CUMMINS HDKCC, HDKCD Operator's Manual
Operator Manual
Commercial Mobile Generator Set
HDKCC (Spec A−C)
HDKCD (Spec A−C)
English − Original Instructions 11−2009 981−0174 (Issue 5)
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Table of Contents
SECTION PAGE
Table of Contents i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY PRECAUTIONS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Obtain Service 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
noise 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electromagnetic compatibility 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emissions 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Genset 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. OPERATION 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Fuel 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Coolant 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Engine Oil 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Batteries 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Panels 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Start Checks 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming the Fuel System 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Starting 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Stopping 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Starting and Stopping 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading the Genset 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting Circuit Breakers 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting to Utility Power 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Cold Weather 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Hot Weather 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating at High Altitude 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Dusty Environments 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Breaking In a New Engine 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercising the Genset 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storing the Genset 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. PERIODIC MAINTENANCE 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
General Inspection 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Engine Oil Level 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Engine Oil and Oil Filter 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining the Battery and Battery Connections 3-6. . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Air Filter Element 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Fuel Filter 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining the Coolant