KY Printed in U.S.A. 11-04 981-0159D Redistribution or publication of this document by any means, is strictly prohibited.
! ! The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. gasoline warnings Redistribution or publication of this document by any means, is strictly prohibited.
Table of Contents SECTION PAGE SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii 1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION PAGE 3. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Conducting General Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY PRECAUTIONS moving or electrically live parts can cause severe personal injury or death. Thoroughly read the OPERATOR’S MANUAL before operating the genset. Safe operation and top performance can be obtained only when equipment is operated and maintained properly. S Used engine oil has been identified by some state and federal agencies as causing cancer or reproductive toxicity. Do not ingest, inhale, or contact used oil or its vapors.
S Leaks can lead to explosive accumulations of gas. Natural gas rises when released and can accumulate under hoods and inside housings and buildings. LPG sinks when released and can accumulate inside housings and basements and other below-grade spaces. Prevent leaks and the accumulation of gas. ENGINE EXHAUST IS DEADLY! S Inspect for exhaust leaks at every startup and after every eight hours of running. S Learn the symptoms of carbon monoxide poisoning in this manual.
1. Introduction ABOUT THIS MANUAL This manual covers operation and maintenance of the KY Series of generator sets (gensets). Each operator should study this manual carefully and observe all of its instructions and safety precautions. Keep this manual and the Installation Manual with the other vehicle manuals. Operation, Periodic Maintenance and Troubleshooting provide the instructions necessary for operating the genset and maintaining top performance.
Securing the access cover: Position the bottom of the cover so that its lip catches the top edge of the base tray, rotate the top of the cover towards the genset and turn the two cover latches clockwise to CLOSED, making sure the latches catch. TYPICAL GENSET Figure 1-2 illustrates a typical genset and the features requiring attention during operation and periodic maintenance. WARNING Operating the genset with the access cover off can lead to severe burns and engine damage due to overheating.
Satisfactory performance requires that the LPG vapor be supplied at a pressure within the range indicated in Specifications (Page 5-1). FUEL RECOMMENDATIONS WARNING Gasoline and LPG are highly flammable and explosive and can cause severe personal injury or death. Do not smoke or turn electrical switches ON or OFF where fuel fumes, tanks or equipment are present or in areas sharing ventilation. Keep flames, sparks, pilot lights, arc-producing equipment, switches and all other sources of ignition well away.
GENSET CONTROL PANEL The genset control panel (Figure 1-3) is located behind the maintenance access cover (Figure 2) and has the following features: Control Switch − This switch is used to prime the fuel system, start and stop the genset and display the fault code. Hold the switch in its START position to crank and start the genset. Press the switch to its STOP position to stop the genset. Hold the switch in its STOP/PRIME position to prime the fuel system (gasoline models only).
2. Operation WARNING EXHAUST GAS IS DEADLY! Exhaust gases contain carbon monoxide, an odorless, colorless gas. Carbon monoxide is poisonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning include: • • • Dizziness Muscular Twitching Weakness and Sleepiness • • • Throbbing in Temples Headache Inability to Think Clearly • • Nausea Vomiting IF YOU OR ANYONE ELSE EXPERIENCES ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY.
TABLE 2-1. TYPICAL APPLIANCE LOADS STOPPING THE GENSET Appliance Air Conditioner Battery Charger DC Converter Refrigerator Microwave Oven Electric Frying Pan or Wok Electric Stove Element Electric Water Heater Electric Iron Electric Hair Dryer Coffee Percolator Television Radio Electric Drill Electric Broom Electric Blanket Turn off the air conditioner and other large appliances and let the genset run for two minutes to cool down. This reduces backfiring and run-on.
RESETTING CIRCUIT BREAKERS If a circuit breaker in the main power distribution panel of the vehicle or on the genset (Figure 2-1) trips, either a circuit shorted or too many appliances were running. Note that the genset will continue to run after a circuit breaker trips. If a circuit breaker trips, disconnect or turn off as many loads as possible and reset the circuit breaker. (It may be necessary to push the circuit breaker OFF to reset it and then ON to reconnect the circuit.
