Service Manual

RV Generator Set

HDKAH (Spec A−M)

HDKAJ (Spec A−M)
HDKAK (Spec A−M)
HDKAT (Spec A−M)
HDKAU (Spec A−M)
HDKAV (Spec A−M)

English − Original Instructions 6−2010 981−0522 (Issue 9)

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

diesel warnings
Table of Contents

SECTION PAGE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Service Parts and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Typical Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3. THREAD TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
4. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fuel Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Engine Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Starting Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Operator’s Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Remote Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
5. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Changing Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Changing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Coolant Temperature Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
6. PREPARATIONS FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Removing Genset From Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

i
SECTION PAGE

Test Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Removing Housing Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Installing Housing Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
7. ENGINE AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
8. MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
9. ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Radiator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Radiator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
10. CONTROLLER-INVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Controller-Inverter Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
11. PMA (GENERATOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Stator Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Stator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Stator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Rotor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Rotor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
12. ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Replacing Coolant Pump Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Replacing Low Oil Pressure Cutoff Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
13. GOVERNOR ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Actuator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

ii
SECTION PAGE

Actuator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

Actuator Speed Control Lever Stop (Beginning Spec B) . . . . . . . . . . . . . . . . . . . . 13-4
High-Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
High-Idle Stop Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
14. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Fuel Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
15. BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
16. STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Starter Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2
17. SERVICE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
18. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
Troubleshooting With Table 18-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
Fault Code Blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
Restoring Fault Code Blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
Bypassable Faults: Prior to Spec F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
ENGINE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
AC WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
BATTERY WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

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

iv
 BATTERY GAS IS EXPLOSIVE • Keep the genset and its compartment clean.
Excess oil and oily rags can catch fire. Dirt and
• Wear safety glasses. gear stowed in the compartment can restrict
• Do not smoke. cooling air.
• To reduce arcing when disconnecting or recon- • Make sure all fasteners are secure and
necting battery cables, always disconnect the torqued properly.
negative (−) battery cable first and reconnect • Do not work on the genset when mentally or
it last. physically fatigued or after consuming alcohol
or drugs.
FLAMMABLE VAPOR CAN CAUSE A • You must be trained and experienced to make
DIESEL ENGINE TO OVERSPEED adjustments while the genset is running—hot,
moving or electrically live parts can cause se-
Flammable vapor can cause a diesel engine to vere personal injury or death.
overspeed and become difficult to stop, resulting in
possible fire, explosion, severe personal injury and • Used engine oil has been identified by some
death. Do not operate a diesel-powered genset U. S. state and federal agencies as causing
where a flammable vapor environment can be cancer or reproductive toxicity. Do not ingest,
created by fuel spill, leak, etc. The owners and inhale, or contact used oil or its vapors.
operators of the genset are solely responsible for • Ethylene glycol, used as engine antifreeze, is
operating the genset safely. toxic to humans and animals. Clean up spills
and dispose of used engine coolant in accor-
GENERAL PRECAUTIONS dance with local environmental regulations.
• Keep children away from the genset. • Keep multi-class ABC fire extinguishers
handy. Class A fires involve ordinary combus-
• Do not use evaporative starting fluids. They tible materials such as wood and cloth; Class B
are highly explosive. fires, combustible and flammable liquid fuels
• To prevent accidental or remote starting while and gaseous fuels; Class C fires, live electrical
working on the genset, disconnect the nega- equipment. (ref. NFPA No. 10)
tive (−) battery cable at the battery. • Genset installation and operation must comply
• Let the engine cool down before removing the with all applicable local, state and federal
coolant pressure cap or opening the coolant codes and regulations.
drain. Hot coolant under pressure can spray • Keep guards in place over fans, belts, pulleys,
out and cause severe burns. and other moving parts.

Mobile-8

v
1. Introduction
ABOUT THIS MANUAL
This is the Service Manual for the generator set
(genset) models listed on the front cover. Read and
carefully observe all of the instructions and precau- 80HDKAK11454J
tions in this manual. F990 123456

WARNING Improper service or parts replace-

ment can lead to severe personal injury or death
and to damage to equipment and property. Ser-
vice personnel must be qualified to perform
electrical and mechanical service.
SKB719U6D2RA 719 cc
CAUTION Unauthorized modifications or re-
placement of fuel, exhaust, air intake or speed
control system components that affect engine
emissions are prohibited by law in the State of
California.

See the Installation Manual for important recom-

mendations concerning the installation and for a list
of the installation codes and standards for safety
which may be applicable.

See the Parts Catalog for parts identification num-

bers and required quantities. Genuine Onan® re-
placement parts are recommended for best results.

SERVICE PARTS AND INFORMATION

When contacting Onan for parts, service or product
information, be ready to provide the model number
and the serial number, both of which appear on the
genset nameplate. Figure 1-1 illustrates the name-
plate and its location. The numbers in the gray
boxes are typical model and serial numbers. Every FIGURE 1-1. TYPICAL NAMEPLATE
character in these numbers is significant. (The last
character of the model number is the specification
letter, which is important for obtaining the right
parts.)

1-1
 TYPICAL GENSET
Figure 1-2 illustrates a typical genset.

COOLANT COOLANT GENERATOR RADIATOR GOVERNOR MUFFLER

PRESSURE RECOVERY (PMA) STATOR ACTUATOR ASSEMBLY
CAP TANK

INNER
BULKHEAD

CONTROLLER/
INVERTER
HOUSING

ENGINE

COOLING INTAKE AIR STARTER FUEL OIL FUEL

BLOWER RESONATOR MOTOR FILTER FILTER PUMP

FIGURE 1-2. TYPICAL GENSET WITH HOUSING PANELS REMOVED

1-2
2. Specifications

HDKAH HDKAJ HDKAK

GENSET CONTROLLER: Integrated Microprocessor Based Engine and Generator Controller
GENERATOR: Brushless, Exciterless, Bearingless, Permanent Magnet Alternator
AC OUTPUT RATINGS:
Power (@1.0 power factor) 6000 W 7500 W 8000 W
Voltage 120 volts 120 volts 120 volts
Frequency 60 Hz 60 Hz 60 Hz
Number of Phases 1 1 1
Current 50.0 ampere 62.5 ampere 66.7 ampere
Line Circuit Breaker(s) 2-pole, 30 amp 2-pole, 30 or 35 amp 2-pole, 30 or 35 amp
ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection, 4-Stroke Cycle Diesel
Bore 2.64 inch (67 mm)
Stroke 2.68 inch (68 mm)
Displacement 44 inch3 (719 cc)
Compression Ratio 23 : 1
Oil Capacity (with filter)* 3 quart (2.6 l)
Cooling System Capacity** 4.2 quart (4 l)
Intake and Exhaust Valve Lash (Cold) 0.0065 inch (0.165 mm)
Lubricating Oil Pressure 14 to 64 psi over speed range
Cylinder Compression Pressure 414 to 469 psi, 327 psi minimum
OPERATING SPEED RANGE: 1600 to 2900 RPM 1600 to 3200 RPM 1600 to 3300 RPM
FUEL CONSUMPTION:
No-load 0.13 gph (.49 l/h) 0.13 gph (.49 l/h) 0.13 gph (.49 l/h)
Half-load (4000 W) 0.49 gph (1.85 l/h) 0.49 gph (1.85 l/h) 0.49 gph (1.85 l/h)
Full-load 0.80 gph (3.03 l/h) 0.96 gph (3.63 l/h) 1.02 gph (3.86 l/h)
DC SYSTEM:
Nominal Battery Voltage 12 volts
450 CCA*** down to 0° F (−17° C)
Minimum Battery Capacity
650 CCA*** down to −20° F (−29° C)
Maximum Regulated-Voltage Battery
Charging Current (Optional)
10 ampere
Fuse F1 (control circuit) 10 ampere mini-bayonet
Fuse F2 (starter solenoid circuit) 10 ampere mini-bayonet
Fuse F3 (glow plug circuit) 25 ampere
WEIGHT AND SIZE:
Weight (wet) 420 lbs (191 kg)
Length x Width x Height 36.3 x 23.6 x 22.3 inch (922 x 599 x 566 mm)
* See oil filling instructions.
** Includes coolant recovery tank.
*** Cold Cranking Amps @ 0° F (−17° C)

2-1
 HDKAV HDKAT HDKAU
GENSET CONTROLLER: Integrated Microprocessor Based Engine and Generator Controller
GENERATOR: Brushless, Exciterless, Bearingless, Permanent Magnet Alternator
AC OUTPUT RATINGS:
Power (@1.0 power factor) 6000 W 7500 W 8000 W
Voltage 120 volts 120 volts 120 volts
Frequency 60 Hz 60 Hz 60 Hz
Number of Phases 1 1 1
Current 50.0 ampere 62.5 ampere 66.7 ampere
Line Circuit Breaker(s) 2-pole, 30 amp 2-pole, 30 or 35 amp 2-pole, 30 or 35 amp
ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection, 4-Stroke Cycle Diesel
Bore 2.64 inch (67 mm)
Stroke 2.68 inch (68 mm)
Displacement 44 inch3 (719 cc)
Compression Ratio 23 : 1
Oil Capacity (with filter)* 3 quart (2.6 l)
Cooling System Capacity** 4.2 quart (4 l)
Intake and Exhaust Valve Lash (Cold) 0.0065 inch (0.165 mm)
Lubricating Oil Pressure 14 to 64 psi over speed range
Cylinder Compression Pressure 414 to 469 psi, 327 psi minimum
OPERATING SPEED RANGE: 1600 to 2900 RPM 1600 to 3200 RPM 1600 to 3300 RPM
FUEL CONSUMPTION:
No-load 0.13 gph (.49 l/h) 0.13 gph (.49 l/h) 0.13 gph (.49 l/h)
Half-load (4000 W) 0.49 gph (1.85 l/h) 0.49 gph (1.85 l/h) 0.49 gph (1.85 l/h)
Full-load 0.80 gph (3.03 l/h) 0.96 gph (3.63 l/h) 1.02 gph (3.86 l/h)
DC SYSTEM:
Nominal Battery Voltage 12 volts
450 CCA*** down to 0° F (−17° C)
Minimum Battery Capacity
650 CCA*** down to −20° F (−29° C)
Maximum Regulated-Voltage Battery
Charging Current (Optional)
10 ampere
Fuse F1 (control circuit) 10 ampere mini-bayonet
Fuse F2 (starter solenoid circuit) 10 ampere mini-bayonet
Fuse F3 (glow plug circuit) 25 ampere
WEIGHT AND SIZE:
Weight (wet) 420 lbs (191 kg)
Length x Width x Height 36.3 x 23.6 x 22.3 inch (922 x 599 x 566 mm)
* See oil filling instructions.
** Includes coolant recovery tank.
*** Cold Cranking Amps @ 0° F (−17° C)

2-2
3. Thread Torques

lbf-ft* N-m *
Air Cleaner Cover Bolt—Three to four clicks past seating. − −
Air Cleaner Housing Mounting Screws 7-9 10-12
Intake Air Hose Clamp Screws 7-9 10-12
Air Intake Resonator Mounting Screws 7-9 10-12
Fuel Pump Mounting Screws 75-80 lbf-inch 8.5-9
Fuel Fitting At Fuel Pump 7-9 10-12
Fuel Fittings at Fuel Filter—One flat passed finger tight. − −
Exhaust Assembly Flange Bolts 16-20 22-28
Exhaust Isolator Clamp Screws 7-9 10-12
Housing Panel Screws 11-13 15-18
Component Mounting Screws (threads into skid-base) 7-9 10-12
Vibration Isolator Center Bolt 43-53 58-72
Vibration Isolator Mounting Screws 7-9 10-12
Battery Cable Terminal Block Terminal Nuts 6.7-8.3 9-11
Battery Cable Terminal Block Mounting Screws 7-9 10-12
Starter Solenoid Terminal Nuts 4.4-8.7 5.9-11.8
AC Output Terminal Block Terminal Screws 12-14 lbf-inch 1.4-1.6
AC Output Terminal Block Mounting Screws 20-22 lbf-inch 2.2-2.5
Circuit Breaker Terminal Screws 12-14 lbf-inch 1.4-1.6
Circuit Breaker Mounting Screws 12-14 lbf-inch 1.4-1.6
Flywheel Housing Mounting Bolts 18-22 24-30
Rotor/Flywheel Mounting Bolts 40-43 53.9-58.8
Stator Mounting Bolts 7-9 10-12
Blower Mounting Bolts 7-9 10-12
Starter Mounting Bolts 18-22 24-30
Oil Pan Mounting Bolts 5.8-6.9 7.9-9.3
Coolant Temperature Sender (use thread sealant) 26-32 35-43
Low Oil Pressure Switch (use thread sealant) 10.8-14.5 14.7-19.6
Governor Actuator Bearing Carrier Mounting Screws 21-27 lbf-inch 2.4-3.0
Oil Fill Hose Support Clip Screw 7-9 10-12
M6 Engine Bolts Except When Otherwise Specified 5.8-6.9 7.9-9.3
M8 Engine Bolts Except When Otherwise Specified 13.0-15.2 17.7-20.6
M10 Engine Bolts Except When Otherwise Specified 28.9-33.3 39.2-45.1
M12 Engine Bolts Except When Otherwise Specified 46.3-53.5 62.8-72.6
* − Use engine oil as a lubricant for all threads except when otherwise specified.

3-1
4. Operation
FUEL RECOMMENDATIONS Class SJ, SH or SG (for example: CH-4/SJ). Also
look for the SAE (Society of Automotive Engineers)
Use clean, fresh No. 2 diesel fuel (ASTM 2-D) in viscosity grade. Referring to Figure 4-1, choose the
ambients above freezing and No. 1 diesel fuel viscosity grade appropriate for the ambient temper-
(ASTM 1-D) in ambients below freezing. The fuel atures expected until the next scheduled oil change.
should have a Cetane number of at least 45 for reli-
able starting. STARTING BATTERIES
These gensets have a 12 volt, direct current (DC)
WARNING Diesel fuel is combustible and can
starting and control system. See Specifications for
cause severe personal injury or death. Do not
minimum battery requirements (cold cranking am-
smoke near diesel fuel tanks or equipment.
peres) for genset starting.
Keep flames, sparks, pilot lights, electrical arcs
and arc-producing equipment and switches and Regular, monthly maintenance of batteries may be
all other sources of ignition well away. Keep a required. See Periodic Maintenance, and any in-
type ABC fire extinguisher in the vehicle. structions available from the vehicle manufacturer
or battery manufacturer. Either the vehicle or the
ENGINE OIL RECOMMENDATIONS genset will be equipped with a battery charger.

Use API (American Petroleum Institute) perfor- Reliable genset starting and starter service life de-
mance Class CH-4, CG-4 or CF-4D engine oil, pend upon adequate battery system capacity and
which may be in combination with performance proper maintenance.

Anticipated Ambient Temperature

FIGURE 4-1. OIL VISCOSITY VS. TEMPERATURE

4-1
 OPERATOR’S CONSOLE REMOTE CONTROL PANEL

The operator’s console (Figure 4-2) has the follow- The vehicle may be equipped with a remote control
ing features: panel having a Control Switch and Preheat/Diag-
nostics Light. In addition, it may have an hour me-
Control Switch − This switch is used to start and ter and the following engine gauges:
stop the genset, prime the engine fuel system and Oil Pressure Gauge − The oil pressure gauge indi-
restore the fault code (blinking status light). cates the presence of engine oil pressure.
Status Light − This is an LED (light emitting diode) Water Temperature Gauge − The water tempera-
in the control switch which blinks rapidly during pre- ture gauge indicates engine coolant temperature.
heat and cranking. (Preheat is the period of time
prior to engine cranking when the glow plugs pre- Voltmeter − The voltmeter indicates battery volt-
heat the combustion chambers. The time is auto- age.
matically varied by the genset controller on the ba-
sis of engine temperature.) After the genset starts
up, this light stays on continuously, indicating that ACCESS COOLANT OIL FILL CAP
the genset is running and that the starter has dis- PLATE RECOVERY TANK AND DIP STICK
connected. Also, if the genset shuts down, this light FILL CAP (BLUE) (YELLOW)
blinks in a coded fashion to indicate the nature of the
shutdown. See Troubleshooting.

