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Operator Manual
RV Generator Set
KY (Spec J−N)
English
Original Instructions 10-2014 981−0159 (Issue 9)
2
i
Table of Contents
SECTION PAGE
SAFETY PRECAUTIONS iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. INTRODUCTION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About this Manual 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Genset 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Recommendations 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Recommendations 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Batteries 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Control Panel 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Panel 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. OPERATION 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conducting the Pre-Start Checks 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming the Fuel System 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Genset 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Genset 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Restarting the Genset 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading the Genset 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting Circuit Breakers 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting to Utility Power 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Cold Weather 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Hot Weather 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Altitude Adjustment 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Dusty Environments 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Breaking in a New Engine 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercising the Genset 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storing the Genset 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Returning the Genset to Service 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
SECTION PAGE
3. PERIODIC MAINTENANCE 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conducting General Inspections 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Engine Oil Level 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Engine Oil 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining the Battery and Battery Connections 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Air Filter Element 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Spark Plug 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Spark Arrestor 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. TROUBLESHOOTING 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. SPECIFICATIONS 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. INFORMATION FOR CALIFORNIA GENSET USERS 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . .
7. HOW TO OBTAIN SERVICE 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. MAINTENANCE RECORD 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iii
SAFETY PRECAUTIONS
Thoroughly read the OPERATOR’S MANUAL
before operating the genset. Safe operation and
top performance can be obtained only when
equipment is operated and maintained properly.
Only trained and experienced service personnel
with knowledge of fuels, electricity, and machin-
ery hazards shall remove, dismantle and dis-
pose of the generator set. See service manual.
Some generator set installation procedures
present hazards that can result in severe per-
sonal injury or death. Only trained and experi-
enced personnel with knowledge of fuels, elec-
tricity, and machinery hazards should perform
generator set installation procedures.
The following symbols in this manual alert you to po-
tential hazards to the operator, service person and
equipment.
DANGER
alerts you to an immediate hazard
which will result in severe personal injury or
death.
WARNING
alerts you to a hazard or unsafe
practice which can result in severe personal in-
jury or death.
CAUTION
alerts you to a hazard or unsafe
practice which can result in personal injury or
equipment damage.
When equipped with an integral or add−on Auto−
matic Generator Starting System (AGS) control,ex-
haust carbon monoxide (CO), electric shock, and-
moving parts hazards are possible due to unex−
pected starting. Turn off AGS whenever performing-
maintenance or service, when the vehicle is stored-
between uses, is awaiting service, or is parked in a
garage or other confined area.
Electricity, fuel, exhaust, moving parts and batteries
present hazards which can result in severe personal
injury or death.
GENERAL PRECAUTIONS
S Keep children away from the genset.
S Do not use evaporative starting fluids. They are
highly explosive.
S To prevent accidental or remote starting while
working on the genset, disconnect the nega-
tive (−) battery cable at the battery.
S Keep the genset and its compartment clean.
Excess oil and oily rags can catch fire. Dirt and
gear stowed in the compartment can restrict
cooling air.
S Make sure all fasteners are secure and torqued
properly.
S Do not work on the genset when mentally or
physically fatigued or after consuming alcohol
or drugs.
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 Benzene and lead in some gasolines have
been identified by some state and federal
agencies as causing cancer or reproductive
toxicity. Do not to ingest, inhale or contact gaso-
line or its vapors.
S Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible ma-
terials such as wood and cloth; Class B fires,
combustible and flammable liquid fuels and
gaseous fuels; Class C fires, live electrical
equipment. (ref. NFPA No. 10)
S Genset installation and operation must comply
with all applicable local, state and federal codes
and regulations.
S Use personal protective equipment when per-
forming periodic maintenance operations such
as gloves, safety glasses, etc.
S Use caution when working on live electrical
equipment. Remove jewelry, make sure cloth-
ing and shoes are dry, stand on a dry wooden
platform or rubber insulating mat and use tools
with insulated handles.
GENERATOR VOLTAGE IS DEADLY!
S Disable the automatic genset starting fea-
ture(AGS) of an inverter−charger or other auto-
matic starting device before servicing the gen-
set to avoid electric shock from an unexpected
start.
iv
WARNING
The genset must not be connected
to shore power or to any other source of electri-
cal power. Back-feed to shore power can cause
electric shock resulting in severe personal inju-
ry or death and damage to equipment. An ap-
proved switching device must be used to pre-
vent interconnections.
S Generator electrical output connections must
be made by a trained and experienced electri-
cian in accordance with applicable codes.
BATTERY GAS IS EXPLOSIVE
S Wear safety glasses.
S Do not smoke.
