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Original Instructions 4-2013 981−0174 (Issue 15)
Table of Contents
SECTION PAGE
i
SECTION PAGE
ii
SAFETY PRECAUTIONS
Thoroughly read the OPERATOR’S MANUAL S To prevent accidental or remote starting while
before operating the genset. Safe operation and working on the genset, disconnect the nega-
top performance can only be obtained when tive (−) battery cable at the battery.
equipment is operated and maintained proper- S Let the engine cool down before removing the
ly. coolant pressure cap or opening the coolant
drain. Hot coolant under pressure can spray
Only trained and experienced service person- out and cause severe burns.
nel with knowledge of fuels, electricity, and ma-
chinery hazards shall remove, dismantle and S Keep the genset and its compartment clean.
dispose of the generator set. See service manu- Excess oil and oily rags can catch fire. Dirt and
al. gear stowed in the compartment can restrict
cooling air.
Some generator set installation procedures S Make sure all fasteners are secure and
present hazards that can result in severe per- torqued properly.
sonal injury or death. Only trained and experi-
enced personnel with knowledge of fuels, elec- S Do not work on the genset when mentally or
tricity, and machinery hazards should perform physically fatigued or after consuming alcohol
generator set installation procedures. or drugs.
S Used engine oil has been identified by some
The following symbols in this manual alert you to U. S. state and federal agencies as causing
potential hazards to the operator, service person cancer or reproductive toxicity. Do not ingest,
and equipment. inhale, or contact used oil or its vapors.
S Ethylene glycol, used as engine antifreeze, is
DANGER Used to alert you to a lethal hazard toxic to humans and animals. Clean up spills
which you must take steps to prevent severe and dispose of used engine coolant in accor-
personal injury or death, as when you are in the dance with local environmental regulations.
vicinity of High Voltage equipment.
S Keep multi-purpose fire extinguishers handy.
WARNING Used to alert you to a hazard or un- Multi−purpose fire extinguishers are used for
safe practice that can result in severe personal fires that involve ordinary combustible and
injury or death. flammable liquid fuels and gaseous fuels; live
electrical equipment. (North America or US:
CAUTION Used to alert you to a hazard or un-
ref. NFPA No. 10)
safe practice that can result in personal injury S Genset installation and operation must comply
or equipment damage. with all applicable local, state and federal
codes and regulations.
Electricity, fuel, exhaust, moving parts and batter- S Generator sets with a sound shield shall not be
ies present hazards which can result in severe per- run with service doors removed/missing.
sonal injury or death.
S Engine components can be hot and cause se-
GENERAL PRECAUTIONS vere burns. Hot coolant under pressure can
spray and cause severe burns.
S Keep children away from the genset.
S Use personal protective equipment when
S Do not use evaporative starting fluids. They maintaining or installing the generator set such
are highly explosive. as gloves, safety glasses, etc.
iii
GENERATOR VOLTAGE IS DEADLY producing equipment and all other sources of
ignition well away.
S Disable the automatic genset starting feature
of an inverter-charger or other automatic start- S Fuel lines must be secured, free of leaks and
ing device before servicing the genset. separated or shielded from electrical wiring.
S Generator electrical output connections must BATTERY GAS IS EXPLOSIVE
be made by a trained and experienced electri-
S Wear splash−proof safety glasses.
cian in accordance with applicable codes.
S Do not smoke or permit flames or sparks to oc-
WARNING Interconnecting the generator set cur neat the battery at any time.
and shore power can lead to electrocution of S To reduce arcing when disconnecting or recon-
utility line workers, equipment damage and fire. necting battery cables, always disconnect the
Use an approved switching device to prevent negative (−) battery cable first and reconnect
interconnections. it last.
S Use caution when working on live electrical
equipment. Remove jewelry, make sure cloth- MOVING PARTS CAN CAUSE SEVERE
ing and shoes are dry, stand on a dry wooden PERSONAL INJURY OR DEATH
platform or rubber insulating mat and use tools S Disable the automatic genset starting feature
with insulated handles. of an inverter-charger or other automatic start-
ing device before servicing the genset.
ENGINE EXHAUST IS DEADLY
S Do not wear loose clothing or jewelry near
S Inspect for exhaust leaks at every startup and moving parts such as PTO shafts, fans, belts
after every eight hours of running. and pulleys.
S Prior to every startup and after every eight S Keep hands away from moving parts.
hours of running, all carbon monoxide detec- S Keep guards in place over fans, belts, pulleys,
tors must be tested and confirmed to be work- and other moving parts.
ing in accordance with the manufacturer’s in-
structions or owners manual. FLAMMABLE VAPOR CAN CAUSE A
S Learn the symptoms of carbon monoxide poi- DIESEL ENGINE TO OVERSPEED
soning in the Operator’s Manual.
WARNING Do not operate a diesel-powered
S Never occupy the vehicle while the genset is genset where a flammable vapor environment
running unless the vehicle is equipped with a can be created by fuel spill, leak, etc.
working carbon monoxide detector.
Flammable vapor can cause a diesel engine to
S Do not operate the genset when the vehicle is
overspeed and become difficult to stop, resulting in
in a confined space, such as a garage.
possible fire, explosion, severe personal injury and
S Disable the automatic genset starting feature death. The owners and operators of the genset are
of an inverter-charger or other automatic start- solely responsible for operating the genset safely.
ing device before storing the vehicle or parking
it in a garage or other confined space. THE HAZARDS OF CARBON MONOXIDE
S The exhaust system must be installed in accor- WARNING Engine−driven generators can pro-
dance with the genset Installation Manual. duce harmful levels of carbon monoxide that
S Engine cooling air must not be used for heating can injure or kill you.
working or living spaces or compartments.
ONLY YOU CAN PROTECT YOURSELF
DIESEL FUEL IS COMBUSTIBLE FROM CO POISONING!
S Do not smoke or turn electrical switches ON or S Watch constantly for people near the exhaust
OFF where fuel fumes are present or in areas of the generator set while it is running.
sharing ventilation with fuel tanks or equip- S Make sure exhaust cannot enter the living
ment. Keep flames, sparks, pilot lights, arc- quarters through a window, vent or door.
Mobile-8
iv
S Make sure all CO detectors and audible alarms Avoid strong oxidizing agents − incompatible with
are working properly. sulfuric acid, nitric acid, caustics and aliphatic
amines.
S Pay attention to the signs of CO poisoning.
S Check the exhaust system for corrosion, ob- It may cause neurological signs and symptoms,
struction and leaks each time you start the and kidney damage. It is also a skin and eye irritant.
generator set and every eight hours if you run Very toxic in particulate form upon inhalation.
it continuously. Harmful if swallowed, lethal dose for humans re-
ported to be 100ml.
SUBSTANCE HAZARDOUS TO HEALTH
PROTECTIVE MEASURES
Generator sets use substances, and emit and
create wastes that can cause health risks. Genera- Refrain from eating, drinking or smoking when us-
tor set operators must use appropriate personal ing the product. Adopt a high standard of personal
protective equipment (such as clothing, gloves, hygiene. In case of skin contact, wash immediately
protective glasses/goggles, and respiration equip- with soap and water.
ment) when exposed to fuel, oil, coolant, wet batter- Ensure good ventilation and avoid heat sources.
ies, grease, cleaning agents, or other substances Avoid breathing mist, if there is a risk of vapour, or
exposed to lungs, eyes, or skin. use appropriate particulate, use a suitable organic vapour mask.
containers for transport, storage, and disposal of
waste substances. Follow local regulations for dis- Eye protection, gloves, overalls, impervious apron
posal and recycling. should be used. Avoid contamination inside the
gloves. If overalls become contaminated, discon-
tinue use and clean thoroughly.
