Operator`s Manual
Contents
1. Be sure fuel supplies have a positive shutoff valve GASOLINE AND LPG FUEL MAY BE ACCIDENTALLY IG NITED BY ELECTRICAL SPARKS presenting the hazard of fire or explosion which can result In severe personal in jury or death When installing the generator set e Do not tie electrical wiring to fuel lines Do not run electrical lines and fuel lines through the same compartment openings e Keep electrical and fuel lines as far apart as possible Place a physical barrier between fuel lines and electrical lines wherever possible e If electrical and fuel lines must pass through the same com partment opening make certain that they are physically separated by running them through individual channels or by passing each line through a separate piece of tubing e DO NOT SMOKE while servicing batteries Lead acid bat teries emit a highly explosive hydrogen gas that can be ig nited by electrical arcing or by smoking EXHAUST GASES ARE DEADLY e Never sleep in the vehicle with the generator set running un less vehicle is equipped with an operating carbon monoxide detector Provide an adequate exhaust system to properly expel dis charged gases Inspect exhaust system daily for leaks per the maintenance schedule Ensure that exhaust manifolds are secure and not warped Do not use exhaust gases to heat a compartment e Be sure the unit is wall ventilated MOVING PARTS CAN CAUSE SEVERE PERSONAL IN JURY OR DE2. 4 1 mI eM C CES 4 1 Spark AITestof ciii ooo dE ARATRI OE VA NV TO bia a re UE 4 1 ENGNG ON TTC 4 1 Periodic Maintenance 4 2 Battery ee bu Eee o ud ea Moo ee ES 4 4 Governor Tm 4 4 AICFIISE DRE ER EAE TRE PA EE E E 4 4 PUG FIO cou eor b RUPEE exa V ea E 4 5 EM oS 4 6 Cleaning Carburetor Combustion Chamber 4 6 Cleaning the Generator 4 7 Inspect and Clean Engine internal 4 7 Redistribution or publication of this document by any means is strictly prohibited Section 1 Introduction ABOUT THIS MANUAL This manual covers the operation and maintenance of the BGD and NHD commercial mobile generator sets For more information see these publications Electrical Mechanical Fundamentals publication 932 0408 HOW TO OBTAIN SERVICE When the set needs service call an authorized service center and give them the complete model number and serial number listed on the generator set nameplate Factory trained parts and service centers can handle all service needs The Parts and Service Center Directory publication F 115 included lists the nearest center Onan Genera
3. Operator s Manual Model BGD and NHD Generator Sets Printed in U S A 965 0129 Safety Precautions Before operating the generator set read the Operator s Manual and become familiar with it and the equipment Safe and efficient operation can be achieved only the unit is properiy operated and maintained Many accidents are caused by failure to follow fundamental rules and precautions The following symbols found throughout this manual alert you to potentially dangerous conditions tothe operator service per sonnel or the equipment This symbol warns of immediate haz ards which will result in severe personal injury or death AWARNING This symbol refers to a hazard or unsafe practice which can resuit in severe personal injury or death CAUTION This symbol refers to a hazard or unsafe practice which can result in personal injury or prod uct or property damage FUEL AND FUMES ARE FLAMMABLE Fire explosion and personal injury can result from improper practices DO NOT fill fuel tanks while engine is running Fuel contact with hot engine or exhaust is a potential fire hazard e DONOT SMOKE OR USE AN OPEN FLAME near the gen erator set or fuel tank Fuel lines must be adequately secured and free of leaks Fuel connection at the engine should be made with an ap proved flexible non conductive line Do not use copper pip hk flexible lines as copper will work harden and become
4. Vomiting Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist seek medical atten tion Shut down the unit and do not operate until it has been inspected and repaired Never sleep in vehicle with the generator set running unless the vehicle inierior is equipped with an operating carbon monoxide detector Protection against carbon monoxide inhalation also includes proper exhaust system installation and visual and audible inspection of the complete exhaust system at the start of each generator set operation BEFORE STARTING General Inspection Inspect the set and the entire exhaust system before startup Check for loose and damaged components and fasteners and correct all problem areas Exhaust gas presents the hazard of severe personal injury or death Make certain that all exhaust components work cor rectly and are secure Do not start the set while itis connected to a load First make certain that any output switching device is in the Utility position and that the vehicle AC distribution panel breakers are off open Do not start the set if exhaust gases will not be effectively expelled away from the vehicle Make sure that the vehicle is not parked in high grass or brush See Starting and Stopping in this section Fire can cause severe personal injury or death Do not operate the generator set when the vehicle is parked