S To reduce arcing when disconnecting or recon-
necting battery cables, always disconnect the
negative (−) battery cable first and reconnect it
last.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
S Disable the automatic genset starting fea-
ture(AGS) of an inverter−charger or other auto-
matic starting device before servicing the gen-
set to avoid unexpected starting.
S Do not wear loose clothing or jewelry near mov-
ing parts such as PTO shafts, fans, belts and
pulleys.
S Keep hands away from moving parts.
S Keep guards in place over fans, belts, pulleys,
and other moving parts.
ENGINE EXHAUST IS DEADLY!
S Inspect for exhaust leaks at every startup and
after every eight hours of running.
S Prior to every startup and after every eight
hours of running, all carbon monoxide detec-
tors must be tested and confirmed to be work-
ing in accordance with the manufacturer’s in-
structions or owners manual.
S Learn the symptoms of carbon monoxide poi-
soning in this manual.
S Never occupy the vehicle while the genset is
running unless the vehicle is equipped with a
working carbon monoxide detector.
S Make sure there is ample fresh air when operat-
ing the genset in a confined area.
S Disable the automatic genset starting feature of
an inverter-charger or other automatic starting
device before storing the vehicle or parking it in
a garage or other confined space.
S The exhaust system must be installed in accor-
dance with the genset Installation Manual.
S Engine cooling air must not be used for heating
the working or living space or compartment.
THE HAZARDS OF CARBON MONOXIDE
WARNING
Engine−driven generators can pro-
duce harmful level of carbon monoxide that can
injury or kill you.
ONLY YOU CAN PROTECT YOURSELF
FROM CO POISONING!
S Watch constantly for people near the exhaust
of the generator set while it is running.
S Make sure exhaust cannot enter the living
quarters through a window, vent or door.
S Make sure all CO detectors or audible alarms
are working properly.
S Pay attention to the signs of CO poisoning.
S Check the exhaust system for corrosion, ob-
struction and leaks each time you start the gen-
erator set and every eight hours if you run it
continuously.
SUBSTANCE HAZARDOUS TO HEALTH
Generator sets use substances, and emit and
create wastes that can cause health risks. Genera-
tor set operators must use appropriate personal
protective equipment (such as clothing, gloves, pro-
tective glasses/goggles, and respiration equip-
ment) when exposed to fuel, oil, coolant, wet batter-
ies, grease, cleaning agents, or other substances
exposed to lungs, eyes, or skin. Use appropriate
containers for transport, storage, and disposal of
waste substances. Follow local regulations for dis-
posal and recycling.
FUEL IS FLAMMABLE AND EXPLOSIVE
S Do not smoke or turn electrical switches ON or
OFF where fuel fumes are present or in areas
sharing ventilation with fuel tanks or equip-
ment. Keep flame, sparks, pilot lights, arc-pro-
ducing equipment and switches and all other
sources of ignition well away.
S Fuel lines must be secured, free of leaks and
separated or shielded from electrical wiring.
v
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 base-
ments and other below-grade spaces. Prevent
leaks and the accumulation of gas.
PROPANE
This product is also known as C
3
H
8
or liquified pro-
pane gas. It consists of predominantly C
3
Hydrocar-
bons (propane and prepane) with typically < 50 ppm
of ethyl mercaptan or other odorizing agent added
to assist leak detection. Contains <0.1% 1, 3 buta-
deine. Hazardous components include c3−4 rich,
petroleum distillate.
The substance has an initial boiling point of −42.1 C
flash point of −104 C (PMCC), and a vapor pres-
sure of 7.5 bar at 15 C.
Keep the container below 50C. The substance
should not be used for any other purpose without
contacting the manufacture or supplier. Installers,
operators and maintainers are likely to encounter
this substance. When doubt exists as to correct
handling procedure, contact supplier.
HAZARDOUS REACTIONS
This liquid is extremely flammable (F+). Readily
forms an explosive air−vapor mixture at ambient
temps. Avoid smoking, heat sources, such as weld-
ing and naked flames, sparks and static electricity
build−up. Thermal decomposition products are haz-
ardous, containing CO
x
compounds.
The vapor is explosive. High vapor concentrations
can cause respiratory irritation, dizziness, nausea,
and loss of consciousness. Excessive and pro-
longed exposure to the mist can cause chronic in-
flammatory reaction of the lungs and form of pulmo-
nary fibrosis.
Vapor is heavier than air and may travel to remote
sources of ignition. Liquid leaks generate large vol-
umes of flammable vapor (approx 250:1).
Avoid strong oxidizing agents, e.g. chlorates which
may be used in agriculture
Cold burns (frost bite) will result from skin/eye con-
tact with liquid. Toxicity following single exposure to
high level of propane is of low order.