Line Circuit Breaker(s) − The line circuit break-

er(s) protect the AC power leads connected to the
genset.

Engine Oil Fill Cap/Dipstick − The oil dipstick is at-

tached to the fill cap and is marked ADD and FULL.

Coolant Recovery Tank Fill Cap − The recovery

tank provides for coolant expansion. Replenish the
normal loss of coolant by filling here.

Coolant Pressure Cap − The coolant pressure cap

is accessible by removing the access plate on the
control console. It provides for a pressurized engine
cooling system. Fill coolant here when refilling the
system. CONTROL
SWITCH AND HOUR METER LINE CIRCUIT
STATUS LIGHT (OPTIONAL) BREAKER
Fuses F1, F2 and F3 − These fuses are accessible
by removing the access plate on the control con-
sole. They protect the control circuits of the genset. FIGURE 4-2. OPERATOR’S CONSOLE

4-2
 WARNING EXHAUST GAS IS DEADLY! All engine exhaust contains carbon monoxide, an odor-
less, colorless, poisonous gas that can cause unconsciousness and death. Symptoms of carbon
monoxide poisoning include:

• Dizziness • Headache
• Nausea • Weakness and Sleepiness
• Vomiting • Inability to Think Coherently

IF YOU EXPERIENCE ANY OF THESE SYMPTOMS, GET INTO FRESH AIR IMMEDIATELY. If symptoms
persist, seek medical attention. Shut down the genset and do not operate it until it has been inspected
and 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.

PRIMING THE FUEL SYSTEM CAUTION Excessive cranking can over-

heat and damage the starter motor. Do not
The fuel system should be primed after replacing crank for more than 30 seconds at a time.
the fuel filter or running the genset out of fuel. To Wait at least 2 minutes before trying again.
prime the fuel system hold the control switch down
in its Stop position for at least 1 minute. 4. See Troubleshooting if the genset does not
start after three tries.
STARTING
5. Let the genset warm up a few minutes until it is
The genset can be started and stopped from the running smoothly before connecting the ve-
genset control panel or from a remote control panel hicle electrical loads (appliances).
inside the vehicle. 6. Monitor the engine gauges if the remote panel
1. Review Powering Equipment, Varying Operat- is so equipped. Normal readings during opera-
ing Conditions, Genset Break-In, Exercise and tion are as follows:
Storage and the Maintenance Record in the
Oil Pressure: Approximately center of scale
Operator’s Manual before starting or servicing
the genset. Temperature: 160°-220° F (71°-104° C)
2. Check fuel, oil and coolant levels, prime the fuel DC Voltage: 14-15 volts.
system if necessary (by pushing the Stop
switch), and turn off the air conditioner(s) and 7. Check for fuel, coolant and exhaust leaks. Stop
other large electrical loads. the genset immediately if there is a fuel, coolant
or exhaust leak and repair it before continuing
3. Push the control switch to its Start position and
operation.
hold it there while the status light blinks rapidly
indicating preheat. Let go when the light comes
on continuously, indicating that the genset is STOPPING
running and that the starter has been discon-
nected. (Depending on how cold it is, preheat Run the genset at no load for a few minutes to allow
can take up to 15 seconds, extending the time the engine to cool down and then push the control
that the light blinks.) switch briefly to its Stop position.

4-3
5. Periodic Maintenance
PERIODIC MAINTENANCE SCHEDULE guide for normal periodic maintenance. Under hot
or dusty operating conditions some maintenance
Periodic maintenance is essential for top perfor- operations should be performed more frequently, as
mance and long genset life. Use Table 5-1 as a indicated by the footnotes in the table.x

TABLE 5-1. PERIODIC MAINTENANCE SCHEDULE

MAINTENANCE FREQUENCY

P
MAINTENANCE OPERATION Every
Every Every Every Every a
1000
Day Month 150 Hours 500 Hours g
Hours
e
General Inspection x 5-2
Check Engine Oil Level x 5-3
Check Engine Coolant Level x 5-8
Clean and Check Battery x3 5-3
Change Engine Oil and Filter x1, 2,3, 4 5-3
Clean Spark Arrestor x4 5-5
Replace Engine Air Filter x2, 4 5-6
Replace Fuel Filter x4 5-7
Check Coolant Anti-freeze Protection x4 5-8
Flush Coolant System x5 5-8
Replace Coolant Pressure Cap x5 5-8
Replace Coolant Hoses and Thermostat x6, 7 12-1
Replace Engine V-belt x6, 7 12-1
Clean Crankcase Breather x6, 7 12-1
Adjust Valve Lash x7 12-1
1. As a part of engine break-in, change the engine oil and oil filter after the first 50 hours of operation.
2. Perform more often when operating in dusty conditions.
3. Perform more often when operating in hot weather.
4. Perform at least once a year.
5. Perform at least once every two years.
6. Perform at least once every five years.
7. Must be performed by a qualified mechanic (authorized Onan dealer).

5-1
 GENERAL INSPECTION Do not operate power ventilators or exhaust fans
while the vehicle is standing with the genset run-
Inspect the genset before the first start of the day. ning. The ventilator or fan can draw exhaust gases
into the vehicle.
Oil Level
WARNING EXHAUST GAS IS DEADLY! Do not
Check engine oil level (p. 5-3). operate the genset if there is an exhaust leak or
any danger of exhaust gases entering or being
Engine Coolant System
drawn into the vehicle.
Check the coolant level and look for coolant leaks
around the bottom of the genset and on the ground WARNING Do not park the vehicle in high grass
below. Minor leaks that can be replenished by daily or brush. Contact with the exhaust system can
additions of coolant to the recovery tank should be cause a fire.
repaired by a qualified service technician as soon as
possible. Larger leaks are cause for shutting down Fuel System
the genset until it can be repaired.
Look for fuel leaks around the bottom of the genset
CAUTION Operating the genset when the and its fuel supply lines when the genset is running.
coolant level is low can cause serious engine Do not operate the genset if there is a fuel leak.
damage. Have the leaks fixed as soon as possible.

Exhaust System WARNING Diesel fuel leaks can lead to fire. Do

not operate the genset if operation causes fuel
Look and listen for exhaust system leaks while the to leak.
genset is running. Shut down the genset if a leak is
found and have it repaired before operating the gen- Mechanical
set.
Look for mechanical damage. Start the genset and
Look for openings or holes between the genset look, listen and feel for any unusual noises and
compartment and vehicle cab or living space if the vibrations.
genset engine sounds louder than usual. Have all
such openings or holes closed off and sealed to pre- Check the genset mounting bolts to make sure they
vent exhaust gases from entering the vehicle. are secure.

Replace dented, bent or severely rusted sections of Check to see that the genset air inlet and outlet
the tailpipe and make sure the tailpipe extends at openings are not clogged with debris or blocked.
least 1 inch (25.4 mm) beyond the perimeter of the
vehicle. Check the engine gauges from time to time while the
genset is running (if so equipped).
Park the vehicle so that the genset exhaust gases
can disperse away from the vehicle. Barriers such Battery Connections
as walls, snow banks, high grass and brush and oth-
er vehicles can cause exhaust gases to accumulate Check the battery terminals for clean, tight connec-
in and around the vehicle. tions. See BATTERIES (p. 5-6).

5-2
 CHECKING ENGINE OIL LEVEL
Shut off the genset before checking the engine oil
level.
1. Remove the oil fill cap (yellow) and wipe the
stick clean (Figure 5-1).
2. Screw the oil fill cap back on and remove it to
check the oil level on the dipstick.
3. Add oil as necessary until the full mark is
reached. See ENGINE OIL RECOMMEN-
DATIONS (p. 4-1). DO NOT FILL TO A LEVEL
ABOVE THE FULL MARK ON THE DIPSTICK.
Drain the excess oil if too much has been add-
ed.
CAUTION Too much oil can cause high oil
consumption, high operating temperatures
and oil foaming. Too little oil can cause se-
vere engine damage. Keep the oil level be-
tween the Full and Add marks on the dip-
stick.
4. Screw the oil fill cap on securely to prevent oil
leakage.
CHANGING ENGINE OIL AND OIL FILTER
Refer to Table 5-1 for scheduled engine oil change.
In hot weather and dusty conditions the oil should be
changed more often.
WARNING State and federal agencies have de-
termined that contact with used engine oil can FIGURE 5-1. OIL DIPSTICK
cause cancer or reproductive toxicity. Take care
to limit skin contact and breathing of vapors as
much as possible. Use rubber gloves and wash
exposed skin.
1. Place a pan under the oil drain plug. Run the
engine until it is warm and shut it off.
2. Remove the oil fill cap (Figure 5-1).
3. Unscrew the oil drain plug (Figure 5-2) and al-
low all of the oil to drain from the engine.
4. Reinstall the oil drain plug and tighten it secure-
ly to prevent oil leakage.

5-3
5. Squeeze the access door latches together and a larger diameter than the original filter cannis-
let the door swing down (Figure 5-2). Spin off ter, but will fit.)
the oil filter canister, drain it of oil and discard it 8. Spin on the new filter canister by hand until the
according to local regulations. gasket just touches the mounting pad and then
6. Thoroughly wipe off the filter mounting surface. turn it an additional 1/2 to 3/4 turn. Do not over-
Remove the old gasket if it does not come off tighten. Close the access door, making sure it
with the filter canister. latches securely.

7. Make sure the new gasket is in place on the 9. Refill and check the oil level. See Specifications
new filter canister and apply a thin film of oil to for oil capacity.
the gasket. (The replacement filter canister has 10. Dispose of the used oil properly.

ACCESS OIL
DOOR FILTER

OIL DRAIN
PLUG

FIGURE 5-2. OIL DRAIN PLUG AND OIL FILTER

5-4
 SPARK ARRESTOR fler, accessible through the air outlet opening in the
bottom of the genset. Clean out the spark arrestor
Refer to Table 5-1 for scheduled cleaning of the muffler as follows:
spark arrestor muffler (which meets U.S. Forest
Service requirements). Cleaning is required for 1. Remove the cleanout plug from the muffler
maximum genset performance. (Figure 5-3).

WARNING A hot muffler can cause severe 2. Restart the genset and load it nearly to full pow-
burns. Let the muffler cool down before remov- er. Let the genset run for about five minutes to
ing or installing the cleanout plug. expel the soot in the muffler.

The muffler is mounted inside the genset housing. 3. Stop the genset, allow the muffler to cool down
The cleanout plug is located on the side of the muf- and then reinstall the plug.

CLEANOUT
PLUG

FIGURE 5-3. SPARK ARRESTOR CLEANOUT PLUG

5-5
 BATTERIES 2. Remove battery cables with a battery terminal
puller.
WARNING Arcing at battery terminals, light 3. Make sure which terminal is positive (+) and
switch or other equipment, flame, and sparks which is negative (−) before making battery
can ignite battery gas causing severe personal connections, always removing the negative (−)
injury. cable first and reconnecting it last to reduce
arcing.
Ventilate battery area before working on or near
battery—Wear safety glasses—Do not smoke— AIR FILTER
Switch trouble light ON or OFF away from bat-
tery—Stop genset and disconnect charger be-
fore disconnecting battery cables—Disconnect Refer to Table 5-1 for scheduled air filter replace-
negative (−) cable first and reconnect last. ment. In dusty conditions the air filter element
should be inspected and changed more frequently
Refer to Table 5-1 for scheduled battery mainte- for best operation. To change the air filter element,
nance, and follow the battery manufacturer’s in- remove the outer and inner covers (Figure 5-4) and
structions. Have the battery charging system ser- reassemble with a new air filter element. Turn the in-
viced if DC system voltage is consistently low or ner cover wingnut three to four clicks past seating.
high. Always: Make sure the outer cover is seated before tighten-
1. Keep the battery case and terminals clean and ing its wingnut. Check for noise when the genset
dry and the terminals tight. is running, and retighten if necessary.

OUTER COVER INNER COVER FILTER ELEMENT SPACER SEAL HOUSING

FIGURE 5-4. AIR FILTER ELEMENT

5-6
 FUEL FILTER Removing the Fuel Filter: To remove the filter, dis-
connect the two fittings at the filter and remove the
mounting nut. Apply a wrench on the filter fitting as
Refer to Table 5-1 for scheduled replacement of the
well as on the flare nut so as not to stress the fitting.
fuel filter (Figure 5-5). A dirty fuel filter may be the
Flare nut wrenches should be used on the flare nuts
cause if the engine fails to start. The fuel filter is ac-
so as not to round the corners on the nuts. Dispose
cessible through the maintenance access door in
of the fuel filter according to local regulations.
the skid-base. Squeeze the latches together to
open the door. Installing the Fuel Filter: Rotate the filter half a
turn around its mounting stud if the fittings interfere
CAUTION Wipe the dirt off the fuel fittings be- with the bracket. It only fits properly one way.
fore disconnecting them to keep dirt from enter-
ing the fuel system. Connect the fuel fittings before tightening the filter
mounting nut. Take care not to crossthread the fuel
fittings. Thread them in by hand and tighten one flat
WARNING Diesel fuel is combustible and can past seating.
cause severe personal injury or death. Do not
smoke. Keep flames, sparks, pilot lights, electri- Close the access door and prime the fuel system by
cal arcs and arc-producing equipment and all holding the control switch down in its Stop position
other sources of ignition well away. Keep a type for at least 1 minute. Priming is necessary to dis-
ABC fire extinguisher handy. place the air in the new filter with fuel.

FUEL FUEL HOSE

FILTER TO ENGINE

FILTER
MOUNTING
NUT

TUBING FROM
FUEL PUMP

FIGURE 5-5. FUEL FILTER

5-7
 CHANGING COOLANT down and turning it until it can be withdrawn. Then
get a suitable container and drain the coolant by re-
Refer to Table 5-1 for scheduled maintenance. The moving the system drain cap (Figure 5-6).
engine cooling system is filled with a 50/50 mixture
of ethylene glycol anti-freeze and water when the WARNING Ethylene glycol antifreeze is con-
genset leaves the factory, which is suitable for tem- sidered toxic. Dispose of it according to local
peratures down to -34° F (-37° C). regulations for hazardous substances.

Replace the coolant every two years. Use ethylene It is recommended that the system be cleaned and
or propylene glycol anti-freeze solution that con- flushed before refilling. Radiator cleaning chemicals
tains a rust and corrosion inhibitor. The anti-freeze are available at local auto parts stores. Follow the
must not contain a stop-leak additive. instructions for cleaning and flushing that come with
the cleaning solution.
The water used for engine coolant must be clean,
low in minerals, and free of corrosive chemicals. Refilling the Cooling System
Use distilled water if available.
Fill the recovery tank with coolant mixture to the
See Specifications for cooling system capacity.
COLD mark.
Pressure Cap
Secure the system drain cap. Fill the cooling system
Replace the pressure cap every two years because with coolant mixture through the pressure cap/fill
its seals can deteriorate and begin to leak. Proper opening. Pull the hose connected to the pressure
cooling system pressure is essential for optimal en- cap assembly out as far as it will go. When coolant
gine cooling and minimal coolant loss. fills up to the fill opening, start and operate the gen-
set for a few minutes and shut it down. (It is recom-
Draining the Cooling System mended that the air conditioners or other large loads
be turned on so that the genset will operate under
WARNING Hot coolant spray can cause severe load, causing the engine to run faster and expel
burns. Let the engine cool before releasing the trapped air.) Add more coolant if necessary and se-
pressure cap or removing the drain cap. cure the pressure cap.

Allow the engine to cool before removing the pres- Coolant Level Check
sure cap. Then relieve any remaining pressure by
turning the pressure cap slowly, without pushing Check coolant level in the recovery tank before the
down on it, until it catches. When the pressure has first startup of each day and fill to the COLD mark if
been relieved, remove the pressure cap by pushing necessary.