5. CAUTION alternating unleaded and leaded regular gasoline unless lead deposits are removed from the cylinder head area before switching to unleaded gasoline LPG Models liquid and vapor withdrawal Use commercial propane or HD 5 grade LPG in a mix ture of atleast 90 percent propane Propane fuels other than HD 5 may contain more than 2 5 percent butane and may cause poor engine starting in low temperatures below 32 F or 0 C A manual shutoff valve must be mounted on the propane fuel supply tank Open this valve fully when running the set to make certain that the excess flow valve will close if the propane fuel line is broken STARTING AND STOPPING This section describes starting and stopping proce dures For the first startup of a new set see Break in Procedure in this section 1 Movethe start stop switch set mounted or remote to START Release the switch when the set starts 2 Let the unit warm up before switching in the load During warmup make sure that the set runs smoothly 3 Switch the load into the circuit by closing a breaker atthe distribution panel See Section 2 of this man ual for set load ratings 3 2 Continuous generator set over ACAUTION loading can cause high operat ing temperatures that could damage the generator windings Keep the load within ihe nameplate rating 4 To stop the set remove the load and let the unit run three to five minutes to cool down Then move the start st
6. source 5 Remove the vehicle negative battery ground cable and the generator set negative ground cable from their batteries 6 Close the generator set fuel system shutoff valves and all other fuel shutoff valves LP gas presents the hazard of AWARNING fire or explosion which can result in severe personal injury or death Eliminate all sources of ignition such as pilot lights spark ing electrical equipment flames lit cigarettes etc before purging the fuel system Provide adequate ventilation to dissipate LP gas as it is released 7 Open the section of flexible fuel line at the solenoid valve just enough to let the gas escape slowly 8 Disconnectthe fuel supply hose from the carburetor and hold it clear of the set 9 Press and hold the primer button on the regulator to release LP gas from the fuel system When gas can no longer be heard escaping from the open end of the fuel supply hose reconnect the hose to the carburetor and move to the procedures described in LPG Fuel Filter Cleaning Procedure in this section 4 5 LPG Fuel Filter Cleaning Procedure 1 Remove the four capscrews and lock washers that hold the filter bowl to the filter body See Figure 4 5 FILTER ELEMENT 5252 ac FILTER MET BODY 2 GASKETS FILTER BOWL FS1614 FIGURE 4 5 LIQUID LPG FUEL FILTER 2 Separate the filter bowl from the filter body and discard the O ring seal 3 Remove the nut an
7. ATH e Before starting work on the generator set disconnect batter ies This will prevent accidental arcing e Keep your hands away from moving parts e Make sure that fasteners on the generator set are Tighten supports and clamps keep guards in position over fans drive belts etc P not wear loose clothing or jewelry while working on gen erator sets Loose clothing and jewelry can become caught in moving parts Jewelry can short out electrical contacts and cause shock or burning e adjustment must be made while the unit is running use ex treme caution around hot manifolds moving parts etc ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH e Disconnect starting battery before removing protective shields or touching electrical equipment Use rubber insula tive mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment Do not wear damp clothing particularly wet shoes or allow skin sur faces to be damp when handling electrical equipment e Use extreme caution when working on electrical compo nents High voltages can cause injury or death e Follow all state and local electrical codes Have all electrical installations performed by a qualified licensed electrician Tag open switches to avoid accidental closure e DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM Hazardous volt ages canflow from the generator set into the util
