Operator Manual
Contents
1. 2 Perform air cleaner maintenance more often Page 15 3 Change engine oil every 50 hours 4 Keep containers of engine oil that have been opened tightly closed to keep out dust BREAKING IN A NEW ENGINE Proper engine break in on a new genset or on one with a rebuilt engine is essential for top engine per formance and acceptable oil consumption Run the genset at approximately 1 2 rated power for the first 2 hours and then at 3 4 rated power for 2 more hours See LOADING THE GENSET Page 9 Proper engine oil and oil level are especially critical during break in because of the higher engine tem peratures that can be expected Change the oil if not appropriate for the ambient temperatures during break in Page 6 Check oil level twice a day or every 4 hours during the first 20 hours of operation and change the oil after the first 20 hours of opera tion EXERCISING THE GENSET Exercise the genset at least 2 hours each month if use is infrequent Run the genset at approximately 1 2 rated power See LOADING THE GENSET Page 9 A single two hour exercise period is bet ter than several shorter periods Exercising a genset drives off moisture re lubri cates the engine replaces stale fuel in fuel lines and carburetor and removes oxides from electrical con tacts and generator slip rings The result is better starting more reliable operation and longer engine life OnaFresh and OnaGard are trademarks of Onan Corporatio2. Call a qualified electrician If the circuit breaker does not trip reconnect the ap pliances one by one up to a total load that does not overload the genset or cause the circuit breaker to trip If a circuit breaker trips right away when an ap pliance is connected the appliance probably has a short Electrical appliances and tools must be used and maintained properly and be properly grounded to cause the line circuit breakers to trip when short cir cuits occur Short circuits in electrical appliances and tools can cause fire and electri cal shock leading to severe personal injury or death Read and follow the equipment and tool manufacturer s instructions and warnings regarding use maintenance and proper grounding CONNECTING SHORE POWER A vehicle with provisions for connecting utility power must have an approved device to keep the genset and utility from being interconnected See the gen set Installation Manual for more information AWARNING Backfeed to shore power can cause electric shock resulting in severe personal inju ry or death and damage to equipment The ve hicle must have an approved device to prevent the genset from being interconnected with shore power 10 Circuit Breaker FIGURE 7 AC CIRCUIT BREAKER OPERATING IN COLD WEATHER Pay particular attention to the following items when operating the genset in cold weather 1 Make sure engine oil viscosity is appropriate for the ambient tem
3. and regulations GENERATOR VOLTAGE IS DEADLY Disable the automatic genset starting fea ture AGS of an inverter charger or other auto mat ic starting device before servicing the gen set toavoid unexpected starting Generator electrical output connections must be made by a trained and experienced electri cian in accordance with applicable codes The genset must not be connected to shore power or to any other source of electrical power Back feed to shore power can cause electric shock resulting in severe personal inju ry or death and damage to equipment An ap proved switching device must be used to pre vent interconnections e Use caution when working on live electrical equipment Remove jewelry make sure cloth ing and shoes are dry stand on a dry wooden platform or rubber insulating mat and use tools with insulated handles ENGINE EXHAUST IS DEADLY e Learn the symptoms of carbon monoxide poi soning in this manual and never sleep in the vehicle while the genset is running unless the vehicle is equipped with a working carbon mon oxide detector e The exhaust system must be installed in accor dance with the genset Installation Manual Engine cooling air must not be used for heating the working or living space or compartment e Inspect for exhaust leaks at every startup and after every eight hours of running e Make sure there is ample fresh air when operat ing the genset in a confined area FUEL IS FLA
4. E ey teen Siegeneye ec etneye ena 9 RESENI UCAC SE o EE 9 Eoading thafGenset SERA ee E a eee 9 Resetting Circuit Breakers 2 ee ee ee eee 10 Connecting Shore Power wwe ee eee eee eee ee eee ee ene 10 Operating in Cold Weather wk eee eee eee eee eee 11 Operating in Hot Weather 2 cee eee eee eee eee eee bene 11 Operating MiIgAAItItUde eee eee eee eee ee eee eb enees 11 Operating in Dusty Environments 00 cece eee eee 12 Breaking i a New Sc a 12 Se ODO eeEeEeEeEeEeEeE 12 Stormgthe Genset e stewie cos fees eiennn are teen ea eee tn cease eases er aioe 12 PERIODIC MAINTENANGE 222500142 coe ioe oe use vn Sos ened wee eee e 15 Conducting GeneraliinspectionS osGc o6 ass sree as ace see eesse oe eee nee 16 Checking Engme Oil bevel naka a courts we as hacen eo eeciee eae eet see 17 Changing ota Ilo Waseem se eels Main ariel E E tar et ie Senin nore 17 Replacingthne Air PilteGblement is lt iccns sv asees a aenes cee ease ae eee 18 Replacingithe Spank lbh 8 e ancien Arias het Albee chet ea baer Parga eieaay ar rma cs mers et Payne ir arte 18 Cleaningithe Spaik Ant Coto aa a a ccs aoe cones athe ee coca eet ee eee es a 19 ReplacingithoFRuekkilte raaa si ae canecee ances ah ache cen cee eee oe 20 Maintaining the Battery and Battery Connections 000 eee 20 TROUBLESHOOTING Creer ae rere ea eee ae ae TE 21 SPECIFICATIONS ee ee cer a eae rr ny 23 INFORMATION FOR CALIFORNIA GEN