5-8
 PRESSURE CAP
AND SYSTEM FILL
OPENING

COOLANT RECOVERY
TANK FILL CAP (BLUE)

COOLING
SYSTEM
DRAIN CAP

FIGURE 5-6. ENGINE COOLING SYSTEM FILL AND DRAIN CAPS

5-9
 COOLANT TEMPERATURE INPUT TABLE 5-2. COOLANT TEMPERATURE INPUT

Resistance measurements should be taken be- DIG _C DEG _F Sensor V to A/D Genset
tween the sensor lead and the battery ground post (OHMS) A/D
(rather than the engine chassis) for most accurate Count
reading with the harness disconnected at the sen- −20 −4 2100 4.27 218
sor. −10 14 1700 4.13 211
This sensor is not a precise temperature measure- −5 23 1500 4.04 206
ment. Differences between the table values and val-
0 32 1300 3.92 200
ues displayed on the LCD or tool are possible. See
sensor print for details. For example, if the sensor is 5 41 1150 3.82 195
placed in an ice bath, the control may read 32_F +/−
10 50 1000 3.68 188
few degrees, depending on the actual resistance of
the sensor being tested (sensor spec is +/−10% resis- 20 68 750 3.39 173
tence for a given temperature.)
30 86 600 3.13 160
40 104 450 2.79 142
50 122 320 2.36 121
60 140 210 1.85 94
65 149 175 1.64 84
70 158 145 1.44 74
75 167 128 1.32 67
80 176 110 1.18 60
85 185 90 1.01 51
90 194 70 0.82 42
100 212 57 0.69 35
110 230 43 0.54 27
120 248 33 0.42 22
130 266 25 0.33 17
140 284 20 0.27 14
150 302 15 0.20 10

5-10
6. Preparations for Service
SPECIAL TOOLS equipment. Do not work alone if possible and
take no risks.
The following tools are necessary for servicing the • Be prepared for an accident: Keep fire extin-
genset: guishers and safety equipment nearby. Agen-
• Torque wrench: 0-75 lbs-ft (0-100 N-m) cies such as the Red Cross and public safety
departments offer courses in first aid, CPR and
• Tachometer fire control. Take advantage of this information
• Digital multi-meter: AC and DC Voltage, Ohms to be ready to respond to an accident. Learn to
be safety-conscious and make safety proce-
• Load test panel and leads dures part of the work routine.
SAFETY TABLE 6-1. HAZARDS AND THEIR SOURCES

There are hazards in servicing gensets. Study Safe- • Leaking or spilled fuel
ty Precautions and become familiar with the haz- • Hydrogen gas from battery
ards listed in Table 6-1. Note the following safe- Fire and
guards and ways of avoiding hazards: Explosion • Oily rags improperly stored
• Flammable liquids improperly
• Use personal protection: Wear appropriate
stored
protective safety equipment, such as safety
shoes and safety glasses. Do not wear rings or • Hot exhaust pipes
jewelry and do not wear loose or damp clothing • Hot engine and generator sur-
that might get caught in equipment or conduct Burns
faces
electricity.
• Electrical shorts
• Reduce the hazard: A safe, orderly workshop
area and well-maintained equipment reduce Poisonous • Operating genset where ex-
the hazard potential. Keep guards and shields Gas haust gases can accumulate
in place on machinery and maintain equipment • Improper generator connec-
in good working condition. Store flammable liq- tions
uids in approved containers; away from fire,
flame, spark, pilot light, switches, arc-produc- Electrical • Faulty wiring
ing equipment and other ignition sources. Keep Shock (AC) • Working in damp conditions
the workshop clean and well-lighted and pro- • Jewelry touching electrical
vide adequate ventilation. components
• Develop safe work habits: Unsafe actions Rotating • Fan guards not in place
cause accidents with tools and machines. Be Machinery
familiar with the equipment and know how to
use it safely. Use the correct tool for the job and Slippery • Leaking or spilled oil
Surfaces
check its condition before starting. Comply with
the warnings in this manual and take special Heavy • Removing genset from vehicle
precautions when working around electrical Objects

6-1
 REMOVING GENSET FROM VEHICLE Removal from the Vehicle
WARNING Gensets are heavy and can cause
See Troubleshooting to determine the probable severe personal injury if dropped during remov-
cause of the problem before removing the genset al. Use adequate lifting devices. Keep hands
for service. The genset is normally mounted in a and feet clear while lifting.
special compartment on the floor of the vehicle or on
a supporting frame. Contact the vehicle manufac- Make sure that the genset is firmly supported before
turer or installer if the best way to remove the genset loosening any mounting bolts. There are four bolt
is not obvious. holes in the skid-base for securing the genset to the
floor or supporting frame. A lifting eye is accessible
Disconnections through the access opening in the top panel of the
genset (Figure 6-2).
1. Disconnect the negative (-) battery cable from
the battery and then disconnect the battery TEST STAND
cables from the genset.
WARNING EXHAUST GAS IS DEADLY! Engine
exhaust must be vented outside if the genset is
WARNING Sparks and high current could operated inside a building.
cause fire and other damage to the battery,
battery cables and vehicle if the loose ends CAUTION Restricting the air inlet and outlet
of cables connected to the battery touch. openings could lead to damage to the genset
Always disconnect the negative (−) battery due to overheating.
cable from the battery before disconnecting
the battery cables from the genset. When testing and servicing the genset on a work-
bench or test stand make sure the openings in the
2. Disconnect the remote control wiring harness skid-base shown in Figure 6-1 (shaded areas) are
connector at the genset. free and clear. Also, make sure there is ample fresh
air when operating the genset.
3. Disconnect the AC output leads at the genset
terminals.

4. Disconnect the exhaust tailpipe from the muf-

fler flange. ACCESS
Á
Á
DOOR

5. Disconnect the supply and return fuel lines from

the genset.

WARNING Diesel fuel is combustible and

can cause severe personal injury or death.
AIR
Do not smoke if you are near fuel tanks or IN
fuel-burning equipment or are in an area AIR
OUT
sharing ventilation with such equipment.
Keep flames, sparks, pilot lights, electrical
arcs and arc-producing equipment and all
other sources of ignition well away. FIGURE 6-1. BOTTOM VIEW OF SKID-BASE

6-2
 REMOVING HOUSING PANELS radiator frame. Because of overlapping edge
flanges, loosen the screws along the bottom edge of
WARNING Do not operate the genset without the left end panel so that it can be tilted out of the
the housing panels secure in place. The panels way while lifting out the back panel.
guard against rotating parts and bare live elec-
trical parts that can cause severe personal inju- Removing the Right End Panel
ry or death. The housing is also required for
proper genset cooling. Remove the top panel and all the screws around the
perimeter of the right end panel and lift it out.
See Figure 6-2. The housing consists of five remov-
able panels. The front (service) panel may also in-
Removing the Left End Panel
clude a removable service door secured by latches.
Note that the screws which secure the panels to the 1. Remove the front, top and back panels.
skid-base are slightly longer than the screws be-
2. Remove the AC terminal block mounting
tween panels. Keep the screws separated to make
screws so that it will be unnecessary to loosen
reassembly easier.
the wire binding screws.
Removing the Front and Top Panels 3. Remove the line circuit breaker mounting
screws (on the operator’s console).
It may be necessary to remove only the front (ser-
vice) or front and top panels for access to the parts 4. Disconnect the engine harness from the control
which need service (Figure 1-2). To do so, remove switch and hour meter (if provided).
all the screws around the perimeter of each panel 5. Remove the screws along the bottom edge, tilt
and pull the panel away. Note that the three screws the panel out, disconnect the leads to the con-
in the top panel which are circled also support the trol switch and hour meter (if so equipped) and
coolant recovery tank. cut the wire ties which secure the wiring har-
CAUTION Screws that are too long will dam-
ness to the panel.
age the coolant recovery tank and may cause it
to break away. Make sure the shorter panel INSTALLING HOUSING PANELS
screws are used for the recovery tank.
Installation is the reverse of removal. Use wire ties
Removing the Back Panel to secure the engine and AC harnesses (p. A-1
and A-2) to the left end panel when reassembling
Remove the top panel, all the screws around the pe- the genset. Tighten the panel screws according to
rimeter of the back panel and the two screws into the Thread Torques.

6-3
 ACCESS COVER LEFT END ACCESS COVER ACCESS COVER BACK
FUSES AND COOLANT PANEL AC TERMINALS LIFTING EYE PANEL
PRESSURE CAP

OPERATOR‘S
CONSOLE

SCREW HOLES FOR

SCREWS WHICH ALSO
SECURE THE COOLANT FRONT (SERVICE) PANEL TOP RIGHT END
RECOVERY TANK (MAY INCLUDE A SERVICE DOOR) PANEL PANEL

FIGURE 6-2. THE GENSET HOUSING PANELS

6-4
7. Engine Air Intake
COMPONENT LAYOUT
Figure 7-1 illustrates the series of parts connected
to the engine air intake manifold. The arrows indi-
cate the flow of air.

SECURE THE END OF THE AIR INLET BAFFLE

INLET HOSE TO THE INLET ASSEMBLY
GRILLE WITH A WIRE TIE

MAKE SURE THESE HOSE

CLAMP SCREWS ARE ON TOP
AND ORIENTED AS SHOWN TO
MAKE DISASSEMBLY EASIER

AIR FILTER
ELEMENT
HOUSING
RESONATOR

CLAMP AT ENGINE BAFFLE SCREWS TO

INTAKE MANIFOLD SKID-BASE

FIGURE 7-1. ENGINE AIR INTAKE ASSEMBLY

7-1
8. Muffler
REMOVAL nector when installing the muffler. Tighten all bolts
and screws according to Thread Torques.
The muffler assembly is mounted inside the genset
housing. See Figure 8-1. To remove the muffler: CAUTION The flexible connector is fragile
when removed from the assembly and must not
1. Disconnect the negative (-) battery cable from be bent or twisted. Make sure the muffler is se-
the battery to prevent the genset from starting curely in place and properly aligned before con-
and remove the top and back genset housing necting the flexible connector.
panels (p. 6-3).
Important safety warnings and instructions regard-
2. Disconnect the tailpipe.
ing the routing and termination of the tailpipe (not
3. Remove the flange bolts on both ends of the supplied by Onan) are included in the Installation
flexible connector and remove it carefully. Manual. Always use a new flange gasket when con-
necting the tail pipe.
4. Remove the outboard bearing clamp and slide
the assembly to the right (while facing the gen- WARNING Exhaust gas is deadly. The exhaust
set from the back) until the pins in the two in- system must not leak. Liability for injury, death,
board bearings are free. damage and warranty expense due to the use of
an unapproved muffler or due to modifications
INSTALLATION becomes the responsibility of the person instal-
ling the unapproved muffler or performing the
Installation is the reverse of removal. Always use modifications. Use Onan approved exhaust
new flange gaskets on both ends of the flexible con- system parts.

8-1
 ELBOW AND
FLEXIBLE
CONNECTOR

MUFFLER
ASSEMBLY

FLANGE
GASKETS
OUTBOARD
MOUNTING
BEARING

MUFFLER
ENGINE EXHAUST
OUTLET
MANIFOLD FLANGE
FLANGE

INBOARD
MOUNTING
BEARING
(TWO)

FIGURE 8-1. MUFFLER ASSEMBLY

8-2
9. Engine Cooling System
GENERAL 4. Remove the two screws which secure the ra-
diator to the inner bulkhead and pull it away.
The genset has a liquid cooled engine. A centrifugal
blower (Figure 11-2) is mounted on the end of the Alternative Removal Procedure
generator (PMA) rotor to move air for cooling the
1. Perform Steps 1 and 2.
genset and radiator. The blower pulls air in from an
opening in the bottom of the genset to pressurize 2. Remove the muffler (p. 8-1).
the engine compartment. Air flows through the ra- 3. Disconnect the upper and lower hoses from the
diator from the top side into the muffler compart- engine and loosen the hose bracket at the front
ment and then out the bottom. See Figures 9-1 and of the engine.
9-2.
4. Remove the screw which secures the system
See Periodic Maintenance for cooling system main- drain “T” (Figure 9-2).
tenance.
5. Remove the two screws in the horizontal por-
See Page 12-1 for instructions on how to replace tion of the bulkhead that projects under the ra-
the coolant pump drive belt. diator.
6. Pull the radiator, coolant recovery tank and in-
See the engine service manual for thermostat and ner bulkhead away as an assembly with all the
pump service. hoses connected.
RADIATOR REMOVAL RADIATOR INSTALLATION
Removal Procedure Installation is the reverse of removal. If the inner
1. Remove the top and back housing panels of the bulkhead was removed, make sure the end of the
genset (p. 6-3). crankcase breather hose (Figure 9-2) is pushed
2. Drain the system. back through the exit hole in the bulkhead (Fig-
ure 9-1).
WARNING Hot coolant spray can cause se-
Make sure to reinstall the hose bracket at the front of
vere burns. Let the engine cool before re-
the engine to keep the belt from rubbing on the
leasing the pressure cap or removing the
hose. (The bracket squeezes the hose slightly.)
drain cap.
3. Disconnect all four hoses. Tighten all screws according to Thread Torques.

9-1
PRESSURE RADIATOR INNER THERMOSTAT
CAP BULKHEAD HOUSING

COOLANT
COOLANT
RECOVERY
PUMP
TANK
PULLEY

UPPER RADIATOR HOSE CRANKCASE BREATHER LOWER ENGINE

HOSE BRACKET HOSE EXIT HOSE

FIGURE 9-1. ENGINE COOLING SYSTEM (I OF 2)

9-2
 COOLANT PRESSURE SYSTEM SYSTEM
UPPER
RECOVERY CAP FILL HOSE VENT HOSE
RADIATOR
TANK
HOSE

CRANKCASE
BREATHER
HOSE

HOSE
BRACKET RADIATOR

LOWER
RADIATOR
HOSE

LOWER SYSTEM
ENGINE INNER DRAIN “T”
HOSE BULKHEAD AND CAP

FIGURE 9-2. ENGINE COOLING SYSTEM (2 OF 2)

9-3
10. Controller-Inverter
GENERAL and remove the genset housing panels
(p. 6-3).
Figure 10-1 shows two views of the controller-in-
verter housing. Also shown are all of the wiring 2. Disconnect all external wiring connections and
leads, connectors and terminals on the housing, the grounding strap from the housing.
and the heat sink for the electronic components in-
side. 3. Remove the screw securing the housing to the
radiator frame and inner bulkhead.
There are no field replaceable parts inside the con-
troller/inverter housing. See Troubleshooting to de- 4. Remove the 6 screws securing the housing to
termine when it may be necessary to replace the as- the inlet baffle assembly (Figure 7-1).
sembly.
5. Remove the 5 screws along the lower back of
Note: Tests with an ohmmeter or diode checker the housing and lift out the housing.
across the leads, terminals and connector pins on
the controller/inverter housing itself have not been
prescribed, as they would not lead to useful service INSTALLATION
information.

Note also that attempting to operate the genset with Installation is the reverse of removal.
any of the wiring disconnected from the controller/
inverter assembly results only in shutdown and a 1. Make sure to reconnect the grounding eyelet in
Fault Code being displayed. the AC harness (p. A-2) and the grounding
REMOVAL strap from the skid-base.

1. Disconnect the negative (-) battery cable from 2. Tighten all screws according to Thread
the battery to prevent the genset from starting Torques.