8. ITCH VOLTAGE REGULATOR NEGATIVE BATTERY CABLE OIL FILL AND CONNECTION DIP STICK NON EXTENDED SHAFT MODELS 4 NX AY FAN Vas HOUSING 22 OIL FILTER POWER OUTPUT LEADS MOUNTING TRAY ALTERNATE LOCATION FOR NE CIRCUIT CABLE CONNECTION POSITIVE FUEL PUMP AND FUEL INLET BATTERY CABLE CONNECTION IGNITIONJCHOKE ED CIRCUIT FUSE BGD NHD Liquid LPG 5 AMP CARBURETOR SPARK BOARD FUSE ADJUSTMENTS IGNITION PLUG spank _ AIR COIL START STOP pLuUG CLEANER BRACKET WITH RELAYS AND SWITCH BATTERY CHARGING VOLTAGE REGULATOR NEGATIVE BATTERY CABLE OIL FILL AND CONNECTION DIP STICK NON EXTENDED SHAFT MODELS zT Te OIL FILTER LINE CIRCUIT 2 BREAKERS MOUNTING TRAY 2 POWER OUTPUT ALTERNATE LOCATION FOR LEADS NEGATIVE BATTERY NOT SHOWN CABLE CONNECTION SIE DRIN FUEL FILTER AND Basilii Nee SOLENOID ASSEMBLY M1504 17s CONNECTION REMOTE START CABLE CONNECTION FIGURE 2 1 BGD NHD GENERATOR SETS 2 3 Redistribution or publication of this document by any means is strictly prohibited Section 3 Operation EXHAUST GAS IS DEADLY Exhaust gases contain carbon monoxide an odorless and colorless gas Carbon monoxide is poisonous and can cause unconsciousness and death Symptoms of carbon monoxide poisoning can include e Dizziness e Nausea e Headache e Weakness and Sleepiness e Throbbing in Temples e Muscular Twitching
9. Load connected 4 Remove load CRANKS BUT WON T START 1 Fuel below genset pick up 1 Add fuel level in tank 2 Fuel supply shutoff valve closed 2 Fully open fuel supply valve 3 Carbon deposits on spark plugs 3 Remove spark plugs and clean 4 Fuse F2 has blown 4 Replace the fuse EXHAUSTING BLACK SMOKE 1 Rich fuel mixture 1 Turn main fuel adjustment in 1 8 turn location of adjustment is shown in Figure 3 1 2 Dirty air filter 2 Replace air filter 3 Choke stuck 3 See authorized representative UNIT RUNS THEN STOPS 1 Out of fuel 1 Refill fuel tank 2 Low oil level 2 Add oil if necessary 3 Excess oil 3 Reduce engine oil level UNIT RUNS BUT SURGES 1 Loose or worn spark plug leads 1 Check security of spark plug leads at spark plugs and ignition coil Replace leads if worn 2 Ignition coil wiring or control 2 Contact an authorized service componenis defective center A hot generator set can cause severe AWARNING burns Always allow the generator set to cool before performing any maintenance or service Redistribution or publication of this document by any means is strictly prohibited Section 4 Maintenance Establish a maintenance and service schedule for the generator set and stick to it Consult an authorized service center if the set will be used in extreme cold heat dust humidity or altitude and shorten the mainte nance intervals K
10. Onan ser vice center SPARK PLUGS A spark plug with heavy combustion deposits can make the generator set misfire run rough or stop when a load is applied When the plugs are removed inspect and regap them Figure 4 6 If a plug is discolored or fouled replace it e Black deposits indicate a rich mixture Wet plugs indicate misfiring gasoline fuel only e Badly or frequently fouled plugs indicate that a major tuneup is needed SPARK PLUG GAP SEE SPECIFICATIONS ES1374 FIGURE 4 6 MEASURING PLUG GAP 4 6 CLEANING THE CARBURETOR AND COMBUSTION CHAMBER WITH ONAN 4C inhalation of chemical sprays can AWARNING cause severe personal injury or death Use safety goggles to protect eyes and a respi rator or painter s mask to prevent inhaling any chemi cal that may spit back from the carburetor during this procedure Also work in a well ventilated area so that other personnel will not inhale any fumes Fumes from this cleaner present the AWARNING hazard of fire or explosion which can cause severe personal injury or death Do not allow any spark flame pilot light lit cigarette or other ignition source near the generator set when perform ing this procedure Keep a fire extinguisher rated ABC near the work area Perform these steps to keep the carburetor and intake manifold clean and to keep carbon deposits off the combustion chamber engine pinging or power loss occur consult an authorized service c
11. ane Supply Pressure Vapor Withdrawal Propane Supply Connection Vapor Withdrawal Propane Supply Connection Liquid Withdrawal Battery Voltage Cold Cranking Amps SAE J537 for Ambients Above Below Freezing Minimum Required Voltage at Starter Motor Terminals During Cranking Battery Charging Voltate at No Load AC Battery Charging Voltate at Full Load AC Maximum Continuous Battery Charging Amperage Trickle Battery Charging Amperage MODEL BGD 204 pounds 92 kg 14 x 25 1 4 x 19 In 856 x 641 x 478 mm 85 sq In 548 sq cm 2 In 51 mm 18 gauge 1 38 In ID rigid steel tubing 3 5 quarts 3 3 L 5 amps slow blow 10 amps 0 025 In 0 64 mm 6 psi 41 kPa 3 Ft 0 9 m 1 4 In ID hose barb 7 14 In 178 356 mm WC 3 4 In NPTF tapping 1 4 In NPTF tapping 12 360 450 14 4 14 6 10 0 5 MODEL NHD 230 pounds 104 kg 14 5 8 x 25 9 16 x 21 1 16 In 371 x 649 x 585 mm 85 sq In 548 sq cm 2 in 51 mm 18 gauge 1 3 8 In ID rigid steel ubing 3 5 quarts 3 3 L 5 amps slow blow 10 amps 0 025 In 0 64 mm 6 psi 41 kPa 3 Ft 0 9 m 1 4 In ID hose barb 7A4 In 178 356 mm WC 3 4 In NPTF tapping 1 4 In NPTF tapping 12 360 450 14 4 14 6 10 0 5 Specifications Cont Gasoline Fueled Sets Rated Power Output Full Load Current 1 Phase Generators At 110 220 Volts At 120 240 Volts Full Load Current 31 Phase Gener