5. remote control of the genset Onan offers three remote control kits as follows e Remote switch with indicator lamp only Fig ure 4 e Remote switch with indicator lamp and hour meter Figure 5 e Remote switch with indicator lamp and DC volt meter Figure 6 The hour meter time totalizing meter records gen set operating time in hours It cannot be reset See the PERIODIC MAINTENANCE SCHEDULE Page 15 The DC voltmeter indicates whether voltage across the 12 VDC control system and battery is normal If the indicator consistently stays above or below the normal zone see MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Page 20 Stop Start wa 5 Amp Fuse p If FIGURE 3 GENSET CONTROL PANEL OTEN GenSet Start Stop O FIGURE 4 START STOP Stop FIGURE 5 START STOP amp HOUR METER GenSet Start FIGURE 6 START STOP amp DC VOLTMETER Operation EXHAUST GAS IS DEADLY Exhaust gases contain carbon monoxide an odorless colorless gas Carbon monoxide is poisonous and can cause unconsciousness and death Symptoms of carbon monoxide poisoning include e Dizziness e Throbbing in Temples e Nausea e Muscular Twitching e Headache e Vomiting e Weakness and Sleepiness e Inability to Think Clearly IF YOU OR A
6. systems 13 FLOAT BOWL DRAIN VALVE FIGURE 9 CARBURETOR DRAIN VALVE Returning The Genset To Service is Check the oil tag on the genset and change the oil if the viscosity indicated is not appropriate for the temperatures expected Page 6 Reconnect the starting battery negative ca ble last Page 20 3 Remove the plug from the exhaust tailpipe Change the air filter element if it is dirty 14 Open the fuel supply valve if so equipped 6 Inspect the genset Page 16 Start the genset There may be smoke and rough operation for a few minutes until the oil from the fogger burns off If the engine does not start clean or replace the spark plug which may have been fouled by the fogger Turn ON the AC circuit breaker Page 10 when the genset is ready to power appliances Periodic Maintenance Periodic maintenance is essential for top perfor mance and long genset life Use Table 4 as a guide for normal periodic maintenance In hot and dusty environments some maintenance procedures should be performed more frequently as indicated by the footnotes in the table Keeping a log of main tenance performed and hours run will help you keep genset maintenance regular and provide a basis for supporting warranty claims Page 26 Maintenance replacement or repair of emission control devices and systems may be performed by any engine repair establishment or individual How ever
7. warranty work must be completed by an authorized Onan dealer TABLE 4 PERIODIC MAINTENANCE SCHEDULE MAINTENANCE FREQUENCY MAINTENANCE PROCEDURE 1 As a part of engine break in change the engine oil after the first 20 hours of operation 2 Perform more often when operating in dusty environments 3 Perform more often when operating in hot weather 4 Perform at least once a year 5 Perform sooner if engine performance deteriorates 6 Must be performed by a qualified mechanic authorized Onan dealer CONDUCTING GENERAL INSPECTIONS Inspect the genset before the first start of the day and after every eight hours of operation Oil Level Check engine oil level Page 17 Exhaust System Look and listen for exhaust system leaks while the genset is running Shut down the genset if a leak is found and have it repaired before operating the gen set again Look for openings or holes between the genset compartment and vehicle cab or living space if the genset engine sounds louder than usual Have all such openings or holes closed off or sealed to pre vent exhaust gases from entering the vehicle Replace dented bent or severely rusted sections of the tailpipe and make sure the tailpipe extends at least 1 inch 25 4 mm beyond the perimeter of the vehicle Park the vehicle so that the genset exhaust gases can disperse away from the vehicle Barriers such as walls snow banks high grass brush and other vehicl
8. 3 for details FUEL FILTER gasoline models only OIL FILL CAP AND DIPSTICK the cover in place Hold the cover in place firmly while releasing the latches to secure the cover Operating the genset with the ac cess cover removed can result in severe per sonal injury or equipment damage Hot compo nents are exposed when the access cover is re moved and genset cooling air does not circulate properly Do not operate the genset with the ac cess cover removed The genset itself is usually located behind a door in a compartment somewhere around the perimeter of the vehicle CARBURETOR ALTITUDE ADJUST KNOB gasoline models only MUFFLER inside cover OIL DRAIN bottom SPARK PLUG ACCESS FIGURE 2 TYPICAL GENSET FUEL RECOMMENDATIONS Gasoline and LPG are highly flam mable and explosive and can cause severe per sonal injury or death Do not smoke or turn elec trical switches ON or OFF where fuel fumes tanks or equipment are present or in areas sharing ventilation Keep flames sparks pilot lights arc producing equipment and switches and all other sources of ignition well away Keep a type ABC fire extinguisher in the vehicle Gasoline Models Use clean fresh unleaded gasoline having a mini mum octane rating Anti Knock Index of 87 A CAUTION Do not use gasoline or gasoline ad ditives containing methanol because methanol can be corrosive to fuel system components Avoid using leaded gasoli
9. MMABLE AND EXPLOSIVE e Do not smoke or turn electrical switches ON or OFF where fuel fumes are present or in areas sharing ventilation with fuel tanks or equip ment Keep flame sparks pilot lights arc pro ducing equipment and switches and all other sources of ignition well away e Fuel lines must be secured free of leaks and separated or shielded from electrical wiring MOBILE 7 Leaks can lead to explosive accumulations of gas Natural gas rises when released and can accumulate under hoods and inside housings and buildings LPG sinks when released and can accumulate inside housings and base ments and other below grade spaces Prevent leaks and the accumulation of gas BATTERY GAS IS EXPLOSIVE Wear safety glasses Do not smoke To reduce arcing when disconnecting or recon necting battery cables always disconnect the negative battery cable first and reconnect it last MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Disable the automatic genset starting fea ture AGS of an inverter charger or other auto mat ic starting device before servicing the gen set toavoid unexpected starting Do not wear loose clothing or jewelry near mov ing parts such as PTO shafts fans belts and pulleys Keep hands away from moving parts Keep guards in place over fans belts pulleys and other moving parts Introduction ABOUT THIS MANUAL This manual covers the operation and maintenance of the KV series