PROTECTIVE MEASURES
Ensure good ventilation and avoid heat sources.
Observance of good housekeeping rules will ensure
general safety. Do not smoke.
When working on, or testing, injection equipment,
special care is required. Use eye protection at all
times.
Adopt a high standard of personal hygiene. In the
case of skin contact, flush with water to normalize
temperature. Use gloves and overalls, and eye
protection goggles. Use oil impervious gloves and
avoid contamination inside the gloves. If overalls
become contaminated, discontinue use and clean
thoroughly. Contaminated clothing should be re-
moved, soaked with water, and laundered before re-
use.
No special respiratory precautions are necessary in
normal use.
STORAGE/TRANSPORT
Store and transport only in correctly marked con-
tainers. Keep containers closed when not in use.
Keep cool, out of sunlight and away from naked
flames. Electrical continuity is required between the
transport and storage vessels during product trans-
fer.
In case of leak clear people away from area to a safe
place. DO NOT operate electrical equipment unless
flame proof. Summon emergency services and treat
or refer casualties as necessary.
Extinguish all naked lights − AVOID MAKING
SPARKS! Try to stop flow of product. Cover drains
and dispense vapor with water spray. Note: Vapor
may collect in confined spaces.
EMERGENCY ACTION
S Fire
Extinguishing media:
Large fire − None. Product flow must be
stopped and container cooled by water spray.
Water fog should be used to assist approach to
source of the fire.
Small fire − foam/dry powder, CO
2
Avoid making sparks. Fire fighters to sue self−
contained breathing apparatus. Keep fire ex-
posed containers cool, using water fog/spray.
Prevent run−off from entering waterway, drains
and drinking water supplies. Every precaution
must be taken to keep containers cool to avoid
vi
the possibility of a boiling liquid expanding va-
por explosion (BLEVE).
S Ingestion: Not applicable
S Inhalation (of vapor)
Remove from further exposure. Obtain medical
assistance immediately.
S Eyes
Cold burns should be flushed with water to
normalize temperature. Cover burns with ster-
ile dressings. Do not use ointments or powders.
Obtain medical assistance as necessary.
S Skin
Cold burns should be flushed with water to
normalize temperature. Cover burns with ster-
ile dressings. Do not use ointments or powders.
Obtain medical assistance as necessary.
S Spillage: See Storage/Transport (Section 5, 7,
3)
PETROL (UK) / GASOLINE
This product is also known as Petrol (UK) or Gaso-
line. It can be clear liquid with slight tan or yellow col-
or with a characteristic mild odor. It is a complex
combination of hydrocarbons consisting primarily of
paraffins, napthlenes, aromic and olefinic hydrocar-
bons having carbon numbers predominantly be-
tween C4 and C12.
The substance has an initial boiling point of
25−220C, a flash point greater than <−40C, and a
vapor pressure between 0.5 − 1 bars and has negli-
gible solubility in water.
It is used as a fuel for off−road Petrol powered ve-
hicles and stationary engines, and can be found in
fuel tanks, pipes and injection systems. The sub-
stance should not be used for any other purpose
without contacting the manufacture or supplier. In-
stallers, operators and maintainers are likely to en-
counter this substance.
HAZARDOUS REACTIONS
This liquid is extremely flammable. Avoid smoking,
heat sources, such as welding and naked flames,
sparks and static electricity build−up. Thermal de-
composition products are hazardous, containing
CO
x
, NO
x
and SO
x
compounds.
The vapor is explosive. High vapor concentrations
can result in central nervous system and respiratory
depression with subsequent loss of consciousness.
Where ventilation is poor or temperatures high, va-
por production may be a hazard. Excessive and pro-
longed exposure to the mist can cause chronic in-
flammatory reaction of the lungs and form of pulmo-
nary fibrosis.
Avoid strong oxidizing agents, e.g. chlorates which
may be use in agriculture.
Petrol is slightly irritating to the skin and has a defat-
ting action. Toxicity following single exposure to
high level of Petrol is of low order. Prolonged, re-
peated skin contact may de−fat the skin resulting in
possible skin irritation and dermatitis. In some
cases warty, cancerous growths have occurred.
This product contains benzene (<1%) which is clas-
sified as a carcinogen. Exposure to Benzene may
result in blood disorders such as anaemia and leu-
kemia. Toxic to aquatic organisms, may cause
long−term adverse effects in aquatic environment.
PROTECTIVE MEASURES
Ensure good ventilation and avoid heat sources.
Observance of good housekeeping rules will ensure
general safety. Do not smoke. Avoid breathing mist.
When working on, or testing, injection equipment,
special care is required to avoid perforation of skin
by high pressure fuel. Use eye protection in the
event of suspected high pressure leak.