12. ators At 110 220 Volts At 120 240 Volts Gasoline Consumption Under Full Load Under Half Load Under No Load Propane Fueled Sets Rated Power Output Full Load Current 1 Phase Generators At 110 220 Volts At 120 240 Volts Propane Consumption Under Full Load Under Half Load Under No Load MODEL BGD 50 Hertz 60 Hertz 1500 RPM 1800 RPM 4 0 kW 4 5 kW 36 4 18 2 amps 37 5 18 8 amps 21 0 10 5 amps 0 73 gph 2 8 L h 0 53 gph 2 0 L h 0 35 gph 1 3 L h 3 5 kW 31 8 15 9 amps 0 98 gph 3 7 L h 0 65 gph 2 5 L h 0 4 gph 1 5 L h 21 7 10 8 amps 0 8 gph 3 0 L h 0 6 gph 2 3 L h 0 4 gph 1 5 L h 4 0 kW 33 3 16 7 amps 1 3 gph 4 9 L h 0 8 gph 3 0 L h 0 5 gph 1 9 L h These values are for generators having a Series Delta connection 2 2 MODEL NHD 50 Hertz 60 Hertz 1500 RPM 1800 RPM 5 0 kW 6 5 kW 45 5 22 7 amps 26 3 13 2 amps 0 8 gph 3 0 L h 0 57 gph 2 2 L h 0 35 gph 1 3 L h 5 0 kW 45 5 22 7 amps 1 18 gph 4 5 L h 0 78 gph 3 0 L h 0 5 gph 1 9 L h 54 2 27 1 amps 31 3 15 7 amps 1 3 gph 4 9 L h 0 7 gph 2 5 L h 0 4 gph 1 5 L h 6 3 kW 52 5 26 3 amps 1 7 gph 6 4 L h 1 05 gph 4 0 L h 0 65 gph 2 5 L h CARBURETOR BGD NHD EIE GOVERNOR SPARK AIR Gasoline Fuel SPARK BOARDFUSE ADJUSTMENTS PLUG CLEANER BRACKET WITH RELAYS AND PLUG BATTERY CHARGING START STOP SW
13. cylinders etc A fire could result or theg _ set operation cooling noise and vibration may be ad versely affected Keep the compartment floor clean and dry e Do not work on this equipment when mentally or physically fatiguest or after consuming any alcohol or drug that makes the operation of equipment unisafe RV 9 Table of Contents SECTION TITLE PAGE SAFETY PRECAUTIONS Inside Front Cover 1 INTRODUCTION ke UE RU xb ERIS PAN EDUC 1 1 Aboagt This Manual armi ert os ORA 1 1 How to Obtain SerViGe 1 1 2 SPECIFICATIONS oo 2 b eR UC iode ERR UD CHER 2 1 3 OPERATION Sce det oe 3 1 Before Sari iode seed xn EC DERE EET 3 1 Recommended 5 3 2 Starting and Stopping issues eR RR ER TIER PIER 3 2 Break in Procedure 3 2 Operating Condilioris u see duda ec ee E E TAS PE EE 3 2 Generator Set EXerciSg 55 1065 Pos VEN iden one EUER Ma V DES 3 3 Remote CODEOL o bau au CERE E ERCERU DS PIRE 3 3 Out of Service Protection 3 4 Troubleshooting Guide 3 5 4 MAINTENANCE ERE 4 1 General RATER e Ur ep
14. d oil properly Oil Filter Changing Procedure 1 Place an oil pan under the oil filter position on the engine Turn the filter counterclockwise to remove it Coatthe new filter gasket with clean engine oil Turn the new filter clockwise until its gasket just touches the filter mounting base then tighten it another half turn Refer to Section 2 Specifications for engine oil capac ity See Recommended Engine Oil in this section for the right type of oil 4 3 Recommended Engine Oil Use oil with the API American Petroleum institute designa tion SG Oil should be labeled as passing MS Sequence Tests also known as ASTMG 1V Sequence Tests Figure 4 2 shows recommended viscosity and temperatures USE THESE SAE VISCOSITY GRADES 40 CER 50 rs 40 Li TEMPERATURE RANGE YOU EXPECT BEFORE NEXT OIL CHANGE LS1138 20 C 30 20 10 h FIGURE 4 2 SAE VISCOSITY GRADES Oil consumption may be higher with a multigrade oil than with a single grade oil Forthis reason single grade oils are recommended unless wide temperature variations are possible BATTERY CARE To increase battery life perform the following steps Accidental starting of the set can AWARNING cause severe personal injury or death Disconnect the battery cables when repairs are made to the engine controls or generator Always disconnect the negative cable first to minimize the possibil
15. d washer from the center stud and pull out the filter element 4 If the filter element is clogged wash the element in kerosene and blow it dry with low pressure 30 psi or 207 kPa compressed air Replace the filter element if damaged Kerosene presents the hazard of AWARNING fire or explosion which can cause severe personal injury or death Do not smoke while using kerosene or expose kerosene to any fire flame spark pilot light arc producing equipment or other ignition sources Use great care when cleaning with kerosene 5 Wipe the center stud magnet clean of rustand scale deposits Do not tap the magnet to loosen deposits this may damage it 6 Install a clean filter element using two new gaskets Tighten the center and stud nuts 7 Place anew O ring in the filter bowl sealing groove 8 Line up the reference mark on the filter bowl with the reference mark on the filter body and install the capscrews Tighten the capscrews 56 to 74 in Ib 6 5 to 8 3 N m torque Pressurize the fuel system and check the filter for leaks LPG presents the hazard of fire or AWARNING explosion which can result in severe personal injury or death After the filter assembly is assembled and the fuel shutoff valve is turned on apply a soap or detergent solution to the joint to check for leaks there is a leak bubbles will show in the area turn off the shutoff valve immediately If the prob lem cannot be determined call the nearest