OPERATING IN COLD WEATHER Pay particular attention to the following when operating the genset in cold weather: 1. Make sure engine oil viscosity is appropriate for the ambient temperatures. Change oil if there is a sudden drop in temperature. See ENGINE OIL RECOMMENDATIONS (Page 1-3). 2. Check the altitude setting (Figure 2-2). 3. Perform spark plug maintenance (Page 3-6). 4. Perform battery maintenance (Page 3-5).
run the genset for about 10 minutes at approximately 1/2 rated power to fill the fuel lines with the fresh fuel and preservative. BREAKING IN A NEW ENGINE Proper engine break-in on a new genset or on one with a rebuilt engine is essential for top engine performance and acceptable oil consumption. Run the genset at approximately 1/2 rated power for the first 2 hours and then at 3/4 rated power for 2 more hours. See LOADING THE GENSET (Page 2-2). WARNING Gasoline preservatives (stabilizers) are toxic.
9. Gasoline Models − Drain the carburetor float bowl to prevent deposits of gum from clogging the tiny passages in the carburetor as the gasoline in the bowl evaporates during storage (Figure 2-3). Drain it as follows: A. Let the engine cool down thoroughly. B. Place paper towels under the drain to absorb all of the drainage (less than 1/2 cup). C. Open the drain valve by turning it counterclockwise with a screwdriver. D.
3. Periodic Maintenance Periodic maintenance is essential for top performance and long genset life. Use Table 3-1 as a guide for normal periodic maintenance. In hot and dusty environments some maintenance procedures should be performed more frequently, as indicated by the footnotes in the table. Keeping a log of maintenance performed and hours run will help you keep genset maintenance regular and provide a basis for supporting warranty claims (Page 8-1).
Fuel System CONDUCTING GENERAL INSPECTIONS Check for leaks at the hose, tube and pipe fittings in the fuel supply system while the genset is running and while it is stopped. Do not use a flame to check for LPG leaks. Check flexible fuel hose sections for cuts, cracks, and abrasions. Make sure the fuel line is not rubbing against other parts. Replace worn or damaged fuel line parts before leaks occur. Inspect the genset before the first start of the day and after every eight hours of operation.
CHECKING ENGINE OIL LEVEL Park the vehicle on level ground and shut off the genset before checking the engine oil level. FILL TO THIS MARK Crankcase pressure can blow hot engine oil out the fill opening causing severe burns. Always stop the genset before removing the oil fill cap. WARNING DO NOT RUN IF BELOW THIS MARK 1. Unscrew the oil fill cap and wipe oil off the dipstick (Figure 3-1). Screw the cap back on, remove it again and check the oil level on the dip stick. 2. Add or drain oil as necessary.
CHANGING ENGINE OIL State and federal agencies have determined that contact with used engine oil can cause cancer or reproductive toxicity. Try to avoid skin contact and breathing of vapors. Use rubber gloves and wash exposed skin. WARNING Refer to Table 3-1 for scheduled engine oil change. Change oil more often in hot and dusty environments. WARNING Crankcase pressure can blow hot engine oil out the fill opening causing severe burns. Always stop the genset before removing the oil fill cap. 1.
3. Make sure which terminal is positive (+) and which is negative (−) before making battery connections, always removing the negative (−) cable first and reconnecting it last to reduce arcing.
REPLACING THE SPARK PLUG Refer to Table 3-1 for scheduled spark plug replacement. (The genset has one spark plug, Figure 3-4.) The spark plug must be in good condition for proper engine starting and performance. A spark plug that fouls frequently or has heavy soot deposits indicates the need for engine service. See Troubleshooting (Page 4-1). Always thread the spark plug in by hand until it seats, to prevent cross threading, and torque to 13 lbs-ft (17 N-m).