Adopt a high standard of personal hygiene. In the
case of skin contact, wash well with soap and water.
Use glove and overalls, and eye protection goggles
if there is a risk of splashing. Use oil impervious
gloves and avoid contamination inside the gloves. If
overalls become contaminated, discontinue use
and clean thoroughly. Contaminated clothing
should be removed, soaked with water, and laun-
dered before use.
No special respiratory precautions are necessary in
normal use.
DO NOT use as a solvent for removing dirt/grease
etc, from skin.
STORAGE/TRANSPORT
Store and transport only in correctly marked con-
tainers. Keep containers closed when not in use.
Keep cool, out of sunlight and away from naked
flames. Electrical continuity is required between the
transport and storage vessels during product trans-
fer.
vii
Contain leak/spill with sand, earth or other suitable
material, and prevent entry of substance into drain-
age/sewerage system, water−courses and land.
Dispose of unwanted or absorbed substance
through an authorized contractor to a licensed site.
Inform local and fire authorities should the product
reach waterways, drains etc.
EMERGENCY ACTION
S Fire
Extinguishing media:
Large fire − Foam/water fog. Never use water
jet.
Small fire − foam/dry powder, AAAF,CO
2,
sand,
earth.
Avoid making sparks. Fire fighters to sue self−
contained breathing apparatus. Keep fire ex-
posed containers cool, using water fog/spray.
Prevent run−off from entering waterway, drains
and drinking water supplies.
S Ingestion
Do not induce vomiting. Wash the mouth out
with water, and send to hospital immediately.
S Inhalation (of vapor)
Remove from further exposure. Obtain medical
assistance immediately.
S Aspiration (inhalation of liquid)
If, following ingestion of gas oil, vomiting oc-
curs, there is danger of aspiration into the
lungs. This would cause intense local irritation
and chemical pneumonitis that can be fatal.
Obtain immediate medical assistance.
S Eyes
Irrigate copiously with water or preferably eye−
wash solution for at least five minutes. If irrita-
tion persists seek medical advice.
S Skin
Wash thoroughly with soap and water. Change
clothing if necessary.
If high pressure injection has occurred prompt
surgical attention is required.
S Spillage
Absorb using sand, earth or other suitable ma-
terial. Dispose of unwanted or absorbed flam-
mable material as directed under Storage/
Transport (Section 5.7.3). In the event of a ma-
jor spillage, only trained personnel wearing self
contained breathing apparatus should handle
the spill. Any spillage or leak should be treated
as a major fire/explosion hazard. If vehicles
present, switch off engines.
LUBRICATION OIL − PREMIUM BLUE E
15W40
Also known as oil, lube oil, sump oil, new oil is dark,
viscous liquid with a slight, characteristic odor. The
base oil contains: distillates (petroleum), solvent−
dewaxed heavy paraffinic. It is not classified as dan-
gerous according to Directive 1999/45/EC and its
amendments, and is not classified according to the
EU regulations.
It has a boiling point greater than 150C, a flash
point Open Cup of 220C (Cleveland), and is insolu-
ble in cold water.
It is used in engine lubricant oil systems, sump pan
and filters, make−up tanks and piping systems as a
lubrication oil for use in wide range of diesel engines
operating under severe conditions. Installers, oper-
ators and maintainers are likely to encounter this
product.
HAZARDOUS REACTIONS
This product is stable although slightly re−active
with oxidizing agents. Results of decomposition are
carbon oxides (CO, CO
2
) and water.
Although harmful if swallowed or aspirated
(breathed in), repeated or prolonged exposure is
not know to aggravate medical conditions.
Used oil may contain harmful combustion by−prod-
ucts and unburnt fuel that will cause skin reactions
as detailed for fuel. Particular care must be taken if
oil form a severely overheated engine is handled −
use impervious gloves, lab coat and safety glasses.
Do not breath vapor/spray.
PROTECTIVE MEASURES
Ensure good ventilation and avoid heat sources.
Adopt a high standard of personal hygiene. In case
of skin contact, wash thoroughly with soap and wa-
ter.
Use safety glasses, impervious gloves and lab coat.
Avoid contamination inside the gloves. If overalls
become contaminated, discontinue use and clean
thoroughly.
viii
No special respiratory precautions are necessary in
normal use. Do not breath vapor/spray when han-
dling hot materials.
STORAGE/TRANSPORT
Store and transport only in correctly marked con-
tainers. Keep containers tightly sealed when not in
use. Keep in cool, well ventilated area, out of sun-
light and away from naked flames. Store well away
from food − stuffs and drinking water.
Wear splash goggles, full suit, boots and gloves.