16. e a long exercise period rather than several short periods REMOTE CONTROL The remote control allows starting the set from the cab of the vehicle This control includes a start stop switch andan indicator lamp that lights when the setis running See Figure 3 2 Using the Remote Control Move the start stop switch to START and hold it until the light turns on to show that the setis running Release the switch See Figure 3 2 GENERATING LAMP ILLUMINATES WHEN SET IS OPERATING BATTERY EU CONDITION STANDARD INAN START PANEL f GENERATING LAMP ILLUMINATES WHEN SET IS OPERATING ELECTRIC POWER STOP gt ES 1684 1 FIGURE 3 2 REMOTE CONTROL PANELS If the switch is held at START for ten seconds and the light does not go on release the switch wait two min utes and try again If the second try does not succeed try the control on the set If the light still does not go on there may be an open circuit in the remote wiring Con tact an authorized service center for assistance The optional running time meter indicates total hours of generator set use During scheduled maintenance record the figure on the meter The battery condition meter shows the condition of the battery and charging circuit This meter should remain in the normal range If it reads high or low most of the time contact a service center IGNITION CHOKE FUSE F2 Spec F generator sets include a se
17. eep a log of all service and mainte nance for warranty support Use the schedule to deter minethe maintenance required then see this manual for the procedure Accidentally starting the generator AWARNING set during maintenance can cause severe personal injury or death Disconnect both generator set starting battery cables negative cable first before performing maintenance GENERAL INSPECTION Inspectthe entire gen erator setatleastonce every eight operating hours Start the set and check for visible and audible faults EXHAUST Examine the exhaust system for leaks Inspect the generator compartment for holes which might let exhaust gas enter the vehicle Do NOT operate the set if itruns louder than usual ifthe compartment has holes to the interior or ifthe exhaust system has leaks Consulta service center as soon as possible and do not run the set until the problem is corrected Exhaust gas presents the hazard of A WARNING severe personal injury or death If there are any exhaust leaks do not operate the genera tor set and have exhaust system repaired as soon as possible 4 1 SPARK ARRESTER The exhaust spark arrester is needed to operate the set safely It requires periodic cleaning to work correctly Checkthe maintenance schedule for cleaning intervals Spark Arrester Cleaning Procedure 1 Remove the 1 8 inch pipe plug from the bottom of the muffler 2 Run the generator set with load for five minute
18. enter Before performing this procedure move the vehicle to an outdoor location far from any flame spark pilot light arc producing equipment or other ignition sources Open all AC circuit breakers and remove the plug from the spark arrester muffler 1 Start the generator set and let it warm up to normal operating temperature Stop the generator set Remove the air cleaner housing and air filter Restart the generator set and spray the 4C into the carburetor Direct the spray to wash the choke plate and inside walls of the carburetor Spray as much as possible into the carburetor without stalling the engine The spray enters the combustion chamber and softens the carbon which flakes off and exits through the exhaust pipe When about an ounce of 4C remains in the can flood the engine until it stops Wait 15 minutes while the 4C continues to soften the carbon Restart the engine with no load connected increase the load gradually to full load Let the set run a few minutes under full load to get rid of the carbon CLEANING THE GENERATOR SET Clean the generator set every six months or more often in severe conditions Remove dust with a damp cloth Use steam to remove tar or other residue do not steam clean the set while it is running Protect the generator air cleaner control box fuel solenoid and electrical connectors from cleaning solutions Do not clean with solvents they may damage electrical con
19. he governor linkage AIR FILTER In dusty conditions changethe air filter often To release the filter remove the through bolt on the outside of the air cleaner housing Figure 4 4 AIR PREHEATER HOSE PREHEATER NS LEVER M e a 2 SUMMER AIR FILTER WITH FOAM WRAPPER GASOLINE MODELS ONLY 51593 25 FIGURE 4 4 REPLACING THE AIR FILTER ACAUTION Gasoline uniis only The carburetor air preheater hose can easily be damaged by rough handling When removing the air cleaner housing be careful not to damage the carbure tor air preheater hose which is attached to the housing FUEL FILTER LPG VERSIONS The fuel filter Figure 4 5 removes solid impurities from the LP gas beforethey reach the regulator and carbure tor A magnet in the filter housing attracts iron and rust particles and a filter element traps other particles The fuel filter operates at fuel tank pressure so it must be reassembled carefully after cleaning to avoid leakage To maintain the LPG fuel filter purge the fuel system first as described below Fuel System Purging Procedure 1 Close the shutoff valve at the fuel tank 2 Startand run the generator set until it is out of fuel 3 Crank the engine a few times after it stops to make certain that it has no fuel 4 Move the vehicle to a well ventilated location that is far from fire flame pilot lights arc producing equipment or other ignition