10-1
 SECURE ENGINE AND
AC HARNESS SUPPORT
CLIPS HERE

J1 AND J2
FOR ENGINE
HARNESS

6 LEADS WITH QUICK CONNECTORS

2 TO CT (CURRENT TRANSFORMER) IN AC HARNESS
AND 4 TO GLOW PLUGS AND STARTER SOLENOID IN
ENGINE HARNESS

TB3
FOR AC
HARNESS

CONNECT GROUND STRAP FROM

SKID-BASE AND GROUNDING 6 LEADS WITH QUICK HEAT
EYELET IN AC HARNESS HERE CONNECTORS TO PMA LEADS SINK

FIGURE 10-1. CONTROLLER-INVERTER HOUSING

10-2
 CONTROLLER-INVERTER FUNCTIONS Stopping

The controller-inverter is an integrated micropro- When the control switch is touched to the Stop posi-
cessor-based engine and generator control. See tion, the Controller disables output voltage, deener-
the block diagram in Figure 10-2. It provides all the gizes the fuel pump and governor actuator, turns off
control, monitoring and diagnostics functions re- the status indicator, writes session data (number of
quired to operate the genset. Major functions in- cranks, minutes of operation, last fault, etc.) to non-
clude: volatile memory (NVM) and removes processor
power when idle 5 minutes (battery saver function).
Initialization
Note: Stop takes precedence over Start if both pres-
Control initialization consists of checking memory ent due to a faulty switch or other cause.
(RAM, ROM, EEPROM) and genset configuration.
Priming
Starting
When the control switch is pressed and held in the
When the control switch is pressed and held in the Stop position for more than 2 seconds, the Control-
Start position until start disconnect, the startup se- ler energizes the fuel pump and turns on the status
quence of the Controller: indicator for as long as Stop is held.
1. Energizes the fuel pump.
Note: Beginning Spec F, Stop must be released if
2. Flashes the status indicator to indicate preheat
stopping the genset and reapplied to prime.
and crank.
3. Energizes the glow plugs for temperature-de- Speed Control
pendent durations (Tables 10-1 and 10-2).
4. Energizes the governor actuator (moves to- The Controller maintains the speed range for which
ward full rack). the genset is configured (Specifications). For RV
5. Energizes the starter when preheat has been configurations (HDKAH, HDKAJ and HDKAK) a
completed. speed of approximately 2300 rpm is commanded
during the first minute, 1950 rpm during the second
6. Deenergizes the starter at 800 rpm. minute and 1600 rpm (idle) thereafter. Speed will be
increased at any time as loading requires (variable
7. Turns on the status indicator to indicate start speed control).
disconnect.
8. Turns on Switched B+ (remote connector Voltage Control
pin J8-F).
9. Enables the inverter (output voltage). The Inverter converts the 3-phase AC output of the
engine-driven PMA (permanent magnet alternator)
TABLE 10-1. PREHEAT TIMINGS
into 1-phase AC output at the voltage and frequency
Coolant Temp > 120 °F 0 sec
for which the genset is configured (follow the heavy
Coolant Temp 50 °F 5 sec
arrows in Figure 10-2). The Controller maintains
Coolant Temp 23 °F 10 sec
nominal AC voltage output during steady state op-
Coolant Temp < −4 °F 15 sec
eration. In response to transient loads the Controller
TABLE 10-2. POSTHEAT TIMINGS* adjusts the voltage setpoint to allow engine recov-
Coolant Temp > 70 °F 0 sec ery.
Coolant Temp < 70 °F 5 sec
* − Following start disconnect
Fault Shutdown and Diagnostics
Note: Beginning Spec F, Start must be released and
reapplied for subsequent start attempts. See Troubleshooting.

10-3
 CONTROLLER-INVERTER ASSEMBLY
(FOR ILLUSTRATION ONLY—INTERNAL PARTS NOT FIELD SERVICEABLE)

INVERTER
OVERTEMP
LOCAL CONTROL

REMOTE CONTROL
PMA

SWITCHED B+
DC BUS

PC SERIAL CONNECTION
(FOR FACTORY ONLY)

FUEL PUMP CONTROLLER

POWER
GLOW PLUGS DEVICES

STARTER

GOVERNOR ACTUATOR
AC
FILTERS
ENGINE SENSORS

BATTERY

CURRENT
SENSOR
CONTROL & FEEDBACK

OUTPUT POWER
AC OUTPUT

FIGURE 10-2. CONTROLLER-INVERTER BLOCK DIAGRAM

10-4
11. PMA (Generator)
GENERAL ment, the test should be repeated after the windings
have been dried. The most effective way of drying
The genset has an 8-pole permanent magnet alter- the stator windings, if the genset is operable, is to
nator (PMA) type of generator with a 3-phase stator run it under full load for at least one hour.
(Figure 11-1). The magnets are bonded to the rotor
with adhesive. The rotor is a one piece casting with Testing with a Digital Ohmmeter: A digital ohm-
the flywheel. A bearing is not used to support the meter can be used (highest scale) as a preliminary
end of the rotor and there are no slip rings, brushes check. It should read infinite resistance.
or exciters. See Figure 11-2.
Winding Resistance
STATOR TESTS
Testing with a Digital Ohmmeter: A digital ohm-
Winding Insulation Resistance Test meter can be used (lowest scale) as a preliminary
check for an open winding. It should read approxi-
Disconnect the negative (-) battery cable from the mately 1 ohm.
battery to prevent the genset from starting and re-
move the top panel of the housing (p. 6-3). Testing with a Wheatstone Bridge: Use a Wheat-
stone bridge having at least a 0.001 ohm precision
WARNING Do not operate the genset without to measure the resistance across each winding lead
the housing panels secured in place. The panels pair: T1-1—T2-1, T3-1—T2-1, T1-1—T3-1,
guard against rotating parts and bare live elec- T1-2—T2-2, T3-2—T2-2, T1-2—T3-2. The resist-
trical parts that can cause severe personal inju- ance should be 0.997-1.219 ohms at 70° F (21° C).
ry or death.

Disconnect the six PMA winding leads from the con- T1-1 T2-1
troller/inverter assembly leads (p. 10-2).

Testing with a Megger: A 500 VDC megger is rec-

ommended for testing winding insulation resist- T1-2 T2-2
ance. Apply the test voltage between a lead from
each winding group (T1-1 and T1-2) and ground
(stator laminations) for 10 minutes and record re-
sistance values at one minute and at 10 minutes.

Resistance values of at least 5 megohms should be

obtained for a new stator with dry windings. The po-
larization index (the ratio of the resistance reading
at 10 minutes to the reading at one minute) should T3-1
also be at least 2. For a genset that has been in ser-
vice, the resistance reading should not be less than
1 megohm nor the polarization index less than 2.
T3-2
If the readings are low, or the genset has been in
storage for a long time in a high-humidity environ- FIGURE 11-1. STATOR WINDING GROUPS

11-1
 PMA ROTOR, FLYWHEEL
AND STARTER RING GEAR

PMA STATOR AND

WINDING LEADS

ENGINE COOLING
BLOWER

ENGINE

FLYWHEEL
HOUSING

FIGURE 11-2. PMA ASSEMBLY

11-2
 STATOR REMOVAL ROTOR REMOVAL
The rotor can be unbolted from the engine after the
See Page 12-2 if the stator and engine are to be re- stator has been removed.
moved as an assembly. If the engine and rotor are to
remain in place, remove the stator as follows: ROTOR INSTALLATION

1. Disconnect the negative (-) battery cable from Note when installing the rotor that the five rotor-to-
the battery to prevent the genset from starting crankshaft bolts are not equally spaced, though
and remove the housing (p. 6-3). they look as if they are. To register the rotor and
crankshaft bolt holes properly before bolting:
2. Disconnect the stator winding leads. 1. Bar the engine until the counterweight on the
front engine pulley is straight down.
3. Remove the controller/inverter assembly
(p. 10-1). 2. Mate the rotor to the crankshaft such that the
middle line on the back of the flywheel lines up
4. Remove the blower (Figure 11-2). with the pointer in the window in the flywheel
housing. See Figure 11-3.
5. Remove the air filter cover and element. 3. Tighten all bolts according to Thread Torques.
6. Remove the three screws which secure the in-
let baffle assembly (Figure 7-1) to the base and
MIDDLE LINE ON FLYWHEEL
the two screws which secure it to the inner bulk- MUST LINE UP WITH
head and tilt it out. POINTER IN HOUSING

7. Remove the 4 stator mounting bolts and pull the

stator straight back. (The rotor magnets will re-
sist the motion.)

STATOR INSTALLATION

Installation is the reverse of removal. The stator

leads must be oriented as shown (Figure 11-2). The
stator must sit square within the four guide ears in
the flywheel housing. Tighten all bolts and screws
according to Thread Torques.

CAUTION The rotor magnets can be chipped

by rough handling, especially along the edges.
Guide the stator on and off carefully to avoid
chipping the edges of the magnets.

To prevent loss of magnetism due to shock, pro- PULLEY COUNTERWEIGHT

MUST BE DOWN
tect the rotor from being dropped or struck
while the stator is off, and keep metal chips
away from the rotor. FIGURE 11-3. ROTOR-CRANKSHAFT ALIGNMENT

11-3
12. Engine
ENGINE SERVICE ENGINE SENSORS
See Engine Workshop Manual 981−0514 for servic- The engine is equipped with a coolant temperature
ing the engine proper and for adjusting valve clear- sensor and low oil pressure cutout switch (Fig-
ance (lash), replacing the glow plugs, cleaning the ure 12-2). The associated fault codes are as fol-
crankcase breather assembly, replacing the coolant lows:
thermostat and pump and servicing the fuel injec- • No. 2—Low Oil Pressure
tion system. See Page 16-1 for starter motor remov-
al. See Periodic Maintenance regarding regular • No. 23—Oil Pressure Switch Fault
maintenance. • No. 24—Temperature Sender Fault
Use the flywheel timing mark shown in Figure 12-1 • No. 33—High Engine Temperature Fault
when adjusting valve lash and fuel injector pump
See Troubleshooting.
timing. The center line is 20° BTDC. The reference
marks on either side are 4° degrees from the timing
mark.

REPLACING COOLANT PUMP BELT TIMING MARK

See Periodic Maintenance for the belt replacement

interval. Since there is no means to adjust belt ten-
sion, it is critical that the correct replacement belt be
used. (Belt tension increases slightly as the engine
runs and is sufficient for the relatively light pump
load.)

CAUTION Using the wrong coolant pump

drive belt can lead to engine overheating.

To remove the belt, remove the negative (−) battery

cable from the battery to prevent accidental starting
of the set during replacement. Remove the 4 bolts
which secure the pump pulley to its hub and pull the
pulley and belt off.

To install a new belt, run the belt over both pulleys

and pull the pump pulley up to its hub and push it on.
Secure the pulley with the 4 bolts and tighten the
bolts according to Thread Torques.

Re-attach negative (−) battery cable to the battery. FIGURE 12-1. ENGINE TIMING MARKS

12-1
 ENGINE REMOVAL ENGINE INSTALLATION
The engine is mounted on 3 vibration isolator
Installation is the reverse of removal.
mounts secured to the skid-base (Figure 12-2). To
remove the engine: 1. Make sure the air seal ring is in place around
1. Disconnect the negative (-) battery cable from the oil drain hole in the skid-base to seal against
the battery to prevent the genset from starting. leakage of cooling air and noise.
Remove the front, top, back and right end hous- 2. Tighten all screws and bolts according to
ing panels (p. 6-3). Thread Torques.
2. Remove the muffler (p. 8-1).
3. Make sure the engine crankcase breather hose
3. Remove the oil dipstick and disconnect the oil is pushed back through the hole in the inner
fill tube from the coolant recovery tank. (If the bulkhead (p. 9-3).
oil fill tube is to be removed from the oil pan,
drain the oil first to avoid spillage.) REPLACING LOW OIL PRESSURE
4. Drain the coolant system, disconnect the hoses CUTOFF SWITCH
at the engine and remove the radiator and inner
bulkhead (p. 9-1). 1. Disconnect the negative (-) battery cable from
the battery to prevent the genset from starting
5. Disconnect the air inlet hose at the resonator and remove the front, top, back and right end
(Figure 7-1). housing panels (p. 6-3).
6. Disconnect the PMA stator leads (Figure 11-2).
2. Remove the muffler (p. 8-1).
7. Disconnect the engine harness from the con-
troller/inverter assembly and fuel pump. 3. Disconnect the the PMA stator leads (Figure
11-2) to prevent strain when the inner bulkhead
8. Disconnect the skid-base ground strap from is tilted.
the flywheel housing.
9. Disconnect the battery harness from the en- 4. Remove the screw that secures the coolant
gine. drain “T” (p. 9-3), the two screws in the horizon-
tal portion of the bulkhead that projects under
CAUTION Using only one lifting eye will the radiator and the screw that secures the ra-
cause the unit to rotate and drop, causing diator to the controller/inverter assembly.
severe equipment damage and possible 5. Lift and tilt the inner bulkhead until the switch is
personal injury. accessible.
10. Attach a hoist at both the flywheel housing lift-
ing eye and the front engine lifting eye. 6. Disconnect the lead and remove the switch.

11. Remove the three isolator-mount center bolts Reassembly is the reverse of removal. Use thread
and lift the engine/PMA assembly away. sealant and tighten according to Thread Torques.
12. Remove the cooling blower, PMA stator, rotor Make sure the engine crankcase breather hose is
and flywheel housing from the engine (Figure pushed back through the hole in the inner bulkhead
11-2). (p. 9-3).

12-2
 HOT COOLANT OUTLET AND
THERMOSTAT HOUSING

COOLANT PUMP
DRIVE PULLEY
AND BELT

GOVERNOR
ACTUATOR

CRANKCASE BREATHER
FILTER HOUSING AND
DISCHARGE TUBE

STARTER
MOTOR AND OIL FILL OIL
SOLENOID TUBE FILTER

COOLANT
TEMPERATURE
SENDER

COOLANT PUMP
INLET

AIR SEAL
LOW OIL PRESSURE AROUND OIL 1 OF 3 ENGINE
CUTOFF SWITCH OIL PAN DRAIN PLUG MOUNTS

FIGURE 12-2. ENGINE AND ACCESSORIES

12-3
13. Governor Actuator
GENERAL Installation is the reverse of removal. Note the fol-
lowing:
The governor actuator (Figure 13-1) is powered by
1. Use a long-nose pliers to rehook the governor
the genset controller to position the fuel rack (Figure
spring to the actuator high-idle speed control
13-2) according to load demand.
lever.
Note: The engine governor used with these gensets 2. Apply a liquid-type gasket (Three Bond 1215 or
has 4 steel balls (Figure 13-2) instead of the 8 shown equivalent) to both sides of the new gasket be-
in the engine Workshop Manual.
tween the engine gear cover and actuator
ACTUATOR REMOVAL base.

1. Disconnect the negative (-) battery cable from 3. Tighten the four base mounting screws accord-
the battery to prevent the genset from starting ing to Thread Torques.
and remove the front housing panel (p. 6-3). 4. Adjust the actuator speed control lever stop
2. Disconnect the two leads from the engine har- (beginning Spec B) before installing the rotor
ness and remove the cover. (p. 13-4).
5. Install the rotor using a new retainer ring. Note
WARNING Uncontrolled release of spring that the ring is concave (dished). Push the
tension can cause eye damage. Wear safety dished side down against the rotor to keep it in
glasses with side shields when removing place on the shaft.
spring.
6. Install the stator and bearing carrier. Tighten
3. Use a screwdriver to pry the leg of the fuel rack the four mounting screws according to Thread
return spring out of its slot in the bearing carrier. Torques.
Be prepared to catch the spring from flying off.
4. Remove the four stator screws and lift off the CAUTION The genset may not stop reli-
bearing carrier and stator. ably on command if the fuel rack return
spring is not assembled properly.
5. Pry the rotor off the shaft.
7. Check the fuel rack return spring for wear and
6. Remove the four screws that secure the base replace it if worn. This spring returns the fuel
to the top of the engine gear cover. Note that rack to the no-fuel position. Push the spring on
there are copper washers under the two in- over the flat on the shaft and then pry the leg
board screw heads. These washers seal into its slot in the bearing carrier (Figure 13-1).
against oil seepage since these screw holes The extension below the knee must catch un-
run through into the gear case. der the bearing carrier. Finally, push the spring
7. Unhook the governor spring from the actuator down as far as it will go on the shaft.
high-idle speed control lever (top lever) while
8. Readjust high-idle speed (p. 13-5).
lifting the actuator assembly away.
9. Snap the cover onto the actuator and then se-
ACTUATOR INSTALLATION cure a wire tie around the actuator and cov-
er to make sure the cover stays in place.
Note: The actuator base assembly used for gensets
beginning Spec B is the replacement part also for 10. Reconnect the two leads from the engine har-
Spec A gensets. ness.