Absorb leak/spill with inert material and dispose of
unwanted or absorbed substance through an au-
thorized contractor to a licensed site. Finish clean-
ing by spreading water on the contaminate surface
and allow to evacuate through the sanitary system.
Generator Set Warning Labels
Warning signs are provided on the generator set at or near the point of risk. To avoid injury,
always take the necessary precautions – as indicated on the sample signs shown below:
Caution / Warning.
Indicates a risk of personal injury.
Caution / Warning of Temperature Hazard.
Indicates a risk of personal injury from high temperature.
Caution / Warning of High Voltage Hazard.
Indicates a risk of personal injury from electric shock/electrocution.
Caution / Warning.
Indicates a risk of personal injury from equipment that may be subject to
automatic starting or remote starting.
Caution / Warning.
Indicates to read Operator manual for additional information.
Caution / Warning of Belt and Rotating Part Hazard.
Indicates a risk of personal injury from entanglement in moving parts.
Caution / Warning of Pressure Hazard.
Indicates a risk of personal injury from pressurized fluids.
1-1
1. Introduction
ABOUT THIS MANUAL
WARNING
This genset is not a life support sys-
tem. It can stop without warning. Children, per-
sons with physical or mental limitations, and
pets could suffer personal injury or death. A per-
sonal attendant, redundant power or an alarm
system must be used if genset operation is criti-
cal.
WARNING
This generator set is not “ignition
protected” and shall not be used in a flammable
vapor environment.
WARNING
Improper installation can result in
serious injury, death or equipment damage. The
installer must be qualified to perform the instal-
lation of electrical and mechanical equipment.
This manual covers operation and maintenance of
the KY Series of generator sets (gensets). Each op-
erator should study this manual carefully and ob-
serve all of its instructions and safety precautions.
Keep this manual and the Installation Manual with
the other vehicle manuals.
Operation, Periodic Maintenance and Trouble-
shooting provide the instructions necessary for op-
erating the genset and maintaining top perfor-
mance. The owner is responsible for maintenance
in accordance with the PERIODIC MAINTENANCE
SCHEDULE (Page 3-1). This manual also includes
genset specifications, information on how to obtain
service, and information for California users.
WARNING
This genset is not a life support sys-
tem. It can stop without warning. Children, per-
sons with physical or mental limitations, and
pets could suffer severe personal injury or
death. A personal attendant, redundant power
or an alarm system must be used if genset op-
eration is critical.
WARNING
Improper service or replacement of
parts 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.
WARNING
This generator set is not “ignition
protected” and shall not be used in a flammable
vapor environment.
MODEL IDENTIFICATION
Model and Serial Numbers: Refer to Figure 1-1 for
the location of the genset nameplate. Record the
model and serial numbers in the designated boxes
in Figure 1-1 so that they are handy when calling for
parts, service or product information. Each charac-
ter, including the last letter in the model number, is
important for obtaining the right parts.
Genuine Onan replacement parts are recom-
mended for best performance and safety.
Federal Emissions Compliance Period: The
Federal Emissions Compliance Period referred to
on the nameplate indicates the number of operating
hours for which the engine has been shown to meet
Federal emissions requirements. Category
C = 250 hrs, B = 500 hrs, A = 1000 hrs.
1-2
RECORD NUMBERS HERE
MODEL NUMBER:
SERIAL NUMBER:
The engine family designation, engine displacement, statement of
compliance with the applicable EPA and / or California emissions
regulations, including the compliance period or category, appear in
this block on the actual nameplate on the genset.
FIGURE 1-1. TYPICAL NAMEPLATE
1-3
NOISE
Generator sets emit noise. As noise level and timing
of exposure increase, risk of hearing damage in-
creses. The Specifications page in the Operator
manual states noise level for this generator set. Se-
lect and use personal hearing protection appropri-
ate for your exposure to generator set noise.
Note for use in countries where compliance to the
EU Noise directive is required: This generator set
has not been evaluate and is not marked for use in
open air. Install the generator set in accordance with
the Installation manual. Obey local noise restric-
tions when you operate the generator set.
ELECTROMAGNETIC COMPATIBILITY
Generator sets emit and receive electromagntic (ra-
dio frequency) energy. If the generator set affects
operation of nearby devices, or nearby devices af-
fect generator set operation, increase the distance
between them.
Note for use in countries where compliance to the
EMC directive is required: This generator set has
been evaluated for use in residential, commercial,
and light industrial environments.
TYPICAL GENSET
Figure 1-2 illustrates a typical genset and the fea-
tures requiring attention during operation and peri-
odic maintenance.
Removing the access cover: Turn the two cover
latches counterclockwise to OPEN and pull the top
of the cover outwards.