20. in high grass or brush 3 1 1 RV Exhaust gases can cause severe A WARNING personal injury or death Never oper ate the generator set unless the exhaust outlet is clear of walls snow banks or any obstructions that can prevent exhaust gases from dissipating Never operate any exhaustfan in the vehicle when the generator set is running an exhaust fan can draw exhaust gas into the vehicle Lubrication Check the engine oil level often Keep the level near the fill indicator FULL mark Do not overfill See Section 4 Maintenance for instructions Fuel Make certain thatthe fuel tanks are full before operating the set See Recommended Fuels in this section of the manual Gasoline and LPG fuel present the A WARNING hazard of fire or explosion which can result in severe personal injury or death Do not smoke or allow any flame spark pilot light arc producing equipment or other ignition sources around fuel or fuel components Keep a type ABC fire exlin guisher nearby RECOMMENDED FUELS Gasoline Models Use clean fresh unleaded gasoline Leaded regular may be used if necessary Unleaded fuel promotes longer service intervals longer spark plug life and less carbon clean out maintenance Leaded fuel creates deposits on the cylinder heads which cause power loss These deposits must be removed periodically Unleaded gas may be used after leaded gas only ifthese deposits are removed Engine damage may result from A
21. ity line This creates a potential for electrocution or property Connect only through an approved device and afte main switch is open Consult an electrician in o emergency power use GENERAL SAFETY PRECAUTIONS e Haveafire extinguisher nearby Maintain extinguisher prop erly and become familiar with its use Extinguishers rated ABC by the NFPA are appropriate for ail applications Con sult the local fire department for the correct type of extin guisher for various applications e Hot coolants under pressure can cause severe personal in jury DONOT open aradiator pressure cap while the engine is running Stop the engine and carefully bleed the system pressure e Benzene and lead found in some gasoline have been iden tified by some state and federal agencies as causing cancer or reproductive toxicity When checking draining or adding gasoline take care not to ingest breathe the fumes or con tact gasoline Used engine oils have been identified by some state or fed eral agencies as causing cancer or reproductive toxicity When checking or changing engine oil take care not to in gest breathe the fumes or contact used Remove all unnecessary grease and oil from the unit Accu mulated grease and oil can cause overheating and engine damage which presents a potential fire hazard e DO NOT store anything in the generator compartm as oil or gas cars cily rags chains wooden blocks 8 propane
22. ity of arcing 1 Keep the battery case clean and dry 2 Make certain that the battery cable connections are clean and tight To remove the cables use a termi nal puller tool 3 Identify the cable as positive or negative before making the connection Always connect the ground negative cable last for less chance of arcing 4 Add water drinking quality or better as needed to reach the split level marker in the battery The water in the electrolyte evaporates but the sulphuric acid remains For this reason add water not electrolyte to the battery 5 Avoid overcharging the battery Stop the charge when the electrolyte specific gravity is 1 260 at 80 F 27 C Batteries present the hazard of A WARNING explosion which can result in severe personal injury Do not smoke or allow any fire flame spark pilot light arc producing equipment or other ignition sources around the battery area Do not disconnect battery cables while the generator set is cranking or running batteries give off explosive gases GOVERNOR LINKAGE The nylon governor linkage must move freely through its range oftravel This jointis self lubricating and requires no lubricant Wipe the joint with a dry cloth to clean it See Figure 4 3 FS 1592 FIGURE 4 3 GOVERNOR LINKAGE Some solvents can damage the gov A CAUTION ernor s nylon joint Read the manu facturer s instructions before using any lubricants or solvents near t