10. NGINE OIL RECOMMENDATIONS Page 6 Keep the oil level between the FULL and ADD marks Too much oil can cause high oil consumption Too little oil can cause severe engine damage Keep the oil level between the FULL and ADD marks 3 Screw the oil fill cap back on securely CHANGING ENGINE OIL State and federal agencies have de termined that contact with used engine oil can cause cancer or reproductive toxicity Try to avoid skin contact and breathing of vapors Use rubber gloves and wash exposed skin Refer to Table 4 for scheduled engine oil change Change oil more often in hot and dusty environ ments 1 Run the engine until warm stop it and remove the oil fill cap Figure 10 2 Place a pan under the oil drain plug and remove the plug Figure 11 with a 14 mm socket Let all oil drain from the engine and then secure the drain plug f you have a torque wrench tighten the plug to 21 Ibs ft 27 N m 3 Refill with 1 quart 0 95 1 of oil See ENGINE OIL RECOMMENDATIONS Page 6 Check the oil level and add or drain oil as necessary 4 Screw the oil fill cap on securely 5 Dispose of the used oil in accordance with local environmental regulations 17 OIL FILL CAP AND DIPSTICK Wee FILL TO HERE DO NOT RUN GENSET IF THE OIL LEVEL IS BELOW THIS MARK FIGURE 10 CHECKING ENGINE OIL LEVEL FIGURE 11 OIL DRAIN PLUG REPLACING THE AIR FILTER ELEMENT Refer to Table 4 for scheduled air
11. NYONE ELSE EXPERIENCES ANY OF THESE SYMPTOMS GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist seek medical attention Shut down the genset and do not op erate it until it has been inspected and repaired Never sleep in the vehicle with the genset running unless the vehicle is equipped with a working car bon monoxide detector Primary protection against inhaling carbon monoxide however is proper installation of the exhaust system daily every eight hour inspection for visible and audible exhaust system leaks 1 Push and hold the switch at START until the genset starts The remote START switch in side the vehicle should have a lamp which lights to indicate that the genset has started and is running Cranking for longer than 10 sec onds at a time can overheat and damage the starter Do not crank for more than 10 sec onds at a time and wait at least 30 seconds before trying again CONDUCTING THE PRE START CHECKS Before the first start of the day and after every eight hours of operation inspect the genset as instructed under CONDUCTING GENERAL INSPECTIONS Page 16 Keep a log of maintenance and the hours run and perform any maintenance that may be due See Returning the Genset to Service Page 14 if the vehicle has been in storage Before each start 1 Make sure all vehicle CO detectors are wor 2 For top performance and engine life especially king in colder weather let the engine warm up for two minutes
12. Operator Manual Cummins Onan Performance you rely on RV Generator set KV English 7 2009 981 0153 Issue 5 California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm A WARNING A The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm A WARNING A Do not use this genset on a boat Such use may violate U S Coast Guard regulations and can result in severe personal injury or death from fire electrocution or carbon monoxide poisoning Table of Contents SAFETY PRECAUTIONS 270 siaceietieniie E a a ia 2 MINT PRODUG TION ecco tcc 55 8 r a Se 4 About this Manua late eee a eee 4 Nameplalemte see ee ss 4 Ty pigaltSenSete eee See T 5 Ee MeconimchGcOnam sere E 0ee gee gle 6 Engine OillRecommendations a ce Meee cumemeengeenee 6 SlavingiBatienles see seee ease a O ooo noone ase 6 GensetControllkane MEESE a a anemone re 7 Remotencomobinciiciemcmermn h T aimumntee seamen reneerneva ge ee 7 OPERATION arma uty SORIA null MARR Ora Ga ee eon ea rt 8 Conducting the Pre Start Checks ee sche eee ae aces Westen eee Aten ers 8 Slang abexaenset ep E age tesa eaten ee te mon eae einer ne er 8 StoppnotheGenseti T Zorer
13. SET USERS 5 24 HOW TO OBTAIN SERVICE 0 cece eect eens 25 MAINTENANCE RECORD 0 0 0 cece eee ete eens 26 Safety Precautions Thoroughly read the OPERATOR S MANUAL before operating the genset Safe operation and top performance can be obtained only when equipment is operated and maintained properly The following symbols in this manual alert you to po tential hazards to the operator service person and equipment alerts you to an immediate hazard which will result in severe personal injury or death alerts you to a hazard or unsafe practice which can result in severe personal injury or death alerts you to a hazard or unsafe practice which can result in personal injury or equipment damage When equipped with an integral or add on Auto matic Generator Starting System AGS control ex haust carbon monoxide CO electric shock and moving parts hazards are possible due to unex pected starting Turn off AGS whenever performing maintenance or service when the vehicle is stored between uses is awaiting service or is parked in agarage or other confined area Electricity fuel exhaust moving parts and batteries present hazards which can result in severe personal injury or death GENERAL PRECAUTIONS e Keep children away from the genset e Do not use evaporative starting fluids They are highly explosive e To prevent accidental or remote starting while workin
14. VISCOSITY TEMPERATURES So 32 F 82 F 0 C and higher 32 F 0 C and higher 10 F to 100 F 12 C to 38 C a aa OnaMax 10W 30 10W 40 5W 30 0 F to 80 F 18 C to 27 C 20 F to 50 F 28 C to 10 C STARTING BATTERIES The genset has a 12 volt direct current DC engine cranking and control system See Specifications Page 23 regarding minimum battery ratings for reliable genset cranking especially in cold weather Also see PERIODIC MAINTENANCE SCHEDULE Page 15 and the battery manufacturer s instruc tions regarding battery maintenance Reliable gen set starting and starter service life depend upon adequate battery system capacity and proper main tenance GENSET CONTROL PANEL The genset control panel Figure 3 is located be hind the access cover on the genset Figure 2 It has the following features Control Switch This is a rocker switch which re turns to its neutral position when you let go Hold the switch in its START position to crank and start the genset Press the switch to its STOP position to stop the genset Control Fuse This fuse provides short circuit protection for the control and remote control circuits Line Circuit Breaker The line circuit breaker pro tects the AC power leads connected to the genset from overloads and equipment short circuits REMOTE CONTROL PANEL The vehicle probably has a control panel inside the vehicle for