13-1
 SPRING, SHAFT, BEARING ASSEMBLY SNAP-ON
COVER

ROTOR
RETAINER
RING

FUEL
ROTOR RACK
RETURN
SPRING

SHAFT

BEARING
CARRIER

TERMINALS

STATOR

FIGURE 13-1. GOVERNOR ACTUATOR

13-2
ACTUATOR HIGH-IDLE FUEL INJECTION FUEL RACK GOVERNOR
SPEED CONTROL PUMP ASSEMBLY CONTROL ROD SPRING
LEVER

ACTUATOR SPEED
CONTROL LEVER

4-BALL HIGH-IDLE
GOVERNOR STOP SCREW

FIGURE 13-2. INTERNAL GOVERNOR PARTS

13-3
 ACTUATOR SPEED CONTROL LEVER
STOP (BEGINNING SPEC B)
The actuator speed control lever stop (Figure 13-3)
must be adjusted whenever a different actuator
base assembly is installed. The stop screw, rather
than the fuel rack control lever, must stop the speed
control linkage when the fuel rack is driven to the no-
fuel position (to the right, as shown in Figure 13-2).
Actuator Rotor Not In Place
1. Assemble the actuator stator and bearing carri-
er to the base so that the shaft will be supported
in its bearing.
2. Loosen the stop screw locknut and back the ACTUATOR SPEED
screw out a few turns. (Top one in the group of CONTROL LEVER
three.) STOP SCREW
3. Turn the stop screw in until it just makes con-
tact. Turn the screw one more full turn in and set
the locknut. FIGURE 13-3. ACTUATOR SPEED CONTROL LE-
VER STOP (BEGINNING SPEC B)
4. Remove the bearing carrier and stator and
complete reassembly with the rotor in place.
Actuator Rotor In Place
1. Loosen the stop screw locknut and back the
screw out a few turns. (Top one in the group of
three.)
2. Turn the stop screw in until it just makes contact
and set the locknut.

13-4
 HIGH-IDLE SPEED B. Adjust high-idle speed by turning the ad-
justing screw and set its lock nut.
High-idle speed must be readjusted each time the
governor actuator base or the fuel injector pump is C. Run the clamping screw back in by hand
installed. until snug, back it out 1-1/2 turns and set its
lock nut.
WARNING This adjustment involves operating
the genset without a housing panel in place. The 8. Let the rotor go. The genset should stop and
panels guard against rotating parts and bare display a fault code. Restart the genset and re-
live electrical parts that can cause severe per- check high idle speed. Readjust if necessary.
sonal injury or death. Keep your hands, cloth-
ing, and jewelry away from the engine pulleys,
blower blades and electrical terminal block TB3
on the controller/inverter housing (Figure 10-1).
Note: The genset will only run a few minutes be-
fore shutting down because the controller has
shut down the fuel pump.
1. Remove the front housing panel (p. 6-3).
2. Set up a tachometer to indicate engine speed.
(If the tachometer has to be held or adjusted
while taking a reading, it will take two people to
make this adjustment.)
3. Remove the actuator cover and reconnect the
leads.
4. Start the genset and push the actuator rotor PUSH HERE SPEED ADJUSTING
clockwise by hand as far as it will go (about 1/2 TO ROTATE SCREW ACCESS
ROTOR (2.5 MM ALLEN HEAD)
inch [12 mm]) and hold it there. (It may be easi-
er to use a wrench on the flat at the top of the FIGURE 13-4. HIGH-IDLE SPEED ADJUSTMENT
shaft to hold the rotor position.) Make sure the (SPEC A)
fuel rack return spring is in place on the rotor
shaft to shut down the genset if you lose hold.

CAUTION Do not let engine speed exceed

3600 rpm. PMA voltages caused by higher
speeds can damage the controller/inverter.
5. Adjust high-idle speed to 3500-3600 rpm:
6. Spec A: (Figure 13-4)

A. If the genset hunts under full load, see

HIGH IDLE STOP SCREW ADJUST-
PUSH HERE
MENT (p. 13-6). TO ROTATE
ROTOR
B. Adjust high-idle speed by turning the ad-
justing screw (2.5 mm allen head).
SPEED
7. Beginning Spec B: (Figure 13-5). ADJUSTING CLAMPING
SCREW SCREW
A. Loosen the lock nuts on the two screws in
the bottom row and remove the clamping FIGURE 13-5. HIGH-IDLE SPEED ADJUSTMENT
screw. (BEGINNING SPEC B)

13-5
 HIGH-IDLE STOP SCREW 2. Adjust the high-idle stop screw in the front of the
engine to obtain a speed of 3550 to 3590 rpm,
On Spec A engines prior to 1997 adjust the high-idle
while holding the actuator fully clockwise, and
stop screw (Figure 13-6) if the genset hunts under
set the jam nuts.
full load.
1. Back off high-idle speed in accordance with 3. Readjust high-idle speed according to Step 5
Steps 4 and 5 of the HIGH-IDLE SPEED ad- of the HIGH-IDLE SPEED adjustment proce-
justment procedure (p. 13-5) to less than dure (p. 13-5).
3300 rpm.

HIGH-IDLE
STOP SCREW

FIGURE 13-6. HIGH-IDLE STOP SCREW (SPEC A PRIOR TO 1997)

13-6
14. Fuel System
GENERAL Removal and Installation
Figure 14-1 shows two views of the fuel filter, pump The fuel pump mounting screws are accessible
and hoses for delivering fuel to and from the fuel in- from below the skid-base and the fuel pump is re-
jection system. moveable through the maintenance access door.
Unless provision has been made to provide access
WARNING Diesel fuel is combustible and can to these screws, the genset will have to be tilted up
cause severe personal injury or death. Do not or removed from the vehicle.
smoke near fuel tanks or fuel-burning equip-
ment or are in an area sharing ventilation with When installing a fuel pump make sure the air seal is
such equipment. Keep flames, sparks, pilot placed around the fuel inlet fitting to seal against
flames, electrical arcs and switches and other leakage of cooling air and noise. Tighten all screws
sources of ignition well away. Keep a type ABC according to Thread Torques.
fire extinguisher handy.
Thread Sealant and Fuel Line Fittings
CAUTION Always wipe dirt off fuel fittings be-
fore disconnecting them to keep dirt from enter- The fuel line between the fuel pump and fuel filter
ing the fuel system. has flare fittings. Do not use any type of thread
sealant on flare fittings.
FUEL PUMP
The connections for fuel supply and return that ex-
Fuel Flow Test tend through the side of the base are pipe thread fit-
tings. For these fittings use liquid-type pipe thread
1. Disconnect the fuel return hose from the line to
sealant Listed as suitable for diesel fuel. Apply the
the supply tank and point the end into a quart
sealant sparingly to the male threads only.
(1 liter) or larger container that has volume
graduations. CAUTION Excess liquid-type pipe thread
2. Prime the genset by pushing the Start/Stop sealant or pieces of teflon-type pipe thread seal-
switch to STOP and holding it there for the ant can plug the engine fuel system. Apply liq-
duration of the test. Flow should not be less uid-type pipe thread sealant sparingly to the
than 200 ml (0.4 pints) per minute. male threads only. Do not use teflon tape.
3. If flow is less than specified:
FUEL FILTER
A. Replace the fuel filter.
The fuel filter is mounted on a bracket just above the
B. Check for other restrictions in the fuel maintenance access door in the skid-base. See Pe-
lines. riodic Maintenance for the filter replacement inter-
val.
C. Check for air bubbles in the fuel. Tighten
fittings and replace fuel lines as necessary. FUEL INJECTION SYSTEM
Replace a cracked fuel filter body.
See the Engine Workshop Manual for fuel injection
D. Replace the fuel pump. system service.

14-1
 INJECTOR
RETURN
LINE

INJECTOR
PUMP
SUPPLY

FUEL SUPPLY FUEL PUMP

FITTING SHIELD

FUEL
FILTER

FUEL PUMP

FUEL FILTER
FUEL RETURN
BRACKET
FITTING
MOUNTING PUMP TO
SCREWS FILTER LINE

AIR SEAL

PUMP
MOUNTING
SCREWS

FIGURE 14-1. FUEL DELIVERY SYSTEM

14-2
15. Battery Charger

REMOVAL and remove the front, top and left end housing
panels (p. 6-3).
The battery charger is optional. The charger and its
transformer are mounted on the skid-base as 2. Remove the battery charger.
shown in Figure 15-1. 3. Remove the controller/inverter assembly (Fig-
ure 10-1), the cooling blower (Figure 11-2) and
Battery Charger Removal
the air intake hoses from the back of the air filter
1. Disconnect the negative (-) battery cable from housing (Figure 7-1).
the battery to prevent the genset from starting
and remove the front housing panel (p. 6-3). 4. Disconnect the quick connectors in the two re-
maining leads (four leads altogether).
2. Disconnect the quick-connectors in the two
leads to the transformer and disconnect the 5. Remove the two mounting screws.
third lead at the starter solenoid.
3. Remove the mounting screw. INSTALLATION

Transformer Removal
Installation of the battery charger and transformer is
1. Disconnect the negative (-) battery cable from the reverse of removal. Tighten all screws accord-
the battery to prevent the genset from starting ing to Thread Torques.

TRANSFORMER

BATTERY CHARGER

FIGURE 15-1. BATTERY CHARGER AND TRANSFORMER

15-1
16. Starter Motor
REMOVAL
See Figure 16-1. To remove the starter motor as-
sembly from the genset:
1. Disconnect the negative (-) battery cable from
the battery to prevent the genset from starting.
2. If the genset is installed in the vehicle and does
not have an access door in the front panel,
open the maintenance access door in the skid-
base and remove the fuel filter and its mounting
bracket (Figure 14-1).

WARNING Diesel fuel is combustible and

can cause severe personal injury or death.
Do not smoke. Keep flames, sparks, pilot
lights, electrical arcs and arc-producing
equipment and all other sources of ignition
well away. Keep a type ABC fire extinguish-
er handy.
3. If the genset has been removed from the ve-
hicle, remove the front housing panel (p. 6-3).
(If the genset has an access door in the front
panel, remove the access door instead.)
4. Disconnect all wires and cables from the motor
terminals.
5. Remove the two starter mounting bolts and re-
move the starter.

INSTALLATION
Installation is the reverse of removal. Tighten bolts
and terminals according to Thread Torques. FIGURE 16-1. STARTER MOTOR AND SOLENOID

16-1
 STARTER SOLENOID REPLACEMENT 3. Using a heavy cable from the negative (−) ter-
minal on the battery, briefly touch the mounting
WARNING This test involves high electrical flange on the motor.
currents, strong arcing and moving parts that
can cause severe personal injury. Do not con-
A. If the motor does not spin up quickly and
duct this test near fuel tanks or when flammable
smoothly, replace the motor/solenoid as-
vapors are present. Wear safety glasses. Keep
sembly.
fingers away from the pinion gear.

The starter solenoid is separately replaceable. To B. If the motor does spin up quickly and
determine whether the problem is in the solenoid or smoothly, the motor is probably okay: re-
in the motor: place the solenoid.
1. Secure the motor assembly in a vice after it has
been removed from the genset. C. The solenoid is removeable by discon-
2. Using a heavy jumper cable, because of the necting the motor lead from the solenoid
large currents involved, connect the motor ter- terminal and removing the two solenoid
minal on the solenoid (the one closest to the mounting nuts. When installing a new sole-
motor) to the positive (+) terminal on a 12 volt noid, make sure the solenoid plunger en-
battery. gages the shift fork.

16-2
17. Service Checklist
GENERAL EXHAUST SYSTEM

After servicing, inspect and test the installation to While the genset is running inspect the entire ex-
confirm that the genset will operate as intended. haust system. Look and listen for leaks at all con-
Check each of the areas described below before nections, welds, gaskets and joints. Also make sure
putting the genset into service. the exhaust pipe is not overheating adjacent materi-
als or equipment. Do not run the genset until all ex-
HOUSING haust leaks have been repaired.

Check to see that all housing panels and access WARNING Exhaust gas is deadly. The exhaust
covers are in place and secure (p. 6-3). system must not leak and must discharge all ex-
haust away from the vehicle. Do not run the gen-
MOUNTING set until the exhaust leaks have been repaired.

Examine all mounting bolts and supporting mem- The exhaust tailpipe must be supported by a
bers to verify that the genset is properly mounted. hanger near the vehicle perimeter and terminate
All fasteners should be tightened securely to pre- at least 1 inch outside the perimeter and at least
vent them from working loose when subjected to 1 foot from doors and windows.
vibration.
FUEL SYSTEM
LUBRICATION
While the genset is running, inspect the fuel supply
If the engine oil was drained, refill as instructed in and return lines, filter and fittings for leaks. Check
Periodic Maintenance. flexible sections for cuts, cracks and abrasions and
make sure they are not rubbing against anything
COOLING SYSTEM that could cause leakage. Repair all fuel leaks im-
mediately.
If the engine coolant was drained, refill as instructed
in Periodic Maintenance. WARNING Diesel fuel is combustible. Leaking
fuel could lead to fire and to severe personal in-
WIRING jury or death. Repair fuel leaks immediately.

Verify that all wiring connections are tight and CONTROL

installed properly. Check each of these connec-
tions: Stop and start the genset several times at the con-
trol panel on the genset and at the remote control
• Load wires
board (if provided) to verify that they work properly.
• Control wires
MECHANICAL
• Ground straps
• Battery cables Stop the genset and inspect it for leaking gaskets,
loose fasteners, damaged components and inter-
OUTPUT CHECK ference with other equipment. Repair as necessary.
Inspect the generator compartment and verify that
Apply a full load to make sure the genset can pro- there are no breaks or openings in the vapor-proof
duce its full rated output. Use a load test panel to ap- wall that separates the compartment from the ve-
ply a progressively greater load until full load is hicle interior. Seal openings as necessary. Make
reached. sure that all soundproofing material is in place.

17-1
18. Troubleshooting
TROUBLESHOOTING WITH TABLE 18-1 blink-blink-blink—pause—blink-blink-blink
—longer pause—
To aid troubleshooting the genset controller causes blink-blink-blink—pause—blink-blink-blink—...
the status indicator light to blink the numeric code RESTORING FAULT CODE BLINKING
assigned to the fault that caused shutdown. For a
brief description of the fault and step-by-step cor- The fault code stops blinking after five minutes.
rective action, refer to TABLE 18-1. TROUBLE- Prior to Spec F, one touch to Stop restores fault
SHOOTING, which lists the fault codes in numerical code blinking. Beginning Spec F, 3 touches to Stop
order. are required (also earlier Spec gensets with newer
replacement controller-inverter assemblies).
Many genset shutdowns can be avoided by perform-
ing periodic maintenance on schedule (TABLE 5-1. NOTE: The last fault logged will blink even though
PERIODIC MAINTENANCE SCHEDULE) and by not the condition that caused the shutdown may have
running the genset out of fuel. Note that when the been corrected.
genset and propulsion engine draw from the same
fuel tank, the fuel dip tubes are usually arranged so BYPASSABLE FAULTS: PRIOR TO SPEC F
that the genset will run out of fuel first. By marking
the genset empty point on the fuel gauge, it will be When a fault condition persists, the genset shuts
easier to tell when the genset may run out of fuel. down when an attempt is made to restart. Prior to
Spec F, (unless the controller assembly has been
FAULT CODE BLINKING replaced) there are four faults the genset controller
will bypass on a second attempt at restart:
At fault shutdown, the status indicator light will re- • No. 17—fuel pump fault
peatedly blink sets of 1, 2 or 3 blinks.
• No. 18—glow plug fault
• One blink indicates shutdown due to high en- • No. 23—oil pressure switch fault
gine coolant temperature.
• No. 24—temperature sender fault.
• Two blinks indicate shutdown due to a loss of
engine oil pressure. Before making the second attempt at starting the
genset, however, consider the following:
• Three blinks is code for shutdown due to some
other abnormal condition. • As long as the ambient temperature is greater
than 77° F (25° C), a glow plug fault (No. 18) will
For a 1-blink or 3-blink fault code, one touch to Stop not affect starting or operation. As the ambient
brings up a second-level fault code. This code con- temperature keeps dropping, however, the
sists of 1, 2, 3 or 4 or blinks, a brief pause, and then genset will eventually fail to start.
1 to 9 blinks. The first set of blinks represents the • Bypassing an oil pressure switch fault (No. 23)
tens digit and the second set of blinks the units digit or temperature sender fault (No. 24) could lead
of the fault code number in Table 18-1. For example, to serious engine damage if the oil pressure
Fault Code No. 23 would be: fails or the engine overheats.

blink-blink—pause—blink-blink-blink—... CAUTION Operating the genset under oil

NOTE: Consciously avoid mistaking Fault Codes 11, pressure switch or temperature sender
22 and 33 for Fault Codes 1, 2 and 3. The pauses be- fault conditions can lead to serious engine
tween repetitions of the fault code are longer than the damage. Read the Warranty regarding pos-
pauses between the tens and units digits of the the sible exclusions when operating the genset
code. For example, Fault Code 33 would be: under such conditions.