EMERGENCY ACTION
HAZARDOUS REACTIONS
S Fire
Ethylene glycol is combustible when exposed to Extinguishing media: CO2, alcohol resistant
heat or flame and can react vigorously with oxi- foam, dry powder, or water spray.
dants. Moderate explosive hazard in form of vapour Fire fighters to use self contained breathing
when exposed to heat or flame. Hazardous prod- apparatus. Keep fire exposed containers cool.
ucts resulting from combustion or decomposition Prevent run−off from entering waterways,
include carbon monoxide, carbon dioxide and acrid drains and drinking water supplies.
smoke. Self−contained breathing apparatus must S Ingestion
be worn in the event of fume build up. Toxic by ingestion. If swallowed induce vomit-
v
ing only under the advice of a Doctor or poison The vapour is explosive. High vapour concentra-
control centre. Delayed treatment may result in tions can cause respiratory irritation, dizziness,
fatality. nausea, and loss of consciousness. Excessive and
prolonged exposure to the mist can cause chronic
S Inhalation (of vapour)
inflammatory reaction of the lungs and form of pul-
Remove from further exposure. In case of ir-
monary fibrosis.
ritation to lungs or throat, seek medical advice.
S Aspiration (inhalation of liquid) Avoid strong oxidizing agents, e.g. chlorates which
Obtain immediate medical assistance. may be use in agriculture.
S Eyes Gas oil is slightly irritating to the skin and has a de−
Flush copiously with water or preferably eye− fatting action. Toxicity following single exposure to
wash solution for at least five minutes. Seek high level of gas oil is of low order. Prolonged, re-
medical advice. peated skin contact may de−fat the skin resulting in
S Skin possible skin irritation and dermatitis. In some
cases warty, cancerous growths have occurred.
Wash thoroughly with soap and water, and
seek medical attention if irritation develops. PROTECTIVE MEASURES
Change clothing if necessary and wash before
re−use. Ensure good ventilation and avoid heat sources.
S Spillage Observance of good housekeeping rules will en-
Soak−up using an absorbent material and dis- sure general safety. Do not smoke. Avoid breathing
pose of this as directed under Storage/Trans- mist.
port (Section 5.1.3)
When working on, or testing, injection equipment,
special care is required to avoid perforation of skin
GAS OIL by high pressure fuel. Use eye protection in the
event of suspected high pressure leak.
This product is also known as Red Diesel, Fuel Oil,
and type A1 or A2. It can be pale red or a clear liquid Adopt a high standard of personal hygiene. In the
with a characteristic mild odour. It contains catalyti- case of skin contact, wash well with soap and water.
cally cracked oil, petroleum distillates, quinizarin,
and gas oil maker dye red. The catalytically cracked Use glove and overalls, and eye protection goggles
oil and petroleum distillates are potentially hazard- if there is a risk of splashing. Use oil impervious
ous constituents. gloves and avoid contamination inside the gloves.
If overalls become contaminated, discontinue use
The substance has an initial boiling point of 180C, and clean thoroughly. Contaminated clothing
a flash point greater than 56C, and a vapour pres- should be removed, soaked with water, and laun-
sure less than 0.7mm Hg at 20C and has negligible dered before re−use.
solubility in water.
No special respiratory precautions are necessary in
It is used as a fuel for off−road diesel powered ve- normal use.
hicles and stationary engines, and can be found in
fuel tanks, pipes and injection systems. The sub- DO NOT use as a solvent for removing dirt/grease
stance should not be used for any other purpose etc, from skin.
without contacting the manufacturer or supplier. In-
STORAGE/TRANSPORT
stallers, operators and maintainers are likely to en-
counter this substance. Store and transport only in correctly marked con-
tainers. Keep containers closed when not in use.
HAZARDOUS REACTIONS Keep cool, out of sunlight and away from naked
flames. Electrical continuity is required between the
This liquid is flammable. Avoid smoking, heat transport and storage vessels during product trans-
sources, such as welding and naked flames, fer.
sparks and static electricity build−up. Thermal de-
composition products are hazardous, containing Contain leak/spill with sand, earth or other suitable
COX, NOX and SOX compounds. material, and prevent entry of substance into drain-
vi
age/sewerage system, water−courses and land. The base oil contains: distillates (petroleum), sol-
Dispose of unwanted or absorbed substance vent−dewaxed heavy paraffinic. It is not classified
through an authorized contractor to a licensed site. as dangerous according to Directive 1999/45/EC
and its amendments, and is not classified accord-
Inform local and fire authorities should the product ing to the EU regulations.
reach waterways, drains etc.
It has a boiling point greater than 150C, a flash
EMERGENCY ACTION point Open Cup of 220C (Cleveland), and is insol-
uble in cold water.
S Fire
Extinguishing media: It is used in engine lubricant oil systems, sump pan
Large fire − Foam/water fog. Never use water and filters, make−up tanks and piping systems as a
jet. lubrication oil for use in wide range of diesel en-
Small fire − foam/dry powder, AAAF, CO2, gines operating under severe conditions. Installers,
sand, earth. operators and maintainers are likely to encounter
Avoid making sparks. Fire fighters to use self− this product.
contained breathing apparatus. Keep fire ex-
posed containers cool, using water fog/spray. HAZARDOUS REACTIONS
Prevent run−off from entering waterway,
drains and drinking water supplies. This product is stable although slightly re−active
with oxidizing agents. Results of decomposition are
S Ingestion carbon oxides (CO, CO2) and water.
Do not induce vomiting. Wash the mouth out
with water, and send to hospital immediately. Although harmful if swallowed or aspirated
S Inhalation (of vapour) (breathed in), repeated or prolonged exposure is
Remove from further exposure. Obtain medi- not known to aggravate medical conditions.
cal assistance immediately.
Used oil may contain harmful combustion by−prod-
S Aspiration (inhalation of liquid) ucts and unburnt fuel that will cause skin reactions
If, following ingestion of gas oil, vomiting oc- as detailed for fuel. Particular care must be taken if
curs, there is danger of aspiration into the oil form a severely overheated engine is handled −
lungs. This would cause intense local irritation use impervious gloves, lab coat and safety glasses.
and chemical pneumonitis that can be fatal.
Obtain immediate medical assistance. Do not breathe vapour/spray.
S Eyes PROTECTIVE MEASURES
Irrigate copiously with water or preferably eye−
wash solution for at least five minutes. If irrita- Ensure good ventilation and avoid heat sources.
tion persists seek medical advice.
Adopt a high standard of personal hygiene. In case
S Skin of skin contact, wash thoroughly with soap and wa-
Wash thoroughly with soap and water. Change ter.
clothing if necessary.