15. ac tured carburetors which are not adjustable Engine Adjustments Adjustments None ee engine emissions control system consists of inherent en Engine Emission Control System gine design How to Obtain Service When you need service parts or product literature such as the Service Manual for your genset con tact the nearest authorized distributor Onan has factory trained representatives to handle your needs for genset parts and service Call 1 800 888 ONAN to contact the nearest Cum mins Onan or Onan only distributor in the United States or Canada This automated service utilizes touch tone phones only Select OPTION 1 press 1 to be automatically connected to the dis tributor nearest to you If you are unable to contact a distributor using the automated service consult the Yellow Pages Typi cally our distributors are listed under GENERATORS ELECTRIC ENGINES GASOLINE OR DIESEL or RECREATIONAL VEHICLES EQUIPMENT PARTS AND SERVICE If you are outside North America call Onan Corpo ration at 1 763 574 5000 from 7 30 AM to 25 4 00 PM Central Standard Time Monday through Friday or fax 1 763 528 7229 Before calling for service have the following information available 1 The complete genset model number and serial number See Model Identification Page 4 2 The date of purchase 3 The nature of the problem See Trouble shooting Page 21 If you have difficulty in arranging s
16. before connecting appliances 2 Check for signs of fuel and exhaust leaks and for damage to the exhaust system 3 Check for fuel and exhaust leaks Stop the gen set immediately if there is a fuel or exhaust leak 3 To prevent overheating and to reduce fouling and have it repaired with dust and debris make sure the genset s normal ground clearance is not being reduced 4 See Troubleshooting Page 21 if the engine by sloping ground curbs logs or other objects Repark the vehicle if necessary and or remove any objects blocking the air inlet or air outlet Turn off the air conditioner and other large appliances STARTING THE GENSET Start the genset from the genset control panel or re mote control panel inside the vehicle Page 7 does not crank or start after several tries Always secure the genset compartment door after starting the genset at the genset control panel Proper engine cooling requires that the access cover be secured during op eration Also hot engine parts can cause severe burns Always secure the access cover as soon as the engine starts up STOPPING THE GENSET Turn off the air conditioner and other large appliances and let the genset run for two minutes to cool down This reduces backfiring and run on Then press the switch to STOP to stop the genset RESTARTING THE GENSET If the genset shuts down disconnect or turn off as many appliances as possible and try restarting the gen
17. components that affect engine emissions are prohibited Unauthorized modification removal or replacement of the genset label is prohibited You should carefully review Operator Owner Installation and other manuals and information you receive with your genset If you are unsure that the installation use maintenance or service of your genset is authorized you should seek assistance from an approved Onan dealer California genset users may use Table 6 as an aid in locating information related to the California Air Re sources Board requirements for emissions control TABLE 6 EMISSIONS CONTROL INFORMATION The California emissions control warranty statement is located Genset Warranty Information in the same packet of information as this manual when the gen set is shipped from the factory Engine Valve Lash See Specifications Page 23 Engine Ignition Timing See Specifications Page 23 Gasoline Models The engine is certified to operate on un leaded gasoline See Fuel Recommendations Page 6 Engine Fuel Requirements LPG Models The engine is certified to operate on LPG vapor See Fuel Recommendations Page 6 Engine Lubricating Oil Requirements See ENGINE OIL RECOMMENDATIONS Page 6 Gasoline Models These genset engines have precision manufactured carburetors which are not adjustable except for altitude Figure 8 Page 11 Engine Fuel Mixture Settings LPG Models These genset engines have precision manuf
18. dations Page 20 5 Plug the exhaust tail pipe to keep out dirt mois ture rodents and such 6 Close the fuel supply valve if so equipped 7 Turn OFF the AC circuit breaker Page 10 Do not open the carburetor drain when the engine is hot Close the drain immediately after draining Failure to heed this warning can lead to fire resulting in severe personal injury or death Gasoline Models Draining the carburetor float bowl prevents deposits of gum from clog ging the tiny passages in the carburetor as the gasoline in the bowl evaporates during storage If the carburetor has a drain Figure 9 drain it as follows A Let the engine cool down thoroughly B Place paper towels under the drain to ab sorb all of the drainage less than 1 2 cup C Open the drain valve by turning counter clockwise with a screwdriver D Immediately close the drain valve after draining by turning clockwise with a screw driver until just snug LPG Models Check local ordinances if the vehicle is to be garaged Generally ordinances require that the LPG system be leak free that the LPG container not be filled beyond speci fied limits that the container shutoff valve be closed and that the vehicle not be parked near sources of heat or ignition LPG leaks can lead to explosive accumulations in pits sumps or other below grade locations Comply with all lo cal ordinances regarding the garaging of vehicles with LPG engine fuel