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.
WARNING
Operating the genset with the ac-
cess cover off can lead to severe burns and en-
gine damage due to overheating. Always secure
the cover after starting the genset.
1-4
MUFFLER WITH
CLEANOUT PLUGS
(accessible from below)
AIR CLEANER
COVER
ALTITUDE
ADJUST KNOB
OIL FILL CAP
& DIPSTICK
SPARK PLUG
(not shown)
CONTROL
PANEL
(See Figure 1-3)
OIL DRAIN PLUG
(accessible from below)
MAINTENANCE
ACCESS COVER
AC
OUTPUT
LEADS
POS (+) BATTERY
CONNECTION
(inside)
NEG (−) BATTERY
& GROUND
CONNECTION
REMOTE
CONTROL
CONNECTION
(inside)
FUEL INLET
& FILTER
FIGURE 1-2. TYPICAL GENSET
FUEL RECOMMENDATIONS
WARNING
Gasoline and LPG are highly flam-
mable and explosive and can cause severe per-
sonal injury or death. Do not smoke or turn elec-
trical switches ON or OFF where fuel fumes,
tanks or equipment are present or in areas shar-
ing ventilation. Keep flames, sparks, pilot lights,
arc-producing equipment, switches and all oth-
er sources of ignition well away. Keep a type
ABC fire extinguisher in the vehicle.
Gasoline Models
Use clean, fresh unleaded gasoline having a mini-
mum octane rating (Anti-Knock Index) of 87.
Leaded gasoline may be used but will result in the
extra maintenance required for removing combus-
tion chamber and spark plug deposits. Do not use
gasoline or gasoline additives (de-icers) containing
methanol because methanol can be corrosive to
fuel system components.
1-5
CAUTION
Do not use gasoline or gasoline ad-
ditives containing methanol because methanol
can be corrosive to fuel system components.
CAUTION
Avoid using highly leaded gaso-
lines and lead additives because of the extra en-
gine maintenance that will be required.
LPG Models
Use clean, fresh HD-5 grade liquified petroleum gas
(LPG) or equivalent product consisting of at least
90 percent propane. Commercial liquified petro-
leum gas fuels may contain more than 2.5 percent
butane, which can result in poor fuel vaporization
and poor engine starting in ambient temperatures
below 32 F (0 C).
Satisfactory performance requires that the LPG va-
por be supplied at a pressure within the range indi-
cated in Specifications (Page 5-1).
WARNING
High LPG supply pressure can
cause gas leaks which can lead to fire and se-
vere personal injury or death. LPG supply pres-
sure must be adjusted to Specifications by qual-
ified personnel.
ENGINE OIL RECOMMENDATIONS
Use API (American Petroleum Institute) perfor-
mance Class SJ engine oil or better. Also look for
the SAE (Society of Automotive Engineers) viscos-
ity grade. Referring to Table 1-1, choose the viscos-
ity grade appropriate for the ambient temperatures
expected until the next scheduled oil change.
Single-grade SAE 30 oil is preferable when temper-
atures are consistently above freezing. Multigrade
oils are better when wide temperature variations are
expected.
TABLE 1-1. OIL VISCOSITY VS. TEMPERATURE
EXPECTED AMBIENT
TEMPERATURES
SAE VISCOSITY
GRADE
32 F (0 C) and higher 30
10 F to 100 F (−12 C to 38 C) 15W-40
0 F to 80 F (−18 C to 27 C)
10W-30
10W-40
−20 F to 50 F (−28 C to 10 C) 5W-30
STARTING BATTERIES
See Specifications (Page 5-1) regarding minimum
battery ratings for reliable genset cranking, espe-
cially in cold weather. Also see PERIODIC MAINTE-
NANCE SCHEDULE (Page 3-1) and the battery
manufacturer’s instructions regarding battery main-
tenance. Reliable genset starting and starter ser-
vice life depend upon adequate battery capacity
and proper maintenance.
1-6
GENSET CONTROL PANEL
The genset control panel (Figure 1-3) is located be-
hind 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). See Troubleshooting
(Page 4-1) about displaying fault codes.
Status Indicator Light − This light is an LED (light
emitting diode) in the control switch that blinks rap-
idly during cranking and stays on continuously when
the genset is running. If the genset shuts down ab-
normally, the light will blink a numerical code to indi-
cate the cause of the shutdown. See Troubleshoot-
ing (Page 4-1).
Line Circuit Breaker − The line circuit breaker pro-
tects the AC power leads connected to the genset
from overloads and equipment short circuits.
REMOTE CONTROL PANEL
The vehicle probably has a control panel inside the
vehicle for remote control of the genset. Onan offers
three remote control kits:
S Remote switch with status indicator light only
(Figure 1-4).
