATURE
SENDER(METER)
SERVICE ACCESS SIDE (FRONT) OF GENERATOR SET
NOTE: GUARDS, BRACKETS, SHEET METAL PARTS NOT SHOWN
FIGURE 13. OIL AND COOLANT SENSORS
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Specifications
GENERATOR
Type 4-pole revolving field, brush-type, reconnectible. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standby ratings: 50 Hz
Standard three-phase: 8.0 kW, three phase, 0.8 power factor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 kW, single phase, 1.0 power factor
Standby ratings: 60 HzStandard single-phase: 10.0 kW, single phase, 1.0 power factor. . . . . . . . . . . . . . . . . . . . . . . . . . Standard three-phase: 10.0 kW, three phase, 0.8 power factor. . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.7 kW, single phase, 1.0 power factorExtended-stack three-phase: 10.0 kW, three phase, 0.8 power factor. . . . . . . . . . . . . . . . . . . . . .
10.0 kW, single phase, 1.0 power factorExtended-stack three-phase (heavy-duty): 10.0 kW, three phase, 0.8 power factor. . . . . . . . . .
10.0 kW, single phase, 0.8 power factorFrequency regulation under varying load:
50 Hz ±5 percent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hz ±5 percent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage regulation under varying load: 3 Hz maximum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Random voltage variation: ±1 percent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE—KUBOTA V1305-B(E)
Engine type Vertical, water-cooled, 4-cycle diesel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of cylinders 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bore and stroke 76 x 73.6 mm (2.99 x 2.90 inch). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Total displacement 1335 cm3 (81.46 cubic inch). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Combustion chamber Spherical type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine speed (50 Hz) 1500 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine speed (60 Hz) 1800 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel 2-D Diesel (ASTM D975). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel inlet 5/16 inch hose fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel return 3/16 inch hose fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum fuel pump lift (self-priming) 914.4 mm (36 inch) in 15 sec.. . . . . . . . . . . . . . . . . . . . . . . . . . Maximum fuel consumption: Full load 3.78 L/h (1.0 gph). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Half load 2.12 L/h (.56 gph). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust outlet size, ID 1-1/4 inch NPT, male. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery requirement
Voltage 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold cranking amps (0° F [-18° C]) 425. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant capacity: 4.7 liters (5 quarts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating oil capacity (with oil filter) 4.7 liters (5 quarts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Information for California Genset Users
These gensets meet the requirements of Californi-a’s Exhaust Emissions Standards for 1995 and laterfor Utility and Lawn and Garden Equipment En-gines.
As a California user of these gensets, please beaware that unauthorized modifications or replace-ment of fuel, exhaust, air intake, or speed controlsystem components that affect engine emissionsare prohibited. Unauthorized modification, removalor replacement of the genset label is prohibited.
You should carefully review Operator (Owner),Installation and other manuals and information youreceive with your genset. If you are unsure that theinstallation, use, maintenance or service of yourgenset is authorized, you should seek assistancefrom an authorized dealer.
California genset users may use Table 5 as an aid inlocating information related to the California Air Re-sources Board requirements for emissions control.
TABLE 5. EMISSIONS CONTROL INFORMATION
Genset Warranty InformationThe California emissions control warranty statement is located inthe same packet of information as this manual when the engine isshipped from the factory.
Engine Fuel Requirements The engine is certified to operate on diesel fuel. See FUEL REC-OMMENDATIONS in Pre-Start Checks.
Engine Lubricating Oil Requirements See ENGINE OIL RECOMMENDATIONS in Pre-Start Checks.
Engine Adjustments High Idle Speed. This is a service procedure requiring trainedpersonnel and proper tools. See the Service Manual.
Engine Emission Control System The engine emission control system consists of engine designand precision manufacture. (IFI)
26
How to Obtain Service
When you need parts or service for your gensetcontact the nearest authorized dealer or distributor.Onan has factory-trained representatives to handleyour needs for genset parts and service. To locatethe nearest authorized distributor:
1. Check the North American Sales and ServiceDirectory (F-118) and the International Salesand Service Directory (IN-1013) supplied withyour Onan genset. These directories list autho-rized distributors who will assist you in locatingthe nearest authorized dealer.
2. Consult the Yellow Pages. Typically, our distrib-utors are listed under:
GENERATORS - ELECTRIC,ENGINES - GASOLINE OR DIESEL, orRECREATIONAL VEHICLES - EQUIPMENT,PARTS AND SERVICE.
3. Call 1-800-888-ONAN for the name and tele-phone number of the nearest Cummins/Onanor Onan-only distributor in the United States orCanada. (This automated service utilizes
touch-tone phones only). By calling this num-ber you can also request a directory of autho-rized RV servicing dealers: RV Sales and Ser-vice Directory F-919.
To get service, contact the authorized dealer or dis-tributor nearest you, explain the problem and makean appointment. If you have difficulty in arrangingfor service or resolving a problem, please contactthe dealer coordinator or service manager at thenearest Cummins/Onan distributor for assistance.
Before calling for service, have the following infor-mation available:
1. The complete genset model number and serialnumber.
2. The date of purchase.
3. The nature of the problem.
Improper service or replacement ofparts can result in severe personal injury, death,and/or equipment damage. Service personnelmust be qualified to perform electrical and/ormechanical service.
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Maintenance Record
Use the following table to keep a record of all periodic and unscheduled maintenance and service. See Mainte-nance Schedule.
DATEHOURMETER
READINGMAINTENANCE OR SERVICE PERFORMED
Record the name, address, and phone number of your authorized Onan service center.
Cummins Power Generation1400 73rd Avenue N.E.Minneapolis, MN 55432763-574-5000Fax: 763-528-7229
Cummins and Onan are registered trademarks of Cummins Inc.