19. e increases causing genset engine power to decrease Power decreases approximately 3 5 percent of rated power each 1000 feet 305 m of in crease in elevation See Table 3 for typical calcula tions It may be necessary to run fewer appliances at higher altitudes TABLE 3 POWER VS ALTITUDE Elevation above Mean Sea Level up to 500 feet 152 m 2500 ft 762 m Maximum Genset Power 2800 watts rated 2604 watts 2310 watts 2310 watts minus 98 watts each 1000 ft 305 m 5500 ft 1676 m above 5500 ft 1676 m This table does not take into account the effect cir cuit breakers may have in limiting maximum power Appliance load and genset power are measured in terms of watts W or kilowatts kW where 1 kilowatt kW 1000 watts W Power decreases even though the altitude adjust knob is set correctly Page 11 RESETTING CIRCUIT BREAKERS If a circuit breaker in the main power distribution panel of the vehicle or on the genset Figure 7 trips either a circuit shorted or too many appliances were running Note that the genset will continue to run af ter a circuit breaker trips If a circuit breaker trips disconnect or turn off as many loads as possible and reset the circuit breaker Push the circuit breaker to OFF to reset it and then to ON to reconnect the circuit If the circuit breaker trips right away either the electrical dis tribution system has a short or the circuit breaker is faulty
20. ervice or resolv ing a problem please contact the Service Manager at the nearest Cummins Onan distributor for assis tance Improper service or replacement of parts can result in severe personal injury death and or equipment damage Service personnel must be trained and experienced in performing electrical and or mechanical service Maintenance Record Record all periodic and unscheduled maintenance and service See Periodic Maintenance Page 15 HOUR METER MAINTENANCE OR SERVICE PERFORMED Record the name address and phone number of your authorized Onan service center 26 Cummins Onan Cummins Power Generation 1400 73rd Ave NE Minneapolis MN 55432 USA Phone 1 763 574 5000 Toll free 1 800 888 6626 Fax 1 763 574 5298 Email www cumminsonan com contact www cumminsonan com Cummins Onan the C logo and Performance you rely on are trademarks of Cummins Inc 2009 Cummins Power Generation Inc All rights reserved
21. es can cause exhaust gases to accumulate in and around the vehicle Do not operate power ventilators or exhaust fans while the vehicle is standing with the genset run ning The ventilator or fan can draw exhaust gases into the vehicle Check all CO monitors to assure proper operation EXHAUST GAS IS DEADLY Do not operate the genset if there is an exhaust leak or any danger of exhaust gases entering or being drawn into the vehicle Do not park the vehicle in high grass or brush Contact with the exhaust system can cause a fire Fuel System Check for leaks at the hose tube and pipe fittings in the fuel supply system while the genset is running 16 and while it is stopped Do not use a flame to check for LPG leaks Check flexible fuel hose sections for cuts cracks and abrasions Make sure the fuel line is not rubbing against other parts Replace worn or damaged fuel line parts before leaks occur If you smell gas close the LPG container shutoff valve and have the genset serviced before using it again Gasoline and LPG are highly flam mable fuels and can cause severe personal inju ry or death Repair leaks right away Battery Connections Check the battery terminals for clean tight connections Loose or corroded connections have high electrical resistance which makes starting harder See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Page 20 AWARNING Arcing at battery terminals or light switch or other equ
22. filter replacement Under dusty operating conditions inspect and change the air filter element more often To change the air filter element Figure 12 lift the filter cover out of the scroll housing and pull the filter retainer straight out Install the new filter with the open end of the filter facing the carburetor as shown REPLACING THE SPARK PLUG Refer to Table 4 for scheduled spark plug replace ment The genset has one spark plug Figure 13 The spark plug must be in good condition for proper engine starting and performance A spark plug that fouls frequently or has heavy soot deposits indi cates that the engine needs service See Trouble shooting Page 21 Always thread the spark plug in by hand until it seats to prevent crossthreading and torque to 13 Ibs ft 17 N m If you don t have a torque wrench turn the spark plug an additional 1 4 turn if being reused or 3 8 to 1 2 turns if new 18 RETAINER FIGURE 13 SPARK PLUG CLEANING THE SPARK ARRESTOR Refer to Table 4 for scheduled cleaning of the spark arrestor muffler which meets U S Forest Service requirements Cleaning is required for maximum genset performance A hot muffler can cause severe burns Let the muffler cool down before remov ing the spark arrestor screen The spark arrestor screen is mounted inside the muffler outlet Figure 14 Clean as follows 1 Loosen the U bolt clamp that secures the tail pipe to the muffler inside
23. g on the genset disconnect the nega tive battery cable at the battery e Let the engine cool down before removing the coolant pressure cap or opening the coolant drain Hot coolant under pressure can spray out and cause severe burns e Keep the genset and its compartment clean Excess oil and oily rags can catch fire Dirt and gear stowed in the compartment can restrict cooling air Make sure all fasteners are secure and torqued properly Do not work on the genset when mentally or physically fatigued or after consuming alcohol or drugs You must be trained and experienced to make adjustments while the genset is running hot moving or electrically live parts can cause se vere personal injury or death Used engine oil has been identified by some state and federal agencies as causing cancer or reproductive toxicity Do not ingest inhale or contact used oil or its vapors Benzene and lead in some gasolines have been identified by some state and federal agencies as causing cancer or reproductive toxicity Do not to ingest inhale or contact gaso line or its vapors Keep multi class ABC fire extinguishers handy Class A fires involve ordinary combustible ma terials such as wood and cloth Class B fires combustible and flammable liquid fuels and gaseous fuels Class C fires live electrical equipment ref NFPA No 10 Genset installation and operation must comply with all applicable local state and federal codes