If high pressure injection has occurred prompt Use safety glasses, impervious gloves and lab
surgical attention is required. coat. Avoid contamination inside the gloves. If
S Spillage overalls become contaminated, discontinue use
Absorb using sand, earth or other suitable ma- and clean thoroughly.
terial. Dispose of unwanted or absorbed flam- No special respiratory precautions are necessary n
mable material as directed under Storage/ normal use. Do no breathe vapour/spray when
Transport (Section 5.7.3). handling hot materials.
LUBRICATION OIL − PREMIUM BLUE E STORAGE/TRANSPORT
15W40
Store and transport only in correctly marked con-
Also known as oil, lube oil, sump oil, new oil is dark, tainers. Keep containers tightly sealed when not in
viscous liquid with a slight, characteristic odour. use. Keep in a cool, well ventilated area, out of sun-
vii
light and away from naked flames. Store well away S Ingestion
from food−stuffs and drinking water. Do not induce vomiting, Obtain medical advice
immediately.
Wear splash goggles, full suit, boots and gloves. S Inhalation (of vapour)
Absorb leak/spill with an inert material and dispose Remove from further exposure. Obtain medi-
of unwanted or absorbed substance through an au- cal attention.
thorized contractor to a licensed site. Finish clean- S Aspiration (inhalation of liquid)
ing by spreading water on the contaminated sur- Obtain immediate medical assistance.
face and allow to evacuate through the sanitary
system. S Eyes
Flush copiously with water or preferably eye−
wash solution for at least fifteen minutes. Ob-
EMERGENCY ACTION tain medical advice.
S Fire S Skin
Extinguishing media: Wash thoroughly with soap and water. Obtain
Large fire − Use water spray, fog or foam. Do medical advice if irritation develops. Change
not use water jet. clothing if necessary and wash before re−use.
Small fire − Use dry chemical powder or CO2 S Spillage
Fire−fighters to use self contained breathing Absorb with an inert material and dispose of
apparatus and full turnout gear. Keep fire ex- this as directed under Storage/Transport.
posed containers cool.
viii
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.
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.
ix
THIS PAGE IS INTENDED TO BE BLANK
x
1. Introduction
ABOUT THIS MANUAL numbers is significant. The last character of the
model number is the specification letter, which is im-
This is the Operator’s Manual for the generator sets portant for obtaining the right parts. Genuine
(gensets) listed on the front cover. Read and care- Onan replacement parts are recommended for
fully observe all of the instructions and precautions best results. Refer to the genset Parts Catalog.
in this manual. Keep this manual and the genset
Installation Manual with the other vehicle manuals.
Record these numbers in Figure 1-2 so that they are FIGURE 1-2. RECORD NUMBERS HERE
easy to find when needed. Each character in these
1-1
HOW TO OBTAIN SERVICE Information to Have Ready
When you call for service, parts, or product literature Before calling for service, have the following infor-
(such as the Service Manual or Parts Catalog) for mation available:
your genset, contact the nearest authorized distrib- 1. The complete genset model number and serial
utor. Onan has factory-trained representatives to number. See About This Manual (Page 1-1).
handle your requests for genset parts and service.
2. The date of purchase
In North America 3. The nature of the problem. See Section 4. Trou-
bleshooting.
Call 1-800-888-ONAN to contact the nearest Cum-
mins/Onan or Onan-only distributor in the United NOISE
States or Canada. (This automated service utilizes
touch-tone phones only). Select OPTION 1 Generator sets emit noise. As noise level and time
(press 1) to be automatically connected to the dis- of exposure increase, risk of hearing damage in-
tributor nearest to you. creases. The Specifications page in the Operator
manual states noise level for this generator set. Se-
If you are unable to contact a distributor using the lect and use personal hearing protection appropri-
automated service, consult the Yellow Pages. Typi- ate for your exposure to generator set noise.
cally, our distributors are listed under:
Note for use in countries where compliance to the
GENERATORS − ELECTRIC, EU Noise directive is required: This generator set
ENGINES − GASOLINE OR DIESEL, or has not been evaluated and is not marked for use in
RECREATIONAL VEHICLES − EQUIPMENT, open air. Install the generator set in accordance with
PARTS AND SERVICE. the Installation manual. Obey local noise restric-
tions when you operate the generator set.
If you have difficulty in arranging service or resolv-
ing a problem, please contact the Service Manager ELECTROMAGNETIC COMPATIBILITY
at the nearest Cummins/Onan distributor for assis-
tance. Generator sets emit and receive electromagnetic
(radio frequency) energy. If the generator set af-
Outside North America fects operation of nearby devices, or nearby de-
vices affect generator set operation, increase the
If you are outside North America, call Onan Corpo- distance between them.
ration at 1−763−574−5000 from 7:30 AM to
4:00 PM, Central Standard Time, Monday through This generator set has been evaluted for use in in-
Friday, or fax 1−763−528−7229. dustrial environments.
1-2
EMISSIONS genset is authorized, you should seek assistance
from an approved Onan dealer.
You should carefully review Operator (Owner), California genset users may use Table 1-1 as an aid
Installation manuals and other information you re- in locating information related to the California Air
ceive with your genset. If you are unsure that the Resources Board requirements for emissions con-
installation, use, maintenance or service of your trol.
1-3
TYPICAL GENSET cooling and ventilating air and the maintenance and
service access panels of a typical genset. Not
Figure 1-3 illustrates the fuel, battery, remote con- shown are the combustion air inlet and oil drain
trol and AC output connection points, the flow of openings in the base.
CONTROL BATTERY
PANEL CONNECTIONS
1-4
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 1−2.
1-5
Mechanical vibration and shock − Vibration isolation of machines
BS EN 1299:1997+A1:2008
− Information for the application of source isolation
Reciprocating internal combustion engines − Saftey − Part 1:
BS EN 1679−1:1998
Compression ignition engines
Reciprocating internal combustion engine driven generating sets
BS EN 12601:2001
− Safety
1-6
2. Operation
WARNING Diesel fuel is combustible and can B5 bio−diesel fuel that meets industry specifications
cause severe personal injury or death. Do not and quality is suitable for use with this generator set.
smoke near fuel tanks or fuel-burning equip-
ment or in areas sharing ventilation with such
Bio−Diesel Above B5 and up to B20
equipment. Keep flames, sparks, pilot flames, Bio−Diesel Blends
electrical arcs and switches and all other
The following must be verified before using bio−die-
sources of ignition well away. Keep a multi-
sel blends up to B20:
class fire extinguisher handy.
S HDKCC/D generator set is at Spec D or higher.
High quality diesel fuel is necessary for good perfor- S HDKCG generator set is at Spec E or higher.
manace and long engine life.
S The vehicle propulsion engine is capable of us-
S The specifications for the type and sulfur con- ing B20 when sharing the same fuel tank.
tent (ppm, % weight) of the diesel fuel used
S The OEM has installed B20 compatible fuel line
must comply with all emissions regulations ap-
from fuel tank to generator set.
plicable in the areas where the geneset is to be
operated. S The OEM has installed a water separator in the
fuel line just before the generator set.
S Diesel fuels meeting ASTM D975 or EN 590
specifications are recommended. Use Grade Approved Bio−Diesel Fuel:
1−D diesel fuel where ambient temperatures
are below 14 F (−10 C). A minimum Fuel Ce- S Bio−diesel meeting either ASTM D6751 or
tane Rating of 45 is recommended. Where am- EN14214. Fuel meeting either ASTM D6751 or
bient termperatures are below −4 F (−20 C), or EN14214 can be blended with an acceptable
the elevation is above 5000 ft (1500 m), a mini- diesel fuel meeting ASTM D975, meeting
mum Centane Rating of 50 is recommended. ASTM D975 up to 20 percent volume con-
centration (B20).