23. nders The set will run roughly with asmoky exhaust until the oil in the cylinders is burned If the set does not start replace the spark plugs Apply one half load to the set until it runs smoothly Run the set for an hour Remove the load and let the set run three to five minutes to cool down Then move the start switch to the STOP position The generator set is now ready for operation TROUBLESHOOTING GUIDE This troubleshooting guide provides solutions to many common generator set problems If these suggestions do not help contact an authorized Onan service representative A WARNING Many troubleshooting procedures present hazards which can result in severe personal injury or death Only qualified service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Review safety precautions on inside cover page Problem Probable Cause Solution FAILS TO CRANK 1 Low battery 1 Check battery electrolyte level 2 Bad battery connection 2 Clean and tighten all battery and cable connections 3 Blown fuse 3 Replace fuse on control box See specifications for proper fuse rating 4 B circuit breaker tripped A 4 Wait for circuit breaker to return to local ambient temperature to reset CRANKS SLOWLY 1 Low battery 1 See Fails to Crank 1 2 Bad battery connection 2 See Fails to Crank 2 3 Oil is too heavy 3 Replace with lighter oil 4
24. nectors INSPECT AND CLEAN ENGINE INTERNAL Widely varying operating conditions light loads less than 50 percent and fuel with additives and impurities can degrade engine performance and shorten engine life Have the combustion chamber inspected internally for wear and carbon buildup after 300 hours Because this means removing the cylinder head it must only be done by an authorized service representative who is trained in genset maintenance and repair Redistribution or publication of this document by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited Onon Onan Corporation 1400 73rd Avenue N E Minneapolis MN 55432 1 800 888 ONAN 612 574 5000 International Use Telex 275477 Fax 612 574 8087 Onan is a registered trademark of Onan Corporation
25. on leave the preheater in the SUMMER posi tion at high ambient temperatures High Altitudes Engine power output decreases roughly four per cent for each 1000 feet 310 m above sea level after the first 1000 feet If the set runs poorly above 2000 feet 620 m turn the carburetor main fuel adjustment to a slightly leaner fuel mixture This is a sensitive adjustment Note that the carburetor has an altitude decal on the float bowl Set the indi cator on the main jet adjustment to the altitude re quired GASOLINE UNITS MAIN FS1871 LPG UNITS FIGURE 3 1 CARBURETOR MAIN ADJUSTMENT SCREWS Fuel mixture adjustment needles and A CAUTION seats can easily by damaged When adjusting fuel mixture settings never force the fuel mixture adjustment needles against their seats Extremely Dusty or Dirty Conditions 1 Keep the generator set and its cooling surfaces as clean as possible 2 Service the air cleaner frequently 3 Change the engine oil every 50 operating hours 4 Keep oil in a dust tight container 5 Cleanthe governor linkage regularly See Section 4 Maintenance for this procedure GENERATOR SET EXERCISE Moisture can condense in the engine if it is not run often enough to reach normal operating temperature This moisture can damage the engine To prevent moisture damage run the generator set at one half load two hours every four weeks See Section 2 Specifications for the wattage rating Us
26. op switch to STOP BREAK IN PROCEDURE To prevent high oil consumption or glazing of the engine cylinders break in the set as follows 1 Startthe setand apply a load equal to half its capac ity 2 Run the set for two hours with this load 3 Run the setfor another two hours at three quarters capacity 4 Change the engine oil after the first 50 hours of operation and every 150 hours after that See Sec tion 4 Maintenance for instructions This procedure only begins the break in process For optimum set performance make certain not to run the set for extended periods without load during the first 150 to 200 hours of use OPERATING CONDITIONS Hot Weather Keep the engine cooling fins clean at all times espe cially when the outside temperature is higher than 90 F 33 C Make sure that airflow to the set is not blocked Cold Weather Use the correct oil weight for cold weather See Section 4 Maintenance for the type of oil to use Change oil only after the engine is warm If sudden temperature changes occur and the oil is not the correct weight replace it with the proper oil Gasoline Models Only Below 70 F 4 C move the air preheater lever see Figure 2 1 to WINTER Above 70 F 21 C move the lever to SUMMER Operation of the preheater when A CAUTION temperatures are above 70 F 21 C may cause erratic operation and may result in reduced engine power and reduced engine life For this reas