24. h the For example shutdown code No 36 appears condition that caused the shutdown may have been as corrected 22 Specifications SS ae FUEL CONSUMPTION Gasoine Gasoe upc e No load 0 16 gph 0 6 I h 0 16 gph 0 6 I h 1 0 Ibs h 0 44 kg h 0 9 Ibs h 0 40 kg h Half load 0 28 gph 1 1 I h 0 23 gph 0 9 I h 1 5 Ibs h 0 68 kg h 1 3 Ibs h 0 59 kg h Full load 0 46 gph 1 7 I h 0 32 gph 1 2 I h 2 5 Ibs h 1 1 kg h 2 1 Ibs h 92 kg h ENGINE 1 Cylinder 4 Cycle Spark Ignited OHV Air Cooled Oil Capacity 1 quart 0 951 Spark Plug Tightening Torque 13 Ibs ft 17 N m 13 Ibs ft 17 N m nial Jigme megne eE en 25 BTDC non adjustable 25 BTDC non adjustable LPG Vapor 9 to 13 inch 229 to 330 mm Supply Pressure Range W C EE column DC SYSTEM Nominal Battery Voltage Nominal Battery Voltage Voltage 12 Ooo vs SOSY 12 OoOo vs SOE Minimum Battery Cold Cranking 60 Hertz models are Listed by CSA and the U S Testing Company See Periodic Maintenance for oil filling instructions 23 Information for California Genset Users This genset meets the requirements of California s Exhaust Emissions Standards as stated on the nameplate Figure 1 Page 4 illustrates where this information appears on the nameplate As a California user of these gensets please be aware that unauthorized modifications or replace ment of fuel exhaust air intake or speed control system
25. ipment or flames and sparks can ignite battery gas causing severe personal injury Ventilate battery area before working on or near battery Wear safety glasses Do not smoke Switch trouble light ON OFF away from battery Do not disconnect battery cables while genset is running or vehicle battery charg ing system is on Always disconnect nega tive cable first and reconnect it last Mechanical Look for mechanical damage and listen for unusual noises Check the genset mounting bolts Check to see that the genset air inlet and outlet openings are not clogged with debris or blocked Clean accumulated dust and dirt from the genset Do not clean the genset while it is running or still hot Protect the generator air cleaner control panel and electrical connections from water soap and clean ing solvents AWARNING Always wear safety glasses when using compressed air a pressure washer or a steam cleaner to avoid severe eye injury CHECKING ENGINE OIL LEVEL Park the vehicle on level ground and stop the genset before checking engine oil level Crankcase pressure can blow hot engine oil out the fill opening causing severe burns Always stop the genset before removing the oil fill cap 1 Unscrew the oil fill cap and wipe oil off the dip stick Figure 10 Reinsert the dipstick but do not screw the cap down Remove the dipstick again and check the oil level on the dip stick 2 Add or drain oil as necessary See E
26. n 12 STORING THE GENSET Proper storage is essential for preserving top gen set performance and reliability when the genset cannot be exercised regularly and will be idle for more than 120 days Storing the Genset 1 Gasoline Models Fill the fuel tank with fresh fuel and add a fuel preservative OnaFresh following the instructions on the container la bel Unless a preservative stabilizer is added the gasoline in the fuel system will deteriorate causing fuel system corrosion gum formation and varnish like deposits which can lead to hard starting and rough operation Then run the genset for about 10 minutes at approximately 1 2 rated power to fill the fuel lines with the fresh fuel and preservative Gasoline preservatives stabi lizers are toxic Follow the instructions on the container label Avoid skin contact Wash your hands with soap and water after dispensing the fluid 2 Change the engine oil and attach a tag indicat ing its oil viscosity Page 6 3 Remove the air filter and restart the genset While the genset is running spray an engine fogger OnaGard into the carburetor follow ing the instructions on the container label and then stop the genset The fogger leaves a pro tective coat of oil on the internal surfaces of the engine 4 Disconnect the battery cables negative cable first from the starting battery and store the battery according to the battery manufac turer s recommen
27. ne because of the ex tra engine maintenance that will be required LPG Models Use clean fresh HD 5 grade liquified petroleum gas LPG or equivalent product consisting of at least 90 percent propane Commercial liquified petroleum gas fuels may contain more than 2 5 percent butane which can result in poor fuel vaporization and poor engine starting in low ambient temperatures below 32 F 0 C Satisfactory performance on low pressure LPG models requires that the LPG vapor be supplied at a pressure within the range indicated in Specifica tions High LPG supply pressure can cause gas leaks which can lead to fire and se vere personal injury or death LPG supply pres sure must be adjusted to Specifications by trained and experienced personnel OnaMax is a trademark of the Onan Corporation ENGINE OIL RECOMMENDATIONS Use API American Petroleum Institute perfor mance Class SJ SH or SG engine oil which may be in combination with performance Class CH 4 CG 4 or CF 4 for example SJ CH 4 Also look for the SAE Society of Automotive Engineers viscosity grade Referring to Table 1 choose the viscosity grade appropriate for the ambient temperatures expected until the next scheduled oil change Single grade SAE 30 oil is preferable when temper atures are consistently above freezing Multigrade oils are better when wide temperature variations are expected TABLE 1 OIL VISCOSITY VS TEMPERATURE EXPECTED AMBIENT SAE