S Remote switch with status indicator light and
hour meter (Figure 1-5).
S Remote switch with status indicator light and
DC voltmeter (Figure 1-6).
The hour meter records genset operating time in
hours. It cannot be reset. See the PERIODIC MAIN-
TENANCE SCHEDULE (Page 3-1).
The DC voltmeter indicates whether voltage across
the 12 VDC control system and battery is normal. If
the indicator consistently stays above or below the
normal zone, see MAINTAINING THE BATTERY
AND BATTERY CONNECTIONS (Page 3-5).
LINE CIRCUIT
BREAKER
CONTROL SWITCH &
STATUS INDICATOR LIGHT
FIGURE 1-3. GENSET CONTROL PANEL
FIGURE 1-4. REMOTE SWITCH
FIGURE 1-5. REMOTE SWITCH / HOUR METER
FIGURE 1-6. REMOTE SWITCH / DC VOLTMETER
1-7
BUILD STANDARDS
The generator set and its control system have been designed, constructed and tested generally in accordance
with the following Standards where applicable refer to Table 1.
TABLE 1. BUILD STANDARDS
BS EN 1037:1995+A1:2008 Safety of machinery − Prevent of unexpected start up.
BS EN ISO 14121−1:2007 Safety of machinery. Risk assessment. Principles
BS EN ISO 13857:2008
Safety of machinery. Safety distance to prevent hazard zones be-
ing reached by upper and lower limbs.
BS EN 349:1993+a1:2008
Safety of machinery − Minimum gaps to avoid crushing parts on
the human body.
BS EN 547−1: 1996+A1:2008
Safety of machinery − Human body dimensions − Part 1: Prin-
ciples of determining the dimensions required for openings for
whole body access into machinery.
BS EN 547−2:1996+A1:2008
Safety of machinery − Human body dimensions − Part 2: Prin-
ciples for determining the dimensions required for access open-
ings.
BS EN 547−3:1996+A1:2008
Safety of machinery − Human body dimensions − Part 3: Anthro-
pomorphic data.
BS EN 60204−1:2006+A1:2009
Safety of machinery. Electrical equipment of machines. General
requirements
BS EN 614−1:2006+A1:2009
Safety of machinery. Ergonomic design principles. Terminology
and general principles
BS EN 953:1997+A1:2009
Safety of machinery − Guards − General requirements for the de-
sign and construction of fixed and movable guards.
BS EN ISO 12100−1:2003+A1:2009
Safety of machinery. Basic concepts, general principles for de-
sign. Basic terminology, methodology
BS EN ISO 12100−2:2003+A1:2009
Safety of machinery. Basic concepts, general principles for de-
sign. Technical principles
BS EN ISO 13732−1:2008
Ergonomics of the thermal environment. Methods for the assess-
ment of human responses to contact with surfaces. Hot surfaces
BS EN ISO 13849−1:2008 Safety of machinery − Safety related parts of control systems
BS EN ISO 13850:2006 Safety of machinery − Emergency stop. Principles for design.
BS EN 61310−1:2008
Safety of machinery − Indication, marking and actuation − Part 1:
Requirements for visual, auditory and tactile signals.
BS EN 61310−2:2008
Safety of machinery − Indication, marking and actuation − Part 2:
Requirements for marking.
BS EN 61000−6−1:2007
Electromagnetic compatibility (EMC). Generic standards. Immu-
nity standard for residential, commercial and light−industrial envi-
ronments
1-8
BS EN 61000−6−3:2007
Electromagnetic compatibility (EMC). Generic standards. Emis-
sion standard for residential, commercial and light−industrial en-
vironments
BS EN 1299:1997+A1:2008
Mechanical vibration and shock − Vibration isolation of machines
− Information for the application of source isolation
BS EN 12601:2001
Reciprocating internal combustion engine driven generating sets
− Safety
2-1
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 Throbbing in Temples Nausea
Muscular Twitching Headache Vomiting
Weakness and Sleepiness Inability to Think Clearly
IF YOU OR ANYONE ELSE EXPERIENCES ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH
AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the genset and do not op-
erate it until it has been inspected and repaired.
Never occupy the vehicle with the genset running unless the vehicle is equipped with a working car-
bon monoxide detector. Primary protection against inhaling carbon monoxide, however, is proper
installation of the exhaust system, daily (every eight hour) inspection for visible and audible exhaust
system leaks.
CONDUCTING THE PRE-START CHECKS
Before the first start of the day and after every eight
hours of operation, inspect the genset as instructed
under CONDUCTING GENERAL INSPECTIONS
(Page 3-2). Keep a log of maintenance and the
hours run and perform any maintenance that may
be due. See RETURNING THE GENSET TO SER-
VICE (Page 2-6) if the vehicle has been in storage.