18-1
 TABLE 18-1. TROUBLESHOOTING
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

GENSET WON’T STOP RUNNING—STATUS INDICATOR LIGHT ON

(Faulty Stop Switch or grounded wiring)

@@@@
WARNING Removing genset panels or disconnecting fuel lines to stop a genset that won’t stop
can lead to severe personal injury or death from electrocution, contact with moving parts or fire.
• Try the genset Stop Switch if the remote Stop Switch does not work and vice versa.
• If possible, pinch flexible fuel hoses until the genset stops.
• Otherwise, let the genset run out of fuel before attempting service.

Corrective Action:
1. Try the genset Stop Switch if the remote Stop Switch does not work, and vice versa. If only the genset
Stop Switch works, go to Step 2. If neither switch works, or only the remote Stop Switch, go to Step 3.
2. Disconnect the remote control panel connector (J8/P8). While pressing the Remote Stop Switch,
check for electrical continuity between remote control connector pins J8-A and J8-E. Replace a
switch that does not close when pressed to Stop and repair or reconnect wiring as necessary.
3. Remove the front and top housing panels (p. 6-3) and disconnect engine harness connector P2 from
the controller (Figure 10-1, p. A-1, A-4). Reconnect the remote control panel (J8/P8) and while
pressing the respective Stop Switch, check for electrical continuity between:
A. Pin P2-3 (remote stop) and pin P2-2 (remote ground).
B. Pin P2-10 (local stop) and pin P2-11 (local ground).
C. Replace a switch that does not close when pressed to Stop, check for missing, bent or corroded
terminals and connector pins and repair or reconnect wiring as necessary.
4. Replace the controller assembly (p. 10-1).

GENSET WON’T STOP RUNNING—STATUS INDICATOR LIGHT OFF

(Binding governor mechanism, misadjusted speed stop)

@@@@
WARNING Removing genset panels or disconnecting fuel lines to stop a genset that won’t stop
can lead to severe personal injury or death from electrocution, contact with moving parts or fire.
• Try the genset Stop Switch if the remote Stop Switch does not work and vice versa.
• If possible, pinch flexible fuel hoses until the genset stops.
• Otherwise, let the genset run out of fuel before attempting service.

Corrective Action:
1. Remove the front and top housing panels (p. 6-3) and check the fuel rack return spring and replace
it if worn or broken (Figure 13-1). Make sure it is reassembled correctly.
2. Check for binding in the governor mechanism by pushing the actuator rotor clockwise by hand—
against the action of the fuel rack return spring. It should rotate smoothly about 1/2 inch (12 mm) and
return smoothly. If it binds or catches, remove the governor actuator base assembly and replace it
or service the internal engine governor mechanism (Figure 13-2) as necessary.
3. Readjust the actuator speed control lever stop so that the fuel rack can go to no-fuel (p. 13-4).

18-2
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

STATUS INDICATOR LIGHT STAYS ON

(Reversed battery connections)

Corrective Action: Reconnect the battery correctly.

ENGINE CRANKS WHEN BATTERY CONNECTED

(Faulty Start Switch or grounded wiring)

Corrective Action:
1. Disconnect the remote control panel connector (J8/P8). Check for electrical continuity between re-
mote control connector pins J8-A and J8-C. Replace a switch that does not open when released and
repair or reconnect wiring as necessary.
2. Remove the front and top housing panels (p. 6-3) and disconnect engine harness connector P2 from
the controller (Figure 10-1, p. A-1, A-4). Reconnect the remote control panel (J8/P8) and check for
electrical continuity between:
A. Pin P2-1 (remote start) and pin P2-2 (remote ground).
B. Pin P2-12 (local start) and pin P2-11 (local ground).
C. Replace a switch that does not open when released and repair or reconnect wiring as necessary.
3. Replace the controller assembly (p. 10-1).

ENGINE WON’T CRANK—FUEL PUMP WON’T STOP

(Faulty Stop Switch or grounded wiring)

Corrective Action:
1. Disconnect the remote control panel connector. Check for electrical continuity between remote con-
trol connector pins J8-A and J8-E. Replace a switch that does not open when released and repair
or reconnect wiring as necessary.
2. Remove the front and top housing panels (p. 6-3) and disconnect engine harness connector P2 from
the controller (Figure 10-1, p. A-1, A-4). Reconnect the remote control panel (J8/P8) and check for
electrical continuity between:
A. Pin P2-3 (remote stop) and pin P2-2 (remote ground).
B. Pin P2-10 (local stop) and pin P2-11 (local ground).
C. Replace a switch that does not open when released and repair or reconnect wiring as necessary.
3. Replace the controller assembly (p. 10-1).

18-3
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

STATUS INDICATOR LIGHT DEAD

(Faulty connections, no battery voltage)

Corrective Action:
1. Try the genset Start Switch if the remote Start Switch does not work, and vice versa. Disconnect the
remote control panel (J8/P8) and try the genset Start Switch again. If nothing works, go to Step 2.
If only the genset start switch works, go to Step 9. If only the remote start switch works, go to Step 12.
2. Replace Fuse F1 (B+) if blown.
3. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery, vehicle
frame and genset.
4. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
5. Remove the front and top housing panels (p. 6-3). Check that all engine and battery harness wires
(p. A-1, A-3) are properly connected to the grounding bolt on the flywheel housing, to the B+ terminal
on the starter solenoid and to the battery terminal block (p. A-3). Clean and tighten connections and
replace wiring as necessary.
6. Disconnect engine harness connector P1 from the controller (Figure 10-1, p. A-1, A-4). Check for
B+ (12 VDC) at pin P1-8 and for continuity to ground at pin P1-7. Check for missing, bent or corroded
connector pins and faulty wiring and repair as necessary.
7. Disconnect engine harness connector P2 from the controller (Figure 10-1, p. A-1, A-4) and recon-
nect the remote control panel (J8/P8). Press the switch and check for electrical continuity between:
A. Pin P2-1 (remote start) and pin P2-2 (remote ground).
B. Pin P2-3 (remote stop) and pin P2-2 (remote ground).
C. Pin P2-12 (local start) and pin P2-11 (local ground).
D. Pin P2-10 (local stop) and pin P2-11 (local ground).
E. Replace switches that do not close when pressed, check for missing, bent or corroded terminals
and connector pins and faulty wiring and repair as necessary.
8. Replace the controller assembly (p. 10-1).
9. Disconnect the remote control panel (J8/P8). Check for electrical continuity between remote control
connector pins J8-A and J8-C. Replace a switch that does not close when pressed and repair or re-
connect wiring as necessary.
10. Remove the front and top housing panels (p. 6-3) and disconnect engine harness connector P2 from
the controller (Figure 10-1, p. A-1, A-4) and reconnect the remote control panel (J8/P8). Press the
switch, check and for electrical continuity between:
A. Pin P2-1 (remote start) and pin P2-2 (remote ground).
B. Pin P2-3 (remote stop) and pin P2-2 (remote ground).
C. Replace a switch that does not close when pressed, check for missing, bent or corroded termi-
nals and connector pins and faulty wiring and repair as necessary.
11. Replace the controller assembly (p.10-1).
12. Remove the front and top housing panels (p. 6-3) and disconnect engine harness connector P2 from
the controller (Figure 10-1, p. A-1, A-4). Press the switch and check for electrical continuity between:
A. Pin P2-12 (local start) and pin P2-11 (local ground).
B. Pin P2-10 (local stop) and pin P2-11 (local ground).
C. Replace a switch that does not close when pressed, check for missing, bent or corroded termi-
nals and connector pins and faulty wiring and repair as necessary.
13. Replace the controller assembly (p.10-1).

18-4
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

STARTING BATTERIES RUN DOWN

(Marginal battery, battery connections or charging system or parasitic loads)

Corrective Action:
1. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery, vehicle
frame and genset.
2. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
3. Install or service a battery charging system in the vehicle if the genset is not so equipped.
4. If the genset is equipped with a battery charging system, check performance by measuring voltage
across the battery terminals while running the genset. Watch the meter while turning the genset cir-
cuit breaker (operator’s console) on and off several times. The battery charger is probably okay if
voltage jumps to more than 12 VDC each time the breaker is turned on. Check for parasitic loads
external to the genset and/or replace the battery.
5. If the battery charger does not seem to be working, remove the front housing panel (p. 6-3). If loose,
reconnect battery charger transformer input connectors J12 and J13 to the AC harness (p. A-2, A-4),
output connectors J14 and J15 to the battery charger (p. A-4) and the battery charger output lead
to the B+ terminal on the starter solenoid.
6. Disconnect transformer connectors J12 through J15 and check winding continuity across J12−J13
and across J14−J15. Replace the transformer if a winding is open (p. 15-1).
7. Reconnect J12 and J13 and run the genset. Replace the battery charger if transformer output across
J14−J15 is approximately 16.3 VAC. If not, go to Step 8.
8. Disconnect J12 and J13 and measure voltage. Replace the transformer if there is approximately 120
VAC across J12−J13. If not, go to Step 9.
9. Replace or repair wiring in the AC harness if there is no voltage.
@@@@
WARNING This test involves operating the genset with housing panels removed. The pan-
els guard against rotating parts and bare live electrical parts that can cause severe personal
injury or death. Keep your hands away from the engine pulleys, blower blades and electrical
terminal block TB3 on the controller housing (Figure 10-1).

18-5
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

ENGINE CRANKS BUT DOES NOT START

(Fuel delivery, glow plugs or engine are marginal)

Corrective Action:
1. Check fuel level. (Note: The genset fuel pickup is probably higher than the vehicle engine pickup.)
2. Prime the engine fuel system.
3. Check the engine air filter and remove any blockage.
4. Replace Fuse F3 (glow plugs) if blown. If it blows again, go to Step 8.
5. Check for fuel and air leaks at each fitting in the fuel supply line. (Note: White smoke indicates air
in the fuel.)
6. Conduct a fuel flow test and service as necessary (p. 14-1).
7. Remove the top housing panel (p. 6-3) and observe the governor actuator rotor (Figure 13-1) while
cranking. (Remember to reattach the leads after removing the cover.) The rotor should rotate
smoothly through about 1/2 inch (12 mm). If it does not, check for binding in the governor mechanism
by pushing the actuator rotor clockwise by hand—against the action of the fuel rack return spring.
It should rotate smoothly about 1/2 inch (12 mm) and return smoothly. If it binds or catches, remove
the governor actuator base assembly and replace it, or service the internal engine governor mecha-
nism (Figure 13-2), as necessary.
8. Remove the front and top housing panels (p. 6-3) and check out the glow plug system as follows:
A. If the glow plugs are not working, it can be the result of a failed temperature sensor which results
in a no start.
B. If loose, reconnect spade connector HR-1 to the glow plug bus bar at the front of the engine,
engine harness connectors A1-J7 and A1-J8 to the leads from the controller assembly (Fig-
ure 10-1, p. A-1, A-4), and the engine harness ground connections to the flywheel housing.
C. Disconnect HR-1 from the glow plug bus bar and A1-J8 from the controller assembly (p. 10-1).
Check for continuity (ground short) between either connector and ground. Replace wiring as
necessary.
D. Remove the glow plug bus bar along side the engine valve cover and check for electrical conti-
nuity between each glow plug terminal and ground. Replace any open glow plug (p. 12-1).
Note: If a glow plug does not come out after unscrewing it, or the end has broken off, it will
be necessary to remove the engine head. Glow plugs can swell if preheat voltage is great-
er than 14 volts, such as when a battery booster is used for starting.
E. Check for B+ on the glow plug bus bar while pressing Start. Replace the controller assembly
if B+ is not available for preheat in accordance with Table 10-1.
9. Service the engine (p. 12-1).

18-6
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

STARTER ENGAGES-DISENGAGES
(Cranking voltage dips below 6 volts—low battery charge, poor connections, long cables)

Corrective Action:
1. Have the vehicle propulsion engine running while trying to start the genset—the battery charging
alternator may be able to maintain starting voltage high enough to get the genset started.
2. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery, vehicle
frame and genset.
3. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
4. Increase battery cable size or run parallel cables.
5. Remove the front and top housing panels (p. 6-3) Check that all engine and battery harness wires
(p. A-1, A-3) are properly connected to the grounding bolt on the flywheel housing, to the B+ terminal
on the starter solenoid and to the battery terminal block (p. A-3). Clean and tighten connections and
replace wiring as necessary.
6. Disconnect engine harness connector P1 from the controller (Figure 10-1, p. A-1, A-4). Check for
B+ (12 VDC) at pin P1-8 and for continuity to ground at pin P1-7. Check for missing, bent or corroded
connector pins and faulty wiring and repair as necessary.

NO POWER—GENSET RUNNING, RUN LIGHT ON

(Line circuit breaker OFF or tripped or faulty wiring)

Corrective Action:
1. Reset or turn “On” the line circuit breaker on the genset operator’s console.
2. Reset or turn “On” the line circuit breakers on the main distribution panel in the vehicle.
3. Check the voltage at genset AC output terminal block TB2. If there is approximately 120 VAC across
TB2-1 and TB2-3 and across TB2-2 and TB2-4, repair or reconnect the wiring between the genset
and the vehicle. If there is no voltage, go to Step 4.
4. Remove the front and top housing panels (p. 6-3) and check for proper AC harness connections at
TB3, TB2 and the line circuit breakers (Figure 10-1, p. A-2, A-4). Reconnect wiring as necessary and
tighten all terminal screws and nuts.
5. Check for electrical continuity across the terminals of each breaker (p. A-2). Replace a circuit break-
er which lacks electrical continuity when “On”.
6. Run the genset and measure voltages. If there is approximately 120 VAC across TB3-1 and TB3-2,
replace the AC wiring harness. If there is no voltage, replace the controller assembly (p. 10-1).
@@@@
WARNING This test involves operating the genset with housing panels removed. The pan-
els guard against rotating parts and bare live electrical parts that can cause severe personal
injury or death. Keep your hands, clothing, jewelry, and hair away from the engine pulleys,
blower blades and electrical terminal block TB3 on the controller housing (Figure 10-1).

18-7
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

GENSET HUNTS UNDER FULL LOAD

(Fuel delivery marginal, governor misadjusted)

Corrective Action:
1. Prime the engine fuel system by holding the control switch down in its Stop position for at least 1 min-
ute.
2. Check for fuel and air leaks at each fitting in the fuel supply line.
3. Conduct a fuel flow test and service as necessary (p. 14-1).
4. Connect a source of known fuel quality, prime the fuel system, and run the genset. If performance
improves, replace the bad fuel in the supply tank.
5. Readjust high-idle speed (p. 13-5).

HIGH TEMPERATURE—FAULT CODE NO. 1

(Engine coolant or inverter heat sink temperature exceeded design limit)

Corrective Action: Check the second-level fault code by touching Stop. The second-level fault will be
either No. 33 or No. 34.

LOW OIL PRESSURE—FAULT CODE NO. 2

(Low oil pressure cutoff switch did not open)

Corrective Action:
1. Check engine oil level and add oil as necessary.
2. Drain excess oil (above dipstick Full mark).
3. Remove the top housing panel (p. 6-3). Reconnect engine harness spade connector S2 to the low
oil pressure cutout switch (Figure 12-2) if it is loose (short to ground will cause shutdown).
4. Disconnect engine harness connector P2 (p. A-1) from the controller assembly (Figure 10-1) and
the pressure switch. Check both ends for electrical continuity to ground. Replace wiring as necessary
if the lead is shorted to ground.
5. Install an oil pressure gauge in place of the pressure switch and observe oil pressure after the engine
has run a few minutes (let RV models step down to low idle speed). Replace the low oil pressure
cutoff switch if engine oil pressure is 14 psi (98 kPa) or greater. Service the engine if engine oil pres-
sure is less than 14 psi (98 kPa). (Simulate normal switch operation to keep the genset running dur-
ing the test by starting with connector S2 grounded and removing it from ground when the engine
starts.)
@@@@
WARNING This test involves operating the genset with housing panels removed. The pan-
els guard against rotating parts and bare live electrical parts that can cause severe personal
injury or death. Keep your hands, clothing, jewelry, and hair away from the engine pulleys,
blower blades and electrical terminal block TB3 on the controller housing (Figure 10-1).