28. of generator sets gensets Each operator should study this manual carefully and ob serve all of its instructions and safety precautions Keep this manual and the Installation Manual with the other vehicle manuals Operation Periodic Maintenance and Trouble shooting provide the instructions necessary for operating the genset and maintaining it at top per formance The owner is responsible for performing maintenance in accordance with the PERIODIC MAINTENANCE SCHEDULE Page 15 This man ual also includes genset specifications information on how to obtain service and information for Califor nia users This genset is not a life support sys tem It can stop without warning Children per sons with physical or mental limitations and pets could suffer personal injury or death A per sonal attendant redundant power or an alarm system must be used if genset operation is criti cal NAMEPLATE Model and Serial Numbers Have the model and serial numbers handy gray boxes Figure 1 when contacting an Onan dealer for parts service or prod uct information Each character is significant The last character of the model number is the specifica tion letter which is important for obtaining the right parts Record these numbers in the boxes in Fig ure 1 so that they are handy when you need them Genuine Onan replacement parts are recom mended for best performance and safety Federal Emissions Compliance Period The Federal Emis
29. oke out tailpipe Service the air cleaner Page 18 21 FAULT CODE BLINKING blink blink blink pause blink blink blink blink blink blink long pause repeat e Four blinks indicate that cranking time ex At fault shutdown the status indicator light will re ault shutdown the status indicator light will re ceeded 36 seconde peatedly blink sets of 1 2 3 or 4 blinks e Fault Code Nos 1 2 3 and 4 are first level faults e One blink indicates shutdown due to high en Pay close attention to the pause sequence to avoid gine coolant temperature interpreting first level faults as second level Fault Rae Codes Nos 11 22 33 or 44 e Two blinks indicate shutdown due to a loss of engine oil pressure e To avoid the possibility of anyone misinterpreting Code Nos 3 and 4 as Code Nos 33 and 44 the lat e Three blinks indicate a service fault Press ter have not been assigned faults Stop once to cause the two digit second level shutdown code to blink Pressing Stop again RESTORING FAULT CODE BLINKING will stop the blinking The two digit code con sists of 1 2 3 4 or 5 blinks a brief pause and then 1 to 9 blinks The first set of blinks repre sents the tens digit and the second set of blinks The fault code stops blinking after five minutes Press Stop three times within three seconds to re store fault code blinking the units digit of the shutdown code number Note The last fault logged will blink even thoug
30. peratures Change oil if there is a sudden drop in temperature See ENGINE OIL RECOMMENDATIONS Page 6 2 Reset the carburetor gasoline models only for altitude Figure 8 3 Perform spark plug maintenance Page 18 4 Perform battery maintenance Page 20 OPERATING IN HOT WEATHER Pay particular attention to the following items when operating the genset in hot weather 1 Make sure nothing blocks the airflow to and from the set 2 Make sure engine oil viscosity is appropriate for the ambient temperatures See ENGINE OIL RECOMMENDATIONS Page 6 ALTITUDE 3 Keep the genset clean end 4 Perform maintenance due See PERIODIC MAINTENANCE SCHEDULE Page 15 5 Reset the carburetor gasoline models only for altitude Figure 8 OPERATING AT HIGH ALTITUDE GASOLINE MODELS ONLY PP GASOLINE MOEELSONEG For best fuel economy and genset operation reset the carburetor for the current altitude Figure 8 Look at road maps and road signs For the effect of altitude on maximum power see LOADING THE GENSET Page 9 Operating the genset at low altitude with a high altitude setting can cause power loss overheating and engine damage Always reset when returning to lower altitudes 11 OPERATING IN DUSTY ENVIRONMENTS Pay particular attention to the following items when operating the genset in dusty environments 1 Do not let dirt and debris accumulate inside the genset compartment Keep the genset clean
31. sent hazards that can result in severe personal in jury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Review Safety Precautions 1 Engine fails to crank Try starting at the genset rather than at the remote control Clean and tighten the positive and negative battery cable connections at the battery and at the genset Recharge the battery Refer to the battery manufacturer s recommendations 2 Engine cranks slowly Disconnect the air conditioner and other large loads Clean and tighten the positive and negative battery cable connections at the battery and at the genset Recharge the battery Refer to the battery manufacturer s recommendations Change the engine oil to oil having the proper viscosity for the ambient tem perature Pages 6 and 17 3 Engine cranks but fails to Gasoline Models Check the fuel tank and fill if necessary start LPG Models Check and fill the LPG container as necessary On cold days the LPG container may have to be kept at least half full to provide the rate of vaporization necessary to keep up with genset fuel demand LPG Models Regap the spark plug to 0 020 inch Open any closed fuel shut off valve Check engine oil level and add or drain oil as necessary Page 17 Service the air cleaner Page 18 Secure the spark plug lead on the spark plug Replace the
32. set Reconnect only as many appliances as will not overload the genset or cause the circuit breaker to trip LOADING THE GENSET The genset can power AC motors air conditioners AC DC converters and other appliances How much appliance load can be serviced depends upon the genset power rating The genset will shut down or its circuit breakers will trip if the sum of the loads exceeds genset power To avoid overloading the genset and causing shut downs compare the sum of the loads of the appliances that are likely to be used at the same time to the power rating of the genset Use Table 2 or the ratings on the appliances themselves if so marked to obtain the individual appliance loads It may be necessary to run fewer appliances at the same time the sum of the loads must not be greater than genset rating Note that the genset may shut down due to over load even though the sum of the loads is less than genset rating when a large motor or air conditioner is started last or cycles off and then on again The reason for this is that motor startup load is much larger than running load It may be necessary to run fewer appliances when large motors and air conditioners are cycling on and off TABLE 2 TYPICAL APPLIANCE LOADS Load watts Electric Frying Pan or Wok 1000 1500 Electric Stove Element 350 1000 Television Radio Electric Drill Electric Broom Electric Blanket Note also that air density decreases as altitud