S Current US EPA regulations for Non−Road en-
S Blended bio−diesels fuels should be bought
gines limit diesel fuel sulfur content to a maxi-
pre−blended and not made by customers.
mum of 500 ppm (0.05% weight). Therefore,
use Grade 2−D S500 or 2−D S15 diesel fuel. Bio−Diesel Properties:
Where ambient temperatures are below 14 F
(−10C), use Grade 1−D S500 or 1−D S15 die- S Bio−diesel has poor oxidation stability which
sel fuel. Note that beginning in year 2010. US can accelerate fuel oxidation. Fuel oxidation
EPA regulations for Non−road engines will limit will reduce generator performance. This effect
diesel fuel sulfur content to a maximum of 15 is accelerated at increases ambient tempera-
ppm (0.0015% weight) tures.
S Do not use diesel fuel having a sulfur content S Bio−diesel properties change at low ambient
greater than 10,000 ppm (1.0% weight) temperatures (below 23F/−5C). Necessary
precautions must be taken when operating the
S Diesel fuel must meet the ASTM D975 stan- generator with bio−diesel blends in low ambi-
dard for lubricity and pass a minumum load lev- ent temperatures, such as a fuel heater, hose
el of 3100 grams as measured by ASTM insulation, or additional anti−gel fuel additives.
D6078, or maximum scar diameter of 0.45 mm
as measured by ASTM D6079 or ISO 12156−1. S Bio−diesel fuel blends are an excellent medium
for microbial growth. Microbes cause fuel sys-
S B5 Bio−diesel fuel that meets industry specifi- tem corrosion and premature filter plugging.
cations and quality is suitable for use with this The effectiveness of all commercially available
genset. conventional anti−microbial additives, when
2-1
used in bio−diesel, is not known. Consult your with low sulfur fuel (sulfur content less than 500
fuel and additive supplier for assistance. ppm, 0.05% weight) or ultra low sulfur fuel (sul-
fur content less than 15 ppm 0.0015% weight).
WARNING It is highly recommended that specific
market applications are avoided or excercised with S Non−Regulated Areas: CF class oil is recom-
extra care due to some of the properties of bio−die- mended when using high sulfur fuel−sulfur con-
sel fuel blends such as cold weather operation, long tent between 500 ppm (0.05% weight) and
term storage, material incompatibilities and other 5000 ppm (0.5% weight). If CF−4, CG−4, CH−4
effects on engine operating characteristics. Such or CI−4 class oil is used, the oil and oil filter
applications that should use standard fuels include must be changed twice as often as specified in
applications that will experience seasonal usage, the PERIODIC MAINTENANCE SCHEDULE
storage for periods exceeding 60 days, and extreme (Page 3−1).
temperatures or humidity. S Non−Regulated Areas: Use CF, CF−4, CG−4,
CH−4 or CI−4 class oil when using high sulfur
Storage Requirements: fuel−sulfur content between 5000 ppm (0.5%
S If using bio−diesel for seasonal applications weight) and 10,000 ppm (1.0% weight). The oil
(stored more than 90 days), the generator must and oil filter must be changed twice as often as
be purged before storage by running the en- specified in the PERIODIC MAINTENANCE
gine on pure diesel fuel meeting ASTM D975 SCHEDULE (Page 3−1)
for a mininmum of 30 minutes.
Oil viscosity
Warranty Coverage:
Look for the SAE (Society of Automotive Engineers)
Cummins Onan Warranty covers failures that are a viscosity grade. Referring to Figure 2−1, choose the
direct result of defects in material or factory work- viscosity grade appropriate for the ambient temper-
manship. Generator damage, service issues and/or atures expected until the next scheduled oil change.
performance issues determined by Cummins Onan Multi−grade oils such as SAE 15W−40 are recom-
to be caused by bio−diesel fuel blends not meeting mended for year−round use.
the specifications outlined in the applicable Installa-
tion, Operator, and Service Manuals are not consid-
ered to be defects in material or workmanship and
may affect your generator’s warranty.
2-2
RECOMMENDED COOLANT Control Switch − This switch is used to start and
stop the genset, prime the engine fuel system and
Use the best quality ethylene glycol antifreeze so- restore the fault code (blinking status light).
luation availble. It should be fully formulated with
rust inhibitors and coolant stabilizers and mixed with Status Lamp − This is a lamp in the control switch
fresh (distilled) water that is low in minerals and cor- that blinks rapidly during preheat and cranking. It
rosive chemicals. A 50/50 mixture is recommended stays on continuously while the genset is running. If
for all climates and is suitable for temperatures the genset shuts down, it will blink a numerical code
down to −34F (−37 C). to indicate the nature of the fault shutdown (see
Section 4. Troubleshooting).
See Section 5. Specifications for coolant capacity.
(Rapid blinking before cranking starts indicates that
STARTING BATTERIES the glow plugs are preheating the combustion
chambers. The genset controller automatically var-
The genset requires a 12 volt battery to power its
ies the time based on engine temperature.)
control and starting circuits. Reliable genset starting
and starter service life depend upon adequate bat- Line Circuit Breaker(s) − The line circuit breakers
tery system capacity and maintenance. protect the AC power leads connected to the gen-
See MAINTANING THE BATTERY AND BATTERY set.
CONNECTIONS (p. 3−4) and Section 5. Specifica-
tions for minimum required battery ratings. Coolant Recovery Tank Fill Cap − The recovery
tank provides for coolant expansion. Replenish the
CONTROL PANEL normal loss of coolant by filling here.
The control panel (Figure 2-2) has the following fea- Hour Meter − The hour meter records the total run-
tures: ning time of the genset. It cannot be reset.
2-3
LINE CIRCUIT COOLANT RECOVERY
BREAKER(S) TANK FILL CAP
COOLANT RECOVERY
TANK FLUID LEVEL
CONTROL SWITCH
&STATUS LAMP
HOUR METER
2-4
REMOTE CONTROL PANELS
There probably is a remote genset control panel in-
side the vehicle. Onan offers three remote control
kits as follows:
S Remote switch / status lamp (Figure 2-3).
S Remote switch / status lamp and hour meter
(Figure 2-4).
S Remote switch / status lamp and DC voltmeter FIGURE 2-3. REMOTE SWITCH
(Figure 2-5).
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 (p. 3-6).
2-5
WARNING EXHAUST GAS is deadly. All en- 4. Turn off air conditioners and other large ap-
gine exhaust contains carbon monoxide; an pliances.
odorless, colorless, poisonous gas that can
cause unconsciousness and death. Symptoms PRIMING THE FUEL SYSTEM
of carbon monoxide poisoning include:
The fuel system should be primed after replacing
Dizziness Headache
the fuel filter or running the genset out of fuel. To
Nausea Weakness and Sleepiness
prime the fuel system, hold the control switch down
Vomiting Inability to Think Coherently
in its Stop position for half a minute.