Before each start:
1. Make sure all vehicle CO detectors are work-
ing.
2. Check for signs of fuel and exhaust leaks and
for damage to the exhaust system.
3. Turn off the air conditioner and other large ap-
pliances.
PRIMING THE FUEL SYSTEM
If the genset ran out of fuel (gasoline models only)
prime the fuel system by holding the control switch
at STOP/PRIME for 30 seconds. (The status indica-
tor light will stay on while the pump is on.)
STARTING THE GENSET
Start the genset from the genset control panel or re-
mote control panel inside the vehicle (Page 1-6).
1. Visually inspect for fuel and exhaust leaks. Do
not start the genset if there is a fuel or exhaust
leak and have it repaired.
2. Push and hold the switch at START until the
genset starts. The status indicator light on the
switch flashes while cranking. It will stay on
continuously when the genset is running.
3. The genset will shut down in 15 to 20 seconds
if it does not start and the status indicator light
will blink Fault Code No. 4. See Troubleshoot-
ing (Page 4-1). Wait 5 seconds for the control
to reset before trying again. After five tries let
the starter motor cool down for 30 seconds be-
fore trying again.
CAUTION
The starter motor can be dam-
aged by overheating if not allowed to cool
down for at least 30 seconds after every fifth
crank.
4. See Troubleshooting (Page 4-1) if the engine
shuts down and the status indicator light blinks.
5. For top performance and engine life, especially
in colder weather, let the engine warm up for
two minutes before connecting appliances.
6. Always secure the access cover after starting
the genset at the genset control panel.
2-2
WARNING
Operating the genset with the
access cover off can lead to severe burns
and engine damage due to overheating. Al-
ways secure the cover after starting the
genset.
STOPPING THE GENSET
Turn off the air conditioner and other large ap-
pliances and let the genset run for two minutes to
cool down. This reduces backfiring and run-on.
Then press the switch to STOP to stop the genset.
RESTARTING THE GENSET
See Troubleshooting (Page 4-1) if the genset shuts
down abnormally.
LOADING THE GENSET
The genset can power AC motors, air conditioners,
AC/DC converters and other appliances. How much
appliance load* can be powered depends upon the
genset power rating. The genset will shut down or its
circuit breakers will trip if the sum of the loads ex-
ceeds genset power.
To avoid overloading the genset and causing shut-
downs, compare the sum of the loads of the ap-
pliances that are likely to be used at the same time to
the power rating of the genset. Use Table 2-1 or the
ratings on the appliances themselves (if so marked)
to obtain the individual appliance loads. It may be
necessary to run fewer appliances at the same
time—the sum of the loads must not be greater
than genset rating.
Note that the genset may shut down due to over-
load—even though the sum of the loads is less than
genset rating—when a large motor or air conditioner
is started last or cycles off and then on again. The
reason for this is that a motor’s startup load is much
larger than its running load. It may be necessary to
run fewer appliances when large motors and air
conditioners are cycling on and off.
TABLE 2-1. TYPICAL APPLIANCE LOADS
Appliance
Load (watts)
Air Conditioner 1400-2000
Battery Charger Up to 800
DC Converter 300-500
Refrigerator 600-1000
Microwave Oven 1000-1500
Electric Frying Pan or Wok 1000-1500
Electric Stove Element 350-1000
Electric Water Heater 1000-1500
Electric Iron 500-1200
Electric Hair Dryer 800-1500
Coffee Percolator 550-750
Television 200-600
Radio 50-200
Electric Drill 250-750
Electric Broom 200-500
Electric Blanket 50-200
Note also that air density decreases as altitude in-
creases, causing genset engine power to de-
crease.** Power decreases approximately 3.5 per-
cent of rated power each 1000 feet (305 m) of in-
crease in elevation. See Table 2-2 for typical cal-
culations. It may be necessary to run fewer ap-
pliances at higher altitudes.
TABLE 2-2. POWER VS. ALTITUDE
Elevation above Mean
Sea Level
Maximum Genset
Power*
up to 500 ft (152 m) 4000 watts (rated)
2500 ft (762 m) 3720 watts
5500 ft (1676 m) 3300 watts
above 5500 ft
(1676 m)
3300 watts minus 140 watts
each 1000 ft (305 m)
* This table does not take into account the effect cir-
cuit breakers may have in limiting maximum power.
* Appliance load and genset power are measured in terms of watts (W) or kilowatts (kW), where 1 kilowatt (kW) = 1000 watts (W).
** Power decreases even though the altitude adjust knob is set correctly (Page 2-4).
/