33. sions Compliance Period referred to on the nameplate indicates the number of operating hours for which the engine has been shown to meet Federal emissions requirements Category C 250 hrs B 500 hrs A 1000 hrs IMPORTANT ENGINE INFORMATION CUMMINS POW GENERATION DE 1400 73rd Ave NE Minneapolis MN 55432 Model No 2 8KVFA26100K SN D000012345 Made in U S A AC Volts kVA Amps Pf Fuel Hz Options Wiring Diagram Insulation NEMA Class F Ambient 40 C The engine family designation engine displacement state ment of compliance with the applicable EPA and or California emissions regulations including the compliance period or category appear in this block on the actual nameplate on the genset RECORD NUMBERS HERE MODEL NUMBER SERIAL NUMBER FIGURE 1 TYPICAL NAMEPLATE TYPICAL GENSET The control panel and the components requiring attention during periodic maintenance see Periodic Maintenance are located behind a removable ac cess cover See Figure 2 Removing the access cover Slide the cover latches up and pull the cover outward from the bot tom Lower the cover to remove it from the housing Securing the access cover Position the tabs on the top of the access cover in the openings on the housing Slide the latches up and push the bottom of REMOVABLE ACCESS COVER AIR FILTER COVER CONTROL PANEL see Figure
34. spark plug Page 18 i Gasoline Models Replace the fuel filter Page 20 4 Engine runs but stops or Gasoline Models Check the fuel tank and fill if necessary surges LPG Models Check and fill the LPG container as necessary On cold days the LPG container may have to be kept at least half full to provide the rate of vaporization necessary to keep up with genset fuel demand Check engine oil level and add or drain oil as necessary Page 17 Gasoline Models Reset the carburetor for altitude Page 11 Secure the spark plug lead on the spark plug Replace the spark plug Page 18 5 Genset stalls or circuit Connect fewer appliances Page 9 breakers trip LPG Models Check the fuel tank and fill as necessary On cold days the LPG container may have to be kept at least half full to provide the rate of va porization necessary to keep up with the genset fuel demand 6 No electrical power when Reset tripped circuit breakers Page 10 genset running Unless there is an automatic power transfer switch plug the vehicle power cord into the genset power output receptacle if so equipped or turn the ve hicle power selector switch to its genset position if so equipped 7 DC voltmeter Page 7 a Clean and tighten the positive and negative battery cable connections indicates low voltage at the battery and the genset b Recharge the battery Refer to the battery manufacturer s recommendations 8 Black sm
35. the genset housing and move the tailpipe aside Remove the screw that secures the spark arrestor tube screen inside the muffler outlet Remove the spark arrestor tube and inspect the screen inside for damage and clogging Replace if damaged Lightly tap the spark arrestor and remove any remaining deposits with a wire brush Use a commercial solvent to loosen hard deposits Carefully follow the solvent manufacturer s instructions and safety precautions Reinstall the spark arrestor and tail pipe Pon MOUNTING SPARK ARRESTOR SCREW TUBE FIGURE 14 SPARK ARRESTOR 19 REPLACING THE FUEL FILTER Refer to Table 4 for scheduled replacement of the fuel filter Figure 15 gasoline models only Take care to spill as little fuel as possible when dis connecting the filter from the fuel line Close any shut off valve in the fuel line and let the engine cool down before disconnecting the fuel line so that it cannot ignite any fuel that is spilled The filter is re movable by loosening the hose clamps shown Gasoline is highly flammable and can cause severe personal injury or death Let the engine cool and close any fuel line shutoff valve before disconnecting the fuel line from the filter Do not smoke or turn electrical switches ON or OFF where fuel fumes tanks or equip ment are present or in areas sharing ventilation Keep flame sparks pilot lights arc producing equipment and switches and all o
36. ther sources of ignition well away Keep a type ABC fire extinguisher in the vehicle MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Arcing at battery terminals or light switch or other equipment or flames and sparks can ignite battery gas causing severe personal injury Ventilate battery area before working on or near battery Wear safety glasses Do not smoke Switch trouble light ON OFF away from battery Do not disconnect battery cables while genset is running or vehicle battery charg ing system is on Always disconnect nega tive cable first and reconnect it last Refer to Table 4 for scheduled battery maintenance referring to the battery manufacturer s instructions Have the battery charging system serviced if DC system voltage is consistently low or high Always 1 Keep the battery case and terminals clean and dry and the terminals tight 2 Remove battery cables with a battery terminal puller 3 Make sure which terminal is positive and which is negative before making battery connections always removing the negative cable first and reconnecting it last to reduce arcing FIGURE 15 FUEL FILTER Troubleshooting Table 5 provides basic troubleshooting guidance If rective actions suggested contact an authorized you fail to resolve the problem after taking the cor Onan dealer See How to Obtain Service Page 25 TABLE 5 TROUBLESHOOTING Many troubleshooting procedures pre
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