4. Troubleshooting shutdown, the indicator light will repeatedly blink 3 blinks or 4 blinks at a time. WARNING Hot engine parts can cause severe burns. Always allow the engine time to cool before performing any maintenance or service. S Three blinks indicates a service fault. Press Stop once to cause the two-digit, second-level fault code to blink. (Pressing Stop again will stop the blinking.)The two-digit code consists of 1, 2, 3 or 4 blinks, a brief pause, and then 1 to 9 blinks.
TABLE 1. TROUBLESHOOTING (CONT.) Some genset service procedures present hazards that can result in severe perWARNING sonal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. STARTING BATTERIES RUN DOWN (Marginal batteries, connections, or charging system or, parasitic loads) Corrective Action: 1.
TABLE 1. TROUBLESHOOTING (CONT.) Some genset service procedures present hazards that can result in severe perWARNING sonal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. OVERCRANK FAULT—CODE NO. 4 (First-level fault code—Cranking exceeded 20 seconds without engine starting) Corrective Action: 1. Gasoline Models − Check and fill the fuel tank, as necessary.
TABLE 1. TROUBLESHOOTING (CONT.) Some genset service procedures present hazards that can result in severe perWARNING sonal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. HIGH BATTERY VOLTAGE FAULT—CODE NO. 29 (Voltage across battery system greater than 19 volts) Corrective Action: 1.
TABLE 1. TROUBLESHOOTING (CONT.) Some genset service procedures present hazards that can result in severe perWARNING sonal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. OVERCURRENT FAULT—CODE NO. 38 (Low power factor loads) Corrective Action: 1. Reduce the number of appliances running at the same time, especially those with high motor starting loads such as air conditioners.
5. Specifications GASOLINE MODELS 4KY LPG MODELS 3.6KY 3.6KY 3.3KY 3600 watts 3300 watts GENERATOR: 2-Pole Revolving Field, Self-Excited, 1-Phase, Microprocessor Regulated Power Frequency 4000 watts 3600 watts 60 Hertz 50 Hertz 60 Hertz 50 Hertz Voltage 120 volts1 230 volts1, 2 120 volts 230 volts2 Current 33.3 amperes 15.7 amperes 30 amperes 14.3 amperes Speed 3600 rpm 3000 rpm 3600 rpm 3000 rpm 0.29 gph (1.1 l/h) 0.48 gph (1.8 l/h) 0.71 gph (2.7 l/h) 0.21 gph (0.79l/h) 0.
6. Information for California Genset Users You should carefully review Operator (Owner), Installation and other manuals and information you receive with your genset. If you are unsure that the installation, use, maintenance or service of your genset is authorized, you should seek assistance from an approved Onan dealer. This genset meets the requirements of California’s Exhaust Emissions Standards as stated on the nameplate. Figure 1-1 illustrates where this information appears on the nameplate.
7. How to Obtain Service If you are outside North America, call Onan Corporation at 1−763−574−5000 from 7:30 AM to 4:00 PM, Central Standard Time, Monday through Friday, or fax 1−763−528−7229. When you need service, parts, or product literature (such as the Service Manual) for your genset, contact the nearest authorized distributor. Onan has factory-trained representatives to handle your needs for genset parts and service. You may go to Internet site www.onan.
8. Maintenance Record Record all periodic and unscheduled maintenance and service. See Periodic Maintenance (Page 3-1). DATE HOUR METER READING MAINTENANCE OR SERVICE PERFORMED Record the name, address, and phone number of your authorized Onan service center. 8-1 Redistribution or publication of this document by any means, is strictly prohibited.
Cummins Power Generation 1400 73rd Avenue N.E. Minneapolis, MN 55432 763-574-5000 Fax: 763-528-7229 Cummins and Onan are registered trademarks of Cummins Inc. Redistribution or publication of this document by any means, is strictly prohibited.