18-8
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

SERVICE CHECK FAULT—CODE NO. 3

(A second-level fault occurred)

Corrective Action: Check the second-level fault code by touching Stop. The second-level fault will be
one of the following in this table. See Page 18-1 for a description of how the fault code blinks.

SERVICE CHECK FAULT—CODE NO. 4

(Begin Spec K)

Corrective Action: Set has been commanded to crank, and cranks for a total of 35 seconds continu-
ous, without the set starting (speed exceeding − 1200 RPM) Typical troubleshooting should be related
to an out of fuel condition (see FC36) − check fuel flow and return, actuator operation, wiring, etc.

OVERLOAD—CODE NO. 8
(Models HDKAH & HDKAV only: Load exceeded110 percent of genset rating for 2 minutes)

Corrective Action: Reduce load and restart

18-9
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

OVERCURRENT FAULT—CODE NO. 11

(AC output short)

Logic: If inverter is enabled and inverter short circuit is indicated for > 3 counts.
Corrective Action:
1. Turn−off the genset line circuit−breaker. If the genset no longer shuts down, the genset is probably
okay − check for and repair a short−circuit in the vehicle, wiring or shorted battery−charger transform-
er.
• Short Circuit Test:
− Check resistance across inverter output terminals (with and without breaker).
− Meter should read ’Open’ if there are no shorts.
− If meter reads a low resistance value, it indicates a short either in wiring and/or loads.
2. Remove battery charger loads and transfer switch/es connected directly to the inverter output. Also
remove any motor starting loads such as Air conditioners, Vacuum cleaners etc.
Note: If this step resolves the issue, check to see if there are any issues with specific loads.
3. Check whether the vehicle engine and genset share the same starting battery, if so and this fault
occurs when cranking the vehicle engine, low battery voltage maybe causing this shutdown. In-
crease battery capacity or connect to house battery or install a separate battery and battery charging
system for the genset. If the genset still shuts down and has spec # ”11296” in the Model Number,
go to step 4. if not, go to step 5.
4. Remove the front and top housing panels (p. 6-3) and disconnect the AC harness (p. A-2) from TB3
on the controller assembly (Figure 10-1). Reconnect the short grounding lead in the harness to
TB3−2 so that the genset will run. If the genset no longer shuts down, find and repair the short in the
AC harness, reconnecting the line circuit breaker, output terminal block (TB2) and battery−charger
as necessary.
5. Perform PMA stator test (p. 11-1). If all values are within spec, go to step 6.
6. Replace the controller assembly.
Document all details of the troubleshooting steps including load type and conditions.

INVERTER OVERVOLTAGE FAULT—CODE NO. 12

(Controller not able to regulate to rated voltage)

Corrective Action:
1. Check whether the vehicle engine and genset share the same starting battery. If so, and this fault
occurs when cranking the vehicle engine, low battery voltage may be causing this shutdown. In-
crease battery capacity or install a separate battery and battery charging system for the genset.
2. Replace the controller assembly (p. 10-1).

18-10
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

INVERTER UNDERVOLTAGE FAULT—CODE NO. 13

(Controller not able to regulate to rated voltage)

Corrective Action:
1. Check whether the vehicle engine and genset share the same starting battery. If so, and this fault
occurs when cranking the vehicle engine, low battery voltage may be causing this shutdown. In-
crease battery capacity or install a separate battery and battery charging system for the genset.
2. Remove the front and top housing panels (p. 6-3).
A. If loose, reconnect the leads of current transformer (p. A-2, A-4) to controller leads J9 and J10.
If that does not work, check resistance. If electrical resistance is not 15 to 25 ohms, replace the
current transformer.
B. Check for proper connections between the generator (PMA) and the controller assembly and
reconnect as necessary.
C. Check for a shorted generator stator winding (p. 11-1). If a winding is shorted, replace the stator.
3. Replace the controller assembly (p. 10-1).

INVERTER OVERFREQUENCY FAULT—CODE NO. 14

(Controller not able to regulate to rated frequency)

Logic: With inverter enabled, set is running at rpm > 800 and inverter frequency > 102.5% rated for 5
samples (125ms).
Corrective Action:
1. Reduce the number of connected appliances, especially when air conditioners and on board bat-
tery−charger are running.
2. Replace the controller assembly.
Document all details of the troubleshooting steps.

INVERTER UNDERFREQUENCY FAULT—CODE NO. 15

(Controller not able to regulate to rated frequency)

Logic: With inverter enabled, set is running with rpm > 800 and inverter frequency < 97.5% rated for 5 sam-
ples (125ms).
Corrective Action:
1. Reduce the number of connected appliances, especially when air conditioners and battery charger
are running.
2. Verify that air−conditioners are working properly.
3. Remove the top housing panel (p. 6-3) and check for correct connections at terminal TB3−1 and
TB3−2 (Figure 10-1).
4. Check PMA connections for continuity. Reconnect PMA leads and retest.
5. Check high idle adjustments.
6. If problem is not resolved, replace the controller assembly.
Document all details of the troubleshooting steps.

18-11
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

FUEL PUMP FAULT—CODE NO. 17*

(Controller sensed open circuit)

Corrective Action:
1. Try priming the fuel system by holding the control switch at Stop. If the fuel pump functions, the fault
was improperly declared and will probably not recur.
2. If loose, reconnect the two fuel pump leads (p. A-1, A-4). They are accessible through the access
door in the skid-base, and also through an access door in the front panel on some models.
3. Disconnect the fuel pump leads from the engine wiring harness and connect the white fuel pump lead
to the positive (+) terminal of a 12 volt battery and the black lead to the negative (−) terminal. Replace
the pump if there is no audible sound or vibration.
4. Remove the front and top housing panels (p. 6-3) and disconnect engine harness connector P1 (Fig-
ure 10-1, p. A-1, A-4) from the controller assembly. Check for electrical continuity between pin P1-2
and connector E2-1 and between E2-2 and ground and repair as necessary. Also check for missing,
bent or corroded terminals and connector pins and repair or reconnect as necessary.
* − This is a bypassable fault discontinued beginning Spec F.

GLOW PLUG CIRCUIT PROTECTION FAULT—CODE NO. 18*

(Controller sensed short circuit)

Corrective Action:
1. Remove the top housing panel (p. 6-3) and, if loose, reconnect engine harness spade connector
HR-1 (p. A-1, A-4) to the glow plug bus bar at the front of the engine (short to ground will cause shut-
down).
2. Disconnect engine harness connector HR-1 at the glow plug bus bar and A1-J8 at the controller as-
sembly. Check for continuity between either connector and ground (ground short). Replace the en-
gine harness if it is shorted to ground.
3. Replace the controller assembly (p. 10-1).
* − This is a bypassable fault discontinued beginning Spec F.

GOVERNOR ACTUATOR FAULT—CODE NO. 19

(Controller sensed open or short circuit)

Corrective Action:
1. Remove the front housing panel (p. 6-3) and reconnect the engine wiring harness connectors E1-1
and E1-2 to the governor actuator if they are loose. Polarity does not matter.
2. Measure actuator coil resistance with a digital ohmmeter. Replace the actuator stator assembly if
coil resistance is not 1.7 to 2.8 ohms.
3. Disconnect engine harness connector P1 from the controller assembly (Figure 10-1, p. A-1, A-4).
Check for electrical continuity between pin P1-1 and quick connector E1-1 and between E1-2 and
ground. Replace the engine harness if either leg lacks electrical continuity. Also check for missing,
bent or corroded terminals and connector pins and repair or reconnect as necessary.

18-12
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

STARTER SOLENOID CIRCUIT PROTECTION FAULT—CODE NO. 21*

(Controller sensed short circuit)

Corrective Action:
1. Open the maintenance access door and reconnect engine harness quick connector K-1 to the starter
motor solenoid if it is loose (p. A-1, A-4).
2. Disconnect engine harness connector K-1 from the starter solenoid and connect battery positive (+)
by means of a switch and jumper to energize the solenoid. If the starter does not crank the engine
when the solenoid is energized, remove the starter motor assembly. Replace the starter motor as-
sembly or solenoid, as necessary (p. 16-1).
3. Remove the top housing panel (p. 6-3) and reconnect engine harness connector A1-J6 to the lead
from the controller/inverter assembly if it is loose (Figure 10-1).
4. Disconnect engine harness connector A1-J6 at the controller/inverter assembly and connector K1
at the starter solenoid and check for continuity to ground from either connector (ground short). Re-
place the engine harness if it is shorted to ground.
5. Replace the controller assembly (p. 10-1).
* − Discontinued beginning Spec F.

GOVERNOR ACTUATOR OVERLOAD FAULT—CODE NO. 22

(Duration of operation at or near full-duty cycle beyond design limit)

Corrective Action:
1. Reduce the number of connected appliances, especially when air conditioners and battery chargers
are running.
2. Check for fuel and air leaks at each fitting in the fuel supply line.
3. Conduct a fuel flow test and service as necessary (p. 14-1).
4. Replace the engine air filter (p. 5-6) and clean the spark-arrest muffler (p. 5-5).
5. Remove the front and top housing panels (p. 6-3). Check for binding in the governor mechanism by
pushing the actuator rotor clockwise by hand—against the action of the fuel rack return spring. It
should rotate smoothly about 1/2 inch (12 mm) and return smoothly. If it binds or catches, remove
the governor actuator base assembly and replace it or service the internal engine governor mecha-
nism (p. 13-2) as necessary.
6. Check for an open or shorted PMG stator winding (p. 11-1). (The controller will drive the actuator
harder to compensate for loss of output.)
7. Readjust high-idle speed (p. 13-4).
8. Service the fuel injectors and injection pump as necessary (p. 12-1).
9. Check fuel injection timing (p. 12-1).
10. Service a worn engine (p. 12-1).

18-13
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

LOW OIL PRESSURE CUTOFF SWITCH FAULT—CODE NO. 23*

(Controller sensed switch still open during start—not a running fault**)

Corrective Action:
1. Remove the top housing panel (p. 6-3). If loose, reconnect engine harness spade connector S2 to
the low oil pressure cutoff switch (Figure 12-2).
2. Disconnect engine harness connector P2 from the controller assembly (Figure 10-1, p. A-1, A-4).
Check for electrical continuity between pin P2-9 and connector S2 and for missing, bent or corroded
connector pins and repair as necessary.
3. Check for loose or corroded ground connections between the engine and the base and the base and
controller assembly and repair as necessary.
4. Replace the low oil pressure cutoff switch.
* − This is a bypassable fault prior to Spec F.
** − Beginning Spec F, this fault is enabled 20 seconds after the genset stops and is declared during start.

COOLANT TEMPERATURE SENDER FAULT—CODE NO. 24*

(Controller did not sense temperature change during first 5 minutes of operation)

Corrective Action:
1. Remove the top housing panel (p. 6-3). If loose, reconnect engine harness spade connector E3-1
to the coolant temperature sender (Figure 10-1, p. A-1, A-4).
2. Disconnect engine harness connector P1 from the controller assembly. Check for electrical continu-
ity between pin P1-12 and connector E3-1 and for missing, bent or corroded connector pins and re-
pair as necessary.
3. Replace the coolant temperature sender.
* − This is a bypassable fault prior to Spec F. Note also that an open circuit is sensed as cold temperature, resulting in maximum pre-heat and
post-heat times.

ENGINE ABOVE SPEED TARGET FAULT—CODE NO. 25

(Governor unable to regulate to target speed)

Corrective Action:
1. Remove the front and top housing panels (p. 6-3). Check the fuel rack return spring and replace it
if it is worn or broken (Figure 13-1). Make sure it is reassembled correctly.
2. Check for binding in the governor mechanism by pushing the actuator rotor clockwise by hand—
against the action of the fuel rack return spring. It should rotate smoothly about 1/2 inch (12 mm) and
return smoothly. If it binds or catches, remove the governor actuator base assembly and replace it
or service the internal engine governor mechanism (Figure 13-2) as necessary.
3. Readjust high-idle speed (p. 13-5).

18-14
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

ENGINE BELOW SPEED TARGET FAULT—CODE NO. 26

(Governor unable to regulate to target speed)

Corrective Action:
1. Reduce the number of connected appliances, especially when air conditioners and battery chargers
are running.
2. Prime the engine fuel system.
3. Check for fuel and air leaks at each fitting in the fuel supply line.
4. Conduct a fuel flow test and service as necessary (p. 14-1).
5. Replace the engine air filter (p. 5-6) and clean the spark-arrest muffler (p. 5-5).
6. Connect a source of known fuel quality, prime the fuel system and run the genset. If performance
improves, replace the bad fuel in the supply tank.
7. Remove the front and top housing panels (p. 6-3). Check for binding in the governor mechanism by
pushing the actuator rotor clockwise by hand—against the action of the fuel rack return spring (Fig-
ure 13-1). It should rotate smoothly about 1/2 inch (12 mm) and return smoothly. If it binds or catches,
remove the governor actuator base assembly and replace it or service the internal engine governor
mechanism (Figure 13-2) as necessary.
8. Readjust high-idle speed (p. 13-4).
9. Service the fuel injectors and injection pump, as necessary (p. 12-1).
10. Check fuel injection timing (p. 12-1).
11. Service a worn engine (p. 12-1).

18-15
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

PMA SENSE LOST FAULT—CODE NO. 27

(Controller unable to sense PMA frequency)

Logic: If between cranking and run_down, rpm = 0 and dc bus voltage present for > 2 seconds.
Corrective Action:
1. Check for proper connections between the generator (PMA) stator (Figure 11-2) and the controller
assembly (Figure 10-1) and reconnect as necessary.
2. Disconnect the PMA leads from the control. Using InPower, turn on the control starter relay in control-
ler assembly (Refer to Step 7).
WARNING Do Not crank for more than 30 seconds.
@@@@
3. Connect Digital Multi Meter (DMM) to the PMA leads. While the engine is cranking, measure the volt-
age between PMA leads T1−T2, T2−T3 and T3−T1 using DMM. Set DMM to AC and range. Do not
crank the engine for more than 30 seconds.
A. If all of the leads measure > 20Vrms, replace controller−assembly.
B. If any of the leads measure < 20Vrms, troubleshoot PMA (Refer Step 6).
TIP:
• If values of all leads (T1−T2, T2−T3 and T3−T1) is < 20Vrms, problem is with the rotor.
• If value of one/more leads is < 20Vrms, problem lies with the stator.
4. After measuring the PMA leads, turn−off control starter relay in controller assembly (Refer Step 7E)
using InPower.
5. Run the set again and check if fault is cleared.
6. PMA Troubleshooting Steps:
A. Check for PMA to Ground shorts.
• Use a digital multimeter to measure resistance between each PMA lead to Ground.
− Meter will read ’Open’ if there are no shorts.
− If meter reads a finite resistance, it indicates a short.
B. Check for an open generator stator winding (p. 11-1). If winding is open, replace the stator.
@@@@ Ensure actuator is at zero and/or fuel is Off.
CAUTION
C. Remove top housing panel (p. 6-3), check PMA rotor and integrity of the magnets. Attempt to
bar the engine by hand to check for jammed magnets. Replace the rotor if damaged.
Note: If the rotor is damaged, Do Not replace the controller−assembly. Replace the rotor first and
check to verify if that solves the problem.
7. Steps for turning on the control starter relay in controller assembly using Inpower:
A. Enable the parameter “Starter Override Request”.
B. Turn on the parameter “Startes Override Command”.
C. To verify, check to see if “Starter Override Status” = on.
D. To switch off starter relay, turn off the parameter “Starter Override Command”.
E. To verify, check to see if “Starter Override Status” = off.