WARNING IF YOU EXPERIENCE ANY OF
THESE SYMPTOMS, GET INTO FRESH AIR IM-
MANUAL STARTING
MEDIATELY. If symptoms persist, seek medical The genset can be started and stopped from the
attention. Shut down the genset and do not op- genset control panel or from a remote panel.
erate it until it has been inspected and repaired.
1. Perform the PRE-START CHECKS, prime the
WARNING Never occpy the vehicle while the fuel system if necessary, and turn off the air
genset is running unless the vehicle has a work- conditioners and other large electrical loads.
ing carbon monoxide detector. The exhaust 2. Visually inspect for fuel, exhaust and coolant
system must be installed in accordance with the leaks. Do not start the genset if there is a fuel,
genset Installation Manual. Make sure there is exhaust or coolant leak and have it repaired.
ample fresh air when operating the genset in a
confined area. 3. Push and hold Start until the genset starts. The
status lamp will come on when the genset starts
PRE-START CHECKS and will stay on while it runs. While starting it will
blink rapidly indicating preheating and crank-
Before the first start of the day and after every eight ing. (Depending on how cold it is, preheating
hours of operation, inspect the genset as instructed can take up to 15 seconds, extending the time
under GENERAL INSPECTION (p. 3-3). Keep a log that the lamp blinks.)
of maintenance and the hours run and perform any
maintenance that may be due. See Returning the CAUTION Excessive cranking can over-
Genset to Service (p. 2-9) if the vehicle has been in heat and damage the starter motor. Do not
storage. crank for more than 30 seconds at a time.
Wait at least 2 minutes before trying again.
Before each start:
4. See Section 4. Troubleshooting if the genset
1. Make sure all vehicle carbon monoxide (CO) does not start after several tries.
detectors are working.
5. Let the genset warm up a few minutes until it is
2. Check for signs of fuel and exhaust leaks and running smoothly before connecting the ve-
damage to the exhaust system. hicle electrical loads (appliances).
3. To prevent overheating and to reduce fouling
with dust and debris, make sure the genset’s MANUAL STOPPING
normal ground clearance is not being reduced
by sloping ground, curbs, logs or other objects. Run the genset under no load for a few minutes to
Repark the vehicle if necessary and/or remove allow the engine to cool down and then push and re-
any objects blocking the air inlet or air outlet. lease Stop.
2-6
AUTOMATIC STARTING AND STOPPING and then on again, even though the sum of the loads
is less than genset rating. The reason for this is that
The vehicle may be equipped with an inverter-char- a motor’s startup load is much larger than its running
ger or other automatic genset starting device. Al- load. It may be necessary to run fewer ap-
ways follow the instructions and safety precautions pliances when large motors and air condition-
provided by the manufacturer of the automatic start- ers are cycling on and off.
ing device when enabling automatic genset starting.
Maximum power decreases as altitude increases
WARNING EXHAUST GAS is deadly. MOV- because air density decreases. For every 1000-foot
ING PARTS and ELECTRICITY can cause severe (305 m) increase in elevation you can expect power
personal injury or death. To reduce exposure to to decrease approximately 3.5 percent. Table 2-2
these hazards, always disable automatic genset shows the results of typical calculations. It may be
starting before: necessary to run fewer appliances at higher alti-
tudes.
S Occupying the vehicle, unless vehicle has a
working CARBON MONOXIDE detector TABLE 2-1. TYPICAL APPLIANCE LOADS
S Parking vehicle in garage or confined space Appliance Load (watts)
S Parking vehicle for storage Air Conditioner 1400-2000
Battery Charger Up to 3600
S Servicing genset
DC Converter 300-900
S Servicing batteries Refrigerator 600-1000
S Servicing electrical appliances Microwave Oven 1000-1500
S Fueling vehicle Electric Frying Pan or Wok 1000-1500
Electric Stove Element 350-1000
LOADING THE GENSET Electric Water Heater 1000-1500
Electric Iron 500-1200
The genset can power AC motors, air conditioners,
AC/DC converters, battery chargers and other ap- Electric Hair Dryer 800-1500
pliances. How much appliance load* can be pow- Coffee Percolator 550-750
ered depends upon the genset power rating. The Television 200-600
genset will shut down or its circuit breakers will trip if Radio 50-200
the sum of the loads exceeds genset power. See Electric Drill 250-750
Section 4. Troubleshooting.
Electric Broom 200-500
To avoid overloading the genset and causing shut- Electric Blanket 50-200
downs, compare the sum of the loads of the ap-
pliances that are likely to be used at the same time to TABLE 2-2. POWER VS. ALTITUDE
the power rating of the genset. Use Table 2-1 or the
Elevation above Sea
ratings on the appliances themselves (if so marked) Level
Maximum Power
to obtain the individual appliance loads. It may be
necessary to run fewer appliances at the same at/below 500 ft (152 m) 12,000 W (rated)
time—the sum of the loads must not be greater at 2500 ft (762 m) 11,280 W
than genset rating. at 5500 ft (1676 m) 10,200 W
The genset may shut down due to overload when a above 5500 ft (1676 m)
10,200 W minus 360 W
large motor or air conditioner is started or cycles off every 1000 ft (305 m)
* Appliance load and genset power are measured in terms of watts (W) or kilowatts (kW), where 1 kilowatt (kW) = 1000 watts (W).
2-7
RESETTING CIRCUIT BREAKERS OPERATING IN COLD WEATHER
If a circuit breaker in the main power distribution
Make sure the engine oil viscosity is appropriate for
panel of the vehicle or on the genset (Figure 2-2)
the cold weather temperatures. See ENGINE OIL
trips, either a circuit shorted or too many appliances
RECOMMENDATIONS (Page 2-2). Be sure to
were running. Note that the genset will continue to
change the oil if a sudden drop in temperature oc-
run after a circuit breaker trips.
curs.
If a circuit breaker trips, disconnect or turn off as
many loads as possible and reset the circuit break- OPERATING IN HOT WEATHER
er. (Push the circuit breaker to OFF to reset it and
then to ON to reconnect the circuit.) If the circuit Pay particular attention to the following items when
breaker trips right away, either the electrical dis- operating the genset in hot weather:
tribution system has a short or the circuit breaker is
faulty. Call a qualified electrician. 1. Make sure nothing blocks airflow to and from
the genset.
If the circuit breaker does not trip, reconnect the ap-
pliances, one by one, up to a total load that does not 2. Make sure engine oil viscosity is appropriate for
overload the genset or cause the circuit breaker to the ambient temperatures. See ENGINE OIL
trip. If a circuit breaker trips right away when an ap- RECOMMENDATIONS (Page 2-2).
pliance is connected, the appliance probably has a
short. 3. Keep the genset clean.
4. Perform maintenance due. See PERIODIC
Electrical appliances and tools must be used and
MAINTENANCE SCHEDULE (Page 3-1).
maintained properly and be properly grounded to
cause the line circuit breakers to trip when short cir-
cuits occur. OPERATING AT HIGH ALTITUDE
WARNING Short circuits in electrical ap- For the effect of altitude on maximum power, see
pliances and tools can cause fire and electrical LOADING THE GENSET (Page 2-7).
shock leading to severe personal injury or
death. Read and follow the equipment and tool
manufacturer’s instructions and warnings re- OPERATING IN DUSTY ENVIRONMENTS
garding use, maintenance and proper ground-
ing. Pay particular attention to the following items when
operating the genset in dusty environments:
CONNECTING TO UTILITY POWER
1. Do not let dirt and debris accumulate inside the
A vehicle with provisions for connecting utility power genset compartment. Keep the genset clean.
must have an approved device to keep the genset
and utility from being interconnected. See the gen- 2. Perform air cleaner maintenance more often.
set Installation Manual for more information. See PERIODIC MAINTENANCE SCHEDULE
(Page 3-1).