27. parate fuse for the ignition and electrically controlled automatic choke Figure 3 3 illustrates the location of this 10 amp fuse on the side of the control panel Tr HOLDER E p Lj FUSE HOLDER BRACKET FIGURE 3 3 IGNITION CHOKE FUSE F2 LOCATION OUT OF SERVICE PROTECTION If the set cannot be exercised and it wili not be used for 30 days or longer perform the following storage procedure Generator Set Storage Procedure 1 Run the set at one half load for one hour See Sec tion 2 Specifications for the wattage rating Close the fuel supply and remove the air filter As the set runs out of fuel squirt fogger a thick oil formu lated for internal engine protection Onagard brand is recommended into the carburetor intake Reas semble the air filter Stop the set Remove the spark plugs Pour one tablespoon about 30 mi of standard engine oil into each spark plug hole Crank the engine for 10 seconds Replace the spark piugs 4 Change the oil after the exhaust system is cool 5 Disconnect the cables from the starting battery Returning the Generator Set to Operation 1 Inspect the generator set 2 Check the battery electrolyte level and reconnect the cabies Go Check the air filter if the element is dirty replace it Check the engine oil level 5 Turn on the fuel supply Start the set at the set mounted control Start up may be slow due to oil in the cyli
28. s 3 Stop the generator set and let the muffler cool 4 Replace the pipe plug in the muffler ENGINE OIL Be sure the crankcase is filled with oil to the FULL mark on the oil level indicator Figure 4 1 Use the same brand when adding oil between changes See Hecom mended Engine Oil in this section FILL TO HERE DO NOT RUN THE SET WHEN THE OIL LEVEL IS BELOW THIS MARK LS1138 3 FIGURE 4 1 OIL DIP STICK Add oil until it reaches the FULL mark on the oil level indicator Do not overfill excess oil may foam in the crankcase and stop the engine Replace the oil level indicator tightly to avoid leakage Hot oil can cause severe personal A WARNING injury Do not check the oil level while the generator setis running oil may blow outthe filler PERIODIC MAINTENANCE SCHEDULE After Each Cycle of Indicated Hours Mta Tepes um epe Check Oil Level 0000000000000 Cil Level E a AO UK RM oS MI NE LL LL _ A d CleanFuelFiter Fuel Filter po d o lt A AUN UK NUR Clean Carburetor amp Combustion Chamber w Onan 4C Cleaner E __ spect ard Geen era Ene Gsm ame O O e feme Aarena vasaa sasaina nane _ Adjust Carburetor As Required Adjust Output Voitage As Required 1 With set running visually and audibly check exha
29. tor Training Manual publication 932 0404 BGD NHD Installation Manual publication 965 0629 BGD NHD Service Manual publication 965 0529 Read this manual carefully and follow all warnings and cautions Using the genset properly and following a regular maintenance schedule can bring about longer unit life better performance and safer operation The generator set must be installed properly to operate safely Onon Model No IMPORTANT Model amp Serial No Required When Ordering Parts ac vots Teva xw ames Dev Jamps watts Time Rating pe insulation NEMA Class Ambient 40 C tt Wiring Diagram No s Onan Corp 1400 73rd Ave NE M ide in USA Minneapolis MN 55432 USA For Electrical Equipment Only lt Pour Material Electrique Seulement UB Onan Corporation FIGURE 1 1 ONAN NAMEPLATE Redistribution or publication of this document by any means is strictly prohibited Section 2 Specifications General Weight Overall Dimensions xL x W Minimum Free Area for Ventilating Air Minimum Vertical Clearance At Air Discharge Outlet Required Exhaust Pipe Material Engine Oil Capacity Dry Filter Control Panel Fuse F1 Ignition Choke Fuse F2 Spark Plug Gap Fuel Connections Maximum Gasoline Supply Pressure at Carburetor Maximum Gasoline Fuel Pump Lift Gasoline Supply Fitting Min Max Prop
30. ust system for leaks Every 150 operating hours or once a year whichever is first Perform more often in extremely dusty conditions i e check monthly and change if dirty 3 Equipped on LPG models Customer option for gasoline models 4 Or replace annually or prior to storage whichever is first 5 Have your Onan service center perform this task by removing cylinder heads 6 First oil change during first year or 50 hours of operation whichever is first 7 During periods of nonuse exercise for 2 hours every 4 weeks 8 Refer to Out of Service Protection if unit is to be stored 9 Have your Onan service center perform this task Oil Level Checking Procedure The generator set must be level when checking the oil indicator 1 Remove the oil level indicator and wipe it with a clean rag 2 Screw the indicator back into position fully in 3 Unscrew the indicator again and check the oil level on the indicator stem 4 Add oil to FULL mark on the indicator Oil Draining Changing Procedures Figure 2 1 shows the oil drain oil filler and oil level indica tor In dusty or dirty conditions change the oil more fre quently than the maintenance schedule says Run the engine until hot before draining changing the oil Oil Draining Procedure 1 Place a pan under the oil drain valve 2 Open the valve and let the oil drain from the engine 3 Close the valve Dispose of the ol
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