18-16
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

DC SENSE LOST FAULT—CODE NO. 28

(Controller unable to sense DC bus voltage)

Corrective Action:
1. Open the circuit breaker. If the fault does not persist, check for and disconnect excessive loads from
the genset before starting.
2. Check for proper connections between the generator (PMA) stator (Figure 11-2) and the controller
assembly (Figure 10-1) and reconnect as necessary.
3. Replace the controller assembly (p. 10-1).

HIGH BATTERY VOLTAGE FAULT—CODE NO. 29

(Voltage across battery system greater than 17.5 volts)

Corrective Action:
1. Check battery bank connections and reconnect if necessary so that the 12 volt batteries serving the
genset are connected in parallel (12 volt) rather than in series (24 volt).
2. Select a lower battery booster charge rate.

OVERSPEED FAULT—CODE NO. 31

(Engine speed greater than 3600 rpm)

Corrective Action:
1. Remove the front and top housing panels (p. 6-3). Check for binding in the governor mechanism by
pushing the actuator rotor clockwise by hand—against the action of the fuel rack return spring (Fig-
ure 13-1). It should rotate smoothly about 1/2 inch (12 mm) and return smoothly. If it binds or catches,
remove the governor actuator base assembly and replace it or service the internal engine governor
mechanism (Figure 13-2) as necessary.
2. Readjust high-idle speed (p. 13-4).
3. Replace the controller assembly (p. 10-1).

18-17
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

LOW CRANKING SPEED FAULT—CODE NO. 32

(Cranking speed less than 180 rpm for more than 2 seconds)

Logic: If CRANK and generator frequency < 3Hz for > 2 seconds.
Corrective Action:
Troubleshooting for Fault Code 32 is divided into 2 failure modes:
1. The engine does not crank.
2. The engine cranks.
If The Engine Does Not Crank
1. Inspect fuse F2. If blown, inspect wiring connections for shorts to chassis or other shorts. Replace
fuse and repeat test.
2. Check battery voltage at the genset terminal − should be 11  0.2V or above. Replace/recharge
battery as necessary.
3. Inspect battery connections at the terminals. Check DC system and cables.
4. Follow the steps below to troubleshoot and verify control starter relay (in controller assembly) and
starter motor assembly. In the steps below the numbers in parenthesis refer to the wiring diagram
on page A-5.
A. Using InPower, turn ON the control starter relay (in controller assembly) (Refer Step 5).
B. Measure voltage at A1−J6−K1 (1) at starter assembly. If measured voltage is > 10V, replace
starter assembly.
C. If measured voltage is < 10V, unplug A1−J6−K1 at the Starter Assembly (2).
D. Measure voltage at A1−J6−K1 (2) at the harness. It should measure approximately Battery volt-
age.
• If it measures approximately battery voltage, replace starter motor
• If it does not measure approximately battery voltage or measures less than 10V, unplug J6
(4) from A1−J6 (3) at controller assembly and measure voltage at J6 (4) on controller as-
sembly.
− If measured voltage at (4) < 10V, then disconnect A1−J5 (5) from J5 (6) and measure
voltage at A1−J5 (5). If value is > 10V at A1−J5 (5), then replace controller assembly.
− If measured voltage at (5) < 10V, verify wiring.
5. Steps for turning on the control starter relay in controller assembly using Inpower:
A. Enable the parameter ”Starter Override Request”.
B. Turn on the parameter ”Starter Override Command”.
C. To verify, check to see if ”Starter Override Status” = on.
D. To switch off starter relay, turn off the parameter ”Starter Override Command”.
E. To verify, check to see if ”Starter Override Status” = off.

18-18
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

LOW CRANKING SPEED FAULT—CODE NO. 32 (CONT.)

(Cranking speed less than 180 rpm for more than 2 seconds)

If The Engine Cranks

While the start button is pressed, Monitor the parameters ”waveform period”, ”Inverter dc voltage” using
Inpower and refer to table below:
Note: Waveform period <80000 indicates Normal cranking speed. Waveform period >80000 indicates
unit is cranking too slow.

Condition No. Waveform Period Symptom Troubleshooting

1 80000−140000 Engine cranking slow See step 1
Engine cranks normal
2 30000000 for > 4s but control does not See step 2
sense PMA output

Step 1: Engine cranking slow

1. Verify engine setup for ambient conditions.
2. Low/weak batteries cause starting issues. Monitor battery voltage during crank. It must be > 8V.
Ideally it should be greater than 9V.
A. If the battery voltage is  8V, inspect battery connections at the terminals.

Step 2: Engine cranks normal but control does not sense PMA output
1. Check for proper connections between the generator (PMA) stator (Figure 11-2) and the controller
assembly (Figure 10-1) and reconnect as necessary.
2. Disconnect the PMA leads from the control. Using InPower, turn on the control starter relay in control-
ler assembly (Refer Step 7).

WARNING Do Not crank for more than 30 seconds.

@@@@
3. While the engine is cranking, use a digital multimeter (DMM) set to AC and range to measure the
voltage between PMA leads T1−T2, T2−T3 and T3−T1. Do Not crank for more than 30 seconds.
A. If any of the leads measure > 20Vrms, replace controller−assembly.
B. If any of the leads measure < 20Vrms, troubleshoot PMA. (Refer Step 6.)
TIP:
• If values of all leads (T1−T2, T2−T3 and T3−T1) is > 20Vrms, problem is with the magnetic
field.
• If value of one/more leads is < 20Vrms, problem lies with the stator.
4. Turn−off control starter relay in the inverter (Refer Step 7D) using InPower after measuring the leads
5. Run the set again and check if fault is cleared.

18-19
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

LOW CRANKING SPEED FAULT—CODE NO. 32 (CONT.)

(Cranking speed less than 180 rpm for more than 2 seconds)

6. PMA Troubleshooting Steps:

A. Check for PMA to Ground shorts.
1). Use a digital multimenter to measure resistance between each PMA lead to Ground.
a). Meter will read ’Open’ if there are no shorts.
b). If meter reads a finite resistance, it indicates a short.
B. Check for an open generator stator winding (p. 11-1). If winding is open, replace the stator.
@@@@ Ensure actuator is at zero and/or fuel is Off.
CAUTION
C. Remove top housing panel (p. 6-3), check PMA rotor and integrity of the magnets. Attempt to
bar the engine by hand to check for jammed magnets. Replace the rotor if damaged.
Note: If the rotor is damaged, Do Not replace the controller−assembly. Replace the rotor first and check to
verify if that solves the problem.
7. Steps for turning on the control starter relay in controller assembly using Inpower:
A. Enable the parameter ”Starter Override Request”.
B. Turn on the parameter ”Starter Override Command”.
C. To verify, check to see if ”Starter Override Status” = on.
D. To switch off starter relay, turn off the parameter ”Starter Override Command”.
E. To verify, check to see if ”Starter Override Status” = off.

HIGH ENGINE COOLANT TEMPERATURE FAULT—CODE NO. 33

(Engine coolant temperature exceeded design limit)

Corrective Action:
1. Check the engine coolant level and add coolant and repair leaks as necessary.
2. Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset.
3. Reduce the number of appliances connected at the same time. (Note that high altitude and high am-
bient temperature decrease engine cooling capacity.)
4. Look for a broken or worn coolant pump drive belt (Figure 12-2) and replace as necessary. (Visible
through the maintenance access door in the skid-base.)
5. Remove the air intake grille in the skid-base and check to see that the cooling blower (Figure 11-2)
is secure and that the blades are not fouled.
6. Check for air leaks in the housing—missing or loose housing panels and access covers, including
the access covers for the fuses and AC terminals.
7. Clean and flush the cooling system to remove coolant passage fouling.
8. Remove the top housing panel (p. 6-3). If loose, reconnect engine harness spade terminal connector
E3-1 to the coolant temperature sender (Figure 12-2) (If the lead is loose and touching ground, the
controller will sense a high engine temperature.)
9. While the top housing panel is off (Step 6-3), check for fouling of the radiator air passages and clear
out dust and debris with compressed air directed from below (reverse of normal air flow).
10. Replace the coolant thermostat (Figure 12-2).
11. If the genset overheats only underway, see the coach manufacture regarding air baffles or other
means to direct cooling air into the genset.

18-20
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

HIGH INVERTER TEMPERATURE FAULT—CODE NO. 34

(Inverter heat sink temperature exceeded design limit*)

Corrective Action:
1. Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset.
2. Remove the air intake grille in the skid-base and clean the heat sink fins (Figure 10-1) if they are
fouled. Also check to see that the cooling blower (Figure 11-2) is secure and that the blades are not
fouled.
3. Reduce the number of appliances connected at the same time. (Note that high altitude and high am-
bient temperature decrease cooling capacity.)
4. Replace the controller assembly (p. 10-1) if the genset cannot carry rated load.
*− Prior to Spec F, use compressed air to cool off the fins of the heat sink if it is necessary to get the genset started right away. Beginning Spec F, the
genset will run for 2 minutes after being restarted, which is enough time to cool down the heat sink if the connected load is less than 2 kW.

CONTROL CARD FAILURE FAULT—CODE NO. 35

(Microprocessor EEPROM error during self-test)

Corrective Action: Report this failure to the Factory and replace the controller assembly (p.10-1). This
fault occurs when using obsolete software.

ENGINE STOPPED FAULT—CODE NO. 36

(Engine stopped without command by controller)

Corrective Action:
1. Check fuel level. (Note: The genset fuel pickup is probably higher than the vehicle engine pickup.)
2. Prime the engine fuel system if the genset ran out of fuel.
3. Check for fuel and air leaks at each fitting in the fuel supply line. (Note: White smoke indicates air
in the fuel.)
4. Check the engine air filter and remove any blockage.
5. Check for mechanical damage.
6. Check auxiliary fuel pump (if equipped).
7. Conduct a fuel flow test and service as necessary (p. 14-1).
8. Remove the front and top housing panels (p. 6-3) and disconnect engine harness connectors P1 and
P2 from the controller (Figure 10-2, p. A-1, A-4, ). Check for missing, bent or corroded connector pins
and faulty wiring and repair as necessary.
9. Service the engine (p. 12-1).

INVALID GENSET CONFIGURATION FAULT—CODE NO. 37

(Genset configuration is preprogrammed at the factory)

Corrective Action: Corrective Action: Replace the controller assembly (p. 10-1). The controller as-
sembly must be configured at the factory.

18-21
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

OVERCURRENT FAULT—CODE NO. 38

(Too many loads connected)

Corrective Action:
1. Reduce the number of appliances running at the same time, especially those with high motor starting
loads such as air conditioners. Start up with no load and let the genset run for five minutes to cool
down the inverter.
2. If the appliance and air conditioner loading patterns have remained the same but genset perfor-
mance has deteriorated:
A. Check for fuel and air leaks at each fitting in the fuel supply line. (Note: White smoke indicates
air in the fuel.)
B. Conduct a fuel flow test and service as necessary (p. 14-1).
C. Remove the front and top housing panels (p. 6-3). Check for binding in the governor mechanism
by pushing the actuator rotor clockwise by hand—against the action of the fuel rack return spring
(Figure 13-1). It should rotate smoothly about 1/2 inch (12 mm) and return smoothly. If it binds
or catches, remove the governor actuator base assembly and replace it or service the internal
engine governor mechanism (Figure 13-2) as necessary.
D. Readjust high-idle speed (p. 13-4).
E. Service the fuel injectors and injection pump as necessary (p. 12-1).
F. Service a worn engine (p. 12-1).

LOW BATTERY VOLTAGE FAULT—CODE NO. 39*

(Battery voltage dropped below 9 volts while genset running)

Logic: If power supply shutdown is indicated and battery voltage < 9.5V during wakeup state
Corrective Action:
1. Inspect connections at battery and genset.
2. Avoid running the genset while cranking the propulsion engine, specially in installations where gen-
set batteries are used to supplement vehicle engine batteries
3. Check battery voltage at the genset terminal −typical should be 11V  0.3V or above. If not, replace/
recharge battery.
Note: Due to the long battery cables, battery voltage at the genset terminal may be lower than at battery
terminals.
4. Check Battery Voltage at the genset terminal ”while cranking engine”. If battery Voltage drops < 9V
0.2V, replace/recharge the battery.
Note: Battery voltage dipping below 9V during crank indicates a potentially weak battery. Battery needs
to be replaced.
* − Fault Code Active for Specs A−E and beginning M
Fault Inactive for Specs F−L

18-22
 TABLE 18-1. TROUBLESHOOTING (CONT.)
@@@@
WARNING Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform genset service. See Safety Precautions.

PROCESSOR FAULT—CODE NO. 42*

(Microprocessor ROM error during self-test)

Corrective Action: Replace the controller assembly (p. 10-1).

* − Beginning Spec F and replacement controller assemblies

PROCESSOR FAULT—CODE NO. 43*

(Microprocessor RAM error during self-test)

Corrective Action: Replace the controller assembly (p. 10-1).

* − Beginning Spec F and replacement controller assemblies

INVERTER POWER SUPPLY FAULT—CODE NO. 46*

(Low battery voltage or power supply device failure)

Logic: If input indicates power supply shutdown for 3 samples at 32ms rate.
Corrective Action:
1. Avoid running the genset while cranking the propulsion engine, specially in installations where gen-
set batteries are used to supplement vehicle engine batteries.
2. Inspect battery cable connections at the battery, vehicle frame, and genset.
3. Check battery voltage at the genset terminal −typical voltage should be 11V 0.3V or above. If not,
replace/recharge battery.
Note: Due to the long battery cables, battery voltage at the genset terminal may be lower than at battery
terminals.
4. Check battery voltage at the genset terminal ”while cranking engine”. If battery Voltage drops to <
9V  0.2V, replace/recharge the battery.
Note: Battery voltage dipping below 9V during crank indicates a potentially weak battery. Battery needs
to be replaced.
5. Remove battery charger or unplug the battery charger from its AC source, before cranking.
6. Replace the controller assembly (p 10-1).
* − Beginning Spec F and replacement controller assemblies

18-23
TIE TO AC SECURE TO TOP OF CONTROLLER SECURE TO TOP OF INTAKE RESO-
HARNESS HOUSING WITH SUPPORT CLIP NATOR WITH SUPPORT CLIP

SECURE TO END OF
INTAKE RESONATOR
WITH SUPPORT CLIP

LATER MODELS

EARLIER MODELS

ENGINE WIRING HARNESS

A-1
 TIE WITH ENGINE
SECURE TO TOP OF CONTROLLER HARNESS
HOUSING WITH SUPPORT CLIP

HARNESS WHEN GENSET IS NOT

EQUIPPED WITH BATTERY CHARGER

CURRENT
TRANSFORMER

EARLIER MODELS
HARNESS WHEN GENSET IS NOT USED
EQUIPPED WITH BATTERY CHARGER

TWO LEADS WHEN GENSET IS

EQUIPPED WITH A BATTERY
CHARGER

LATER MODELS

AC WIRING HARNESS

A-2
 SECURE PCB
SECURE HARNESS SUP- GROUND HERE
PORT CLIPS HERE

SECURE HARNESS SUP-

PORT CLIPS HERE

SECURE GND SECURE B+

CABLE HERE CABLE HERE

EARLIER MODELS ONLY

BATTERY WIRING HARNESS

A-3
 CONTROLLER/INVERTER ASSEMBLY

PRIOR TO SPEC F

WIRING DIAGRAM

A-4
 CONTROLLER/INVERTER ASSEMBLY

3 4

5 6

1 2

Ref # Description
1. INPUT TERNINAL AT STARTER SOLENOID.
2. A1−J6−K1 HARNESS CONNECTION AT STARTER SOLENOID.
3. A1−J6−K1 HARNESS CONNECTION AT CONTROL ASSEMBLY.
4. J6 TERMINAL AT CONTROL ASSEMBLY.
5. A1−J5−K1 HARNESS CONNECTION AT CONTROL ASSEMBLY.
6. J5 TERMINAL AT CONTROL ASSEMBLY.

WIRING DIAGRAM FOR FC32 TROUBLESHOOTING

A-5
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
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