WARNING Interconnecting the genset and the 3. Change engine oil more often. See PERIODIC
public utility (or any other power source) can MAINTENANCE SCHEDULE (Page 3-1).
lead to electrocution of utility line workers,
equipment damage and fire. Use an approved 4. Keep containers of engine oil that have been
switching device to prevent interconnections. opened tightly closed to keep out dust.
2-8
BREAKING IN A NEW ENGINE WARNING CARBON MONOXIDE is deadly
and can accumulate to dangerous levels in
Proper engine break-in on a new genset or on one garages and other confined spaces. Dis-
with a rebuilt engine is essential for top engine per- able the automatic genset starting feature
formance and acceptable oil consumption. Run the of an inverter-charger or other automatic
genset at approximately 1/2 rated power for the first starting device before storing the vehicle.
2 hours and then at 3/4 rated power for 2 more 2. Push the genset line circuit breaker OFF
hours. See LOADING THE GENSET (Page 2-7). (Page 2-8).
3. Change the engine oil and attach a tag indicat-
Proper engine oil and oil level are especially critical ing oil viscosity. See ENGINE OIL REC-
during break-in because of the higher engine tem- OMMENDATIONS (Page 2-2).
peratures that can be expected. Change the oil if not
appropriate for the ambient temperatures during 4. Disconnect the battery cables (negative [−]
break-in. See ENGINE OIL RECOMMENDATIONS cable first) from the starting battery and store
(Page 2-2). Check oil level twice a day or every the battery according to the battery manufac-
4 hours during the first 24 hours of operation and turer’s recommendations. See MAINTAINING
change the oil and oil filter after the first 50 hours of THE BATTERY AND BATTERY CONNEC-
operation. TIONS (Page 3-6).
5. Plug the exhaust tail pipe to keep out dirt, mois-
EXERCISING THE GENSET ture, bugs, etc.
6. Close the fuel supply valve (if so equipped).
Exercise the genset at least 2 hours each month if
use is infrequent. Run the genset at approximately Returning the Genset to Service
1/2 rated power. See LOADING THE GENSET 1. Check the oil tag on the genset and change the
(Page 2-7). A single two hour exercise period is oil if the viscosity indicated is not appropriate for
better than several shorter periods. the temperatures expected. See ENGINE OIL
RECOMMENDATIONS (Page 2-2).
Exercising a genset drives off moisture, re-lubri- 2. Reconnect the starting battery (negative [−]
cates the engine, replaces stale fuel and removes cable last). See MAINTAINING THE BATTERY
oxides from electrical contacts. The result is better AND BATTERY CONNECTIONS (Page 3-6).
starting, more reliable operation and longer engine
life. 3. Remove the plug from the exhaust tailpipe.
4. Change the air filter element if it is dirty
STORING THE GENSET (Page 3-6).
5. Open the fuel supply valve (if so equipped).
Proper storage is essential for preserving top gen- 6. Inspect the genset. See GENERAL INSPEC-
set performance and reliability when the genset TION (Page 3-3).
cannot be exercised regularly and will be idle for
more than 120 days. 7. Push the genset line circuit breaker ON
(Page 2-8) when the genset is ready to power
appliances.
Storing the Genset
8. Enable the automatic genset starting feature of
1. Disable the automatic genset starting feature of an inverter-charger or other automatic starting
an inverter-charger or other automatic starting device following the device manufacturer’s in-
device. structions and safety precautions.
2-9
THIS PAGE IS INTENDED TO BE BLANK
2-10
3. Periodic Maintenance
Periodic maintenance is essential for top perfor- ever, warranty work must be completed by an au-
mance and long genset life. Use Table 3-1 as a thorized Onan dealer.
guide for normal periodic maintenance. In hot and
dusty environments some maintenance procedures WARNING Accidental or remote starting can
should be performed more frequently, as indicated cause severe personal injury or death. Discon-
by the footnotes in the table. nect the negative (−) cable at the battery to pre-
vent starting while working on the genset.
Maintenance, replacement or repair of emission WARNING Only authorized and competent per-
control devices and systems may be performed by sonnel who are familiar with the equipment and
any engine repair establishment or individual. How- its operation should carry out maintence.
TABLE 3-1. PERIODIC MAINTENANCE SCHEDULE
FREQUENCY
3-1
Replace Generator Bearing7 −
1. Perform more often when operating in hot weather.
2. Perform more often when operating in dusty conditions.
3. Perform at least once a year.
4. Tighten or replace the belt.
5. Perform at least once every two years.
6. Perform at least once every five years.
7. Must be performed by trained and experienced personnel (authorized Onan service representatives).
8. EPA requirement.
9. Perform every 250 hours when using B20 Bio−diesel fuel.
3-2
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
and after every eight hours of operation. into the vehicle.
3-3
WARNING Accidental or remote starting can Refer to Table 3-1 for scheduled engine oil change.
cause severe personal injury or death. Discon- Change oil more often in hot and dusty environ-
nect the negative (−) cable at the battery to pre- ments.
vent starting while working on the genset. 1. Park the vehicle on level ground and set the
parking break.
WARNING Do not run the genset with the main-
tenance access covers off. Contace with haz- 2. Run the generator set until it is warm and shut-
ardous moving parts and hot exhaust manifolds down the generator set.
can cause severe personal injury. 3. Place a pan large enough to hold the fuel oil ca-
1. Park the vehicle on level ground, shut down the pacity (Figure 3-1).
genset and remove the front access door.
WARNING Crankcase pressure can blow hot
2. Pull out the oil dip stick, wipe it clean, reinsert engine oil out the fill opening causing, severe
it and pull it out again to check the oil level (Fig- burns. Always stop the generator set before re-
ure 3-1). moving the oil fill cap.
3. Add or drain oil as necessary. See ENGINE 4. Remove the front access door and remove the
OIL RECOMMENDATIONS (p. 2-2). Keep the oil fill cap.
oil level between the FULL and ADD marks.
5. Remove the oil drain plug using the appropriate
CAUTION Too much oil can cause high oil size socket and breaker bar. Allow all the oil to
consumption. Too little oil can cause severe drain from the engine.
engine damage. Keep the oil level between 6. Reinstall the oil drain plug and torque to 32 lb−ft
the FULL and ADD marks. (44Nm).
4. Reinsert the dipstick and secure the oil fill cap 7. Spin off the oil filter and drain off oil.
and front access door.
8. Throughly wipe off the filter mounting surface
CHANGING ENGINE OIL AND OIL FILTER and remove the old gasket if it does not come
off with the oil filter.
WARNING State and federal agencies have de- 9. Make sure the new gasket is in place on the
termined that contact with used engine oil can new oil filter and apply a thin film of clean oil to
cause cancer or reproductive toxicity. Avoid the gasket. Spin the filter on by hand until the
skin contact and breathing of vapors. Use rub- gasket just touches the mounting surface and
ber gloves and wash exposed skin. turn the filter an additional 1/2 to 3/4 turn. Do not
over tighten.
WARNING Engine components (drains, filters,
hoses, etc) will be hot and can cause severe CAUTION Too little oil can cause severe
burns. The use of protective gloves is recom- engine damage. Too much oil can cause
mended. high oil consumption. Keep the oil level be-
tween the high and low beads on the dip-
WARNING Accidental or remote starting can stick.
cause severe personal injury or death. Discon- 10. Refill with oil. See ENGINE OIL RECOMMEN-
nect the negative (−) cable at the battery to pre- DATIONS (p. 2-2). Check the oil level and add
vent starting while working on the genset. or drain oil as necessary.
WARNING Do not run the genset with the main- 11. Screw the oil cap on securely and reinstall the
tenance access covers off. Contace with haz- front access door.
ardous moving parts and hot exhaust manifolds 12. Dispose of the used oil and oil filter in accor-
can cause severe personal injury. dance with local governmental regulations.
3-4
FILTER
DIP STICK
FILL CAP
DRAIN PLUG
(22 MM HEX HEAD)
3-5
MAINTAINING THE BATTERY AND REPLACING THE AIR FILTER ELEMENT
BATTERY CONNECTIONS
WARNING Engine components (drains, filters,
WARNING Arcing at battery terminals or in hoses, etc) will be hot and can cause severe
light switches or other equipment, and flames or burns. The use of protective gloves is recom-
sparks, can ignite battery gas causing severe mended.
personal injury—Ventilate battery area before
working on or near battery—Wear safety WARNING Do not run the genset with the main-
glasses—Do not smoke—Switch work light ON tenance access covers off. Contact with hazar-
or OFF away from battery—Stop genset and dis- douse moving parts and hot exhaust manifolds
connect charger before disconnecting battery can cause severe personal injury.
cables—Disconnect negative (−) cable first and
reconnect last. WARNING Accidental or remote starting can
cause severe personal injury or death. Discon-
Refer to Table 3-1 for scheduled battery mainte- nect the negative (−) cable at the battery to pre-
nance, and follow the battery manufacturer’s in- vent starting while working on the genset.
structions. Have the battery charging system ser-
viced if DC system voltage is consistently low or Refer to Table 3-1 for scheduled air filter replace-
high. Always: ment. Replace it more often in dusty environments.
1. Keep the battery case and terminals clean and
dry and the terminals tight. The air filter is accessible through the front access
door (Figure 3-2). Loosen the three screws that se-
2. Remove battery cables with a battery terminal cure the coolant recovery tank to the housing top
puller. panel and move it out of the way. Loosen the two
3. Make sure which terminal is positive (+) and screws that secure the air filter housing to the hous-
which is negative (−) before making battery ing top panel so that the spring clips that secure the
connections, always removing the negative (−) filter housing end cap can be unlatched. Remove
cable first and reconnecting it last to reduce the end cap and replace the filter element. Secure
arcing. the filter housing, coolant tank and access door.
3-6
COOLANT
RECOVERY TANK AIR FILTER HOUSING
(SHOWN CUT AWAY) END CAP
3-7
REPLACING THE FUEL FILTER Removing the Fuel Filter
See Table 3-1 for scheduled fuel filter replacement. Disconnect the two fittings at the filter and remove
A dirty fuel filter may be the cause of a failure to start. the mounting nut. Apply a wrench on the filter fitting
The fuel filter is accessible through the front access as well as on the flare nut so as not to stress the fit-
door (Figure 3-3). ting. Flare nut wrenches should be used on the flare
nuts so as not to round the corners on the nuts. Dis-
WARNING Diesel fuel is combustible and can
pose of the fuel filter according to local regulations.
cause severe personal injury or death. Do not
(Note: Filter removal will be easier if the filter mount-
smoke near diesel fuel tanks or equipment.
ing bracket screws are removed.)
Keep flames, sparks, pilot lights, electrical
switches, arc-producing equipment and all oth-
CAUTION Wipe dirt off the fuel hose fittings at
er sources of ignition well away. Keep a type
ABC fire extinguisher in the vehicle. the fuel filter before disconnecting the hoses so
as to keep dirt out of the fuel system.
WARNING Close any fuel line shutoff valve be-
fore disconnecting the fuel line from the filter. Installing the Fuel Filter
WARNING Accidental or remote starting can Rotate the filter half a turn around its mounting stud
cause severe personal injury or death. Discon- if the fittings interfere with the bracket. It only fits one
nect the negative (−) cable at the battery to pre- way.
vent starting while working on the genset.
WARNING Engine components (drains, filters, Connect the fuel fittings before tightening the filter
hoses, etc) will be hot and can cause severe mounting nut. Take care not to crossthread the fuel
burns. The use of protective gloves is recom- fittings. Thread them in by hand and tighten one flat
mended. past seating with two wrenches.
WARNING Accidental or remote starting can Prime the fuel system for half a minute to fill the new
cause severe personal injury or death. Discon- filter with fuel.
nect the negative (−) cable at the battery to pre-
vent starting while working on the genset. Secure the access door.
3-8
HOSE TO FUEL
ENGINE FILTER
FILTER
MOUNTING NUT
BRACKET
HOSE FROM MOUNTING
FUEL PUMP SCREWS
3-9
MAINTAINING THE COOLANT SYSTEM remove the coolant drain plug (Figure 3-4) and
drain the coolant into a suitable container.
Refer to Table 3-1 for scheduled maintenance. The
engine cooling system is filled with a 50/50 mixture WARNING Ethylene glycol antifreeze is con-
of ethylene glycol anti-freeze and water when the sidered toxic. Dispose of it according to local
genset leaves the factory, which is suitable for tem- regulations for hazardous substances.
peratures down to -34 F (-37 C).
Flush and clean the cooling system before refilling.
Radiator cleaning chemicals are available at local
Recommended Coolant
auto parts stores. Follow the instructions for clean-
ing and flushing that come with the cleaning solu-
See RECOMMENDED COOLANT (p. 2−3).
tion.
Pressure Cap Refilling Cooling System
Replace the pressure cap (Figure 3-4) every two Install the coolant drain plug using pipe thread seal-
years (seals deteriorate and leak). Proper cooling ant. Tighten it just enough so that it does not leak
system pressure (14 psi) is essential for optimal en- when the genset is running and has warmed up. Pull
gine cooling and minimal coolant loss. the hose connected to the pressure cap assembly
out as far and as high as it will go and fill the system
Draining and Cleaning Cooling System with coolant. When the coolant level reaches the fill
opening, start and operate the genset for a few min-
WARNING Hot coolant spray can cause severe utes and shut it down. Add more coolant if neces-
burns. Let the engine cool before releasing the sary and secure the pressure cap.
pressure cap or removing the drain cap.
Fill the recovery tank with coolant mixture to the
WARNING Engine components (drains, filters, COLD mark.
hoses, etc) will be hot and can cause severe WARNING Accidental or remote starting can
burns. The use of protective gloves is recom-
cause severe personal injury or death. Discon-
mended.
nect the negative (−) cable at the battery to pre-
vent starting while working on the genset.
WARNING Accidental or remote starting can
cause severe personal injury or death. Discon- WARNING Coolant trapped in the vent hose
nect the negative (−) cable at the battery to pre- will prevent the system from filling to its capac-
vent starting while working on the genset. ity, which can lead to serious engine damage.
Let the engine cool before removing the pressure Coolant Level Check
cap. Relieve any remaining pressure by turning the
pressure cap slowly, without pushing down. When Check coolant level in the recovery tank (Fig-
the pressure has been relieved, push down on the ure 3-4) before the first startup of each day and fill to
cap, turn it the rest of the way and withdraw it. Then the COLD mark if necessary.
3-10
PRESSURE CAP
COOLANT RECOVERY AND SYSTEM
TANK FILL OPENING
RECOVERY TANK
FILL CAP (BLUE)
COOLANT
LEVEL
3-11
Intentionally Left Blank
3-12
4. Troubleshooting
S 3 Blinks: indicates a service fault. For exam- Note: The last fault logged will blink even though the
ple: condition that caused the shutdown may have been
blink−blink−blink−long pause−repeat corrected.
4-1
TABLE 4-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
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.
4-2
TABLE 4-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
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.
4-3
TABLE 4-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
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.
4-4
TABLE 4-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
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.
4-5
TABLE 4-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
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.
4-6
TABLE 4-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
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.
4-7
TABLE 4-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
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.
4-8
TABLE 4-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
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.
4-9
TABLE 4-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
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.
4-10
TABLE 4-1. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
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.
OVERPRIME—CODE NO. 57
(The local or remote control switch was held in the Prime position for more than 3 minutes)
Corrective Action: Check for and remove any object that may be holding either control switch (remote
or local) in the prime position.
4-11
THIS PAGE IS INTENDED TO BE BLANK
4-12
5. Specifications
HDKCC HDKCC
MODEL: HDKCD HDKCG
(60Hz) (50 Hz)
GENSET CONTROL: Integrated Microprocessor-Based Engine and Generator Controller
Single-Bearing, Single-Bearing, Single-Bearing, Single-Bearing,
4 pole 4 pole 4 pole 4 pole
GENERATOR:
Rotating Field, Rotating Field, Rotating Field, Rotating Field,
1800 RPM 1500 RPM 1800 RPM 1800 RPM
Power (@1.0 power
10,000 W 8,000 W 12,000 W 10,000 W
factor)
Voltage 120 / 240 115 / 230 120 / 240 120 / 240
Frequency 60 Hz 50 Hz 60 Hz 60 Hz
Number of Phases 1 1 1 1
Current 41.7 amps per leg 34.8 amps per leg 50 amps per leg 41.7 amps per leg
Line Circuit Breaker 2-pole, 45 amp 2-pole, 35 amp 2-pole, 50 amp 2−pole, 45 amp
FUEL CONSUMPTION:
No-load 0.11 gph(0.41 lph) 0.11 gph(0.41 lph) 0.11 gph(0.41 lp) 0.11 gph(0.41 lph)
Half-load 0.48 gph(1.82 lph) 0.33 gph(1.25 lph) 0.48 gph(1.82 lp) 0.48 gph(1.82 lph)
Full-load 1.01 gph(3.80 lph) 0.82 gph (3.1 lph) 1.20 gph(4.54 lp) 0.82 gph (3.1 lph)
ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection (IDI), 4-Stroke Cycle Diesel
Bore 3.43 in (87 mm)
Stroke 3.64 in (92.4 mm)
Displacement 100.5 in3 (1,647 cc)
Compression Ratio 22.6 : 1
Fuel Injection Timing
14.50 (Spec A−B) 14.25 (Begin Spec C)
(BTDC)
Firing Order 1−3−2
Fuel Nozzle Injection
1991 psi (13.731 mPa)
Pressure
Cylinder Compression
370 psi (2.55 mPa) minimum
Test
Valve Lash: Intake &
Exhaust (cold)
0.0071 to 0.0087 in (0.18 to 0.22 mm)
Oil Capacity (with fil-
ter)
5.9 quart (5.6 liter)
Cooling System Ca-
pacity
6.6 quart (6.2 liter)
DC SYSTEM:
Nominal Battery Volt-
age
12 volts
Minimum Battery Ca-
pacity 475 amps down to 0 F (−17 C)
CCA (Cold Cranking 650 amps down to −20 F (−29 C)
Amps)
Maximum Regulated
Charging Current
20 amps
WEIGHT: 816 lbs (370 kg) 816 lbs (370 kg) 816 lbs (370 kg) 816 lbs (370 kg)
5-1
SIZE (L x W x H): 41.4 x 24.5 x 27 in (105 x 62 x 68.6 cm)
SOUND LEVEL: 68 dB(A) @ 10 ft (3m) & 54 dB(A) @ 50 ft (15m)—in “free field site” @ half load
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6. Bolt Torques
lb-ft N-m
Housing Panel Screws 7-9 10-12
Intake Air Hose Clamp Screws 7-9 10-12
Intake Air Resonator Mounting Screws 6-12 lb-inch 0.7-1.4
Radiator Access Plate Screws 7-9 10-12
Fuel Pump and Fuel Filter Bracket Mounting Screws 7-9 10-12
Fuel Fittings at Pump and Fuel Filter—One Flat passed finger tight. − −
Exhaust Assembly Flange Screws and Nuts 16-20 22-28
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 lb-inch 1.4-1.6
AC Output Terminal Block Mounting Screws 20-22 lb-inch 2.2-2.5
Circuit Breaker Terminal Screws 12-14 lb-inch 1.4-1.6
Circuit Breaker Mounting Screws 12-14 lb-inch 1.4-1.6
Vibration Isolator Mounting Screws 7-9 10-12
Primary Vibration Isolator Center Bolt* 43-53 58-72
Secondary Vibration Isolator Center Bolt* 27-30 37-41
Generator Drive Disc to Flywheel Bolts* 24-32 33-44
Generator Drive Disc to Rotor Bolts* 19-21 25-29
Generator Through Bolt Nuts* 20-25 28-34
Generator to Flywheel Housing Bolts* 39 52
Flywheel Housing Mounting Bolts* 30-40 41-55
Flywheel Mounting Bolts* 65-80 88-108
Starter Mounting Bolts* 18-22 24-30
Engine Mounting Bracket Bolts* 36-43 48-58
Engine Lifting Bracket Bolts* 18-22 24-30
Engine Oil Drain Plug* 32 44
Fan Spacer Bolts* 18-22 24-30
Free-Spinning Fan Coupling (Pulley)* 103-118 137-157
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
Oil Filter Adapter Mounting Nut 40−50 −
Remote Oil Line Fittings 24−26 −
Remote Oil Filter Elbow — One Full Turn Past Hand Tighten − −
* − Use engine oil as a thread lubricant.
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7. Maintenance Record
Record all periodic and unscheduled maintenance and service. See Section 3. Periodic Maintenance.
HOUR
DATE METER MAINTENANCE OR SERVICE PERFORMED
READING
Record the name, address, and phone number of your authorized Onan service center.
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Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email www.cumminsonan.com/contact
www.cumminsonan.com
CumminsR , OnanR , the “C” logo, and “Performance you rely on.”
are trademarks of Cummins Inc.
E 2013 Cummins Power Generation, Inc. All rights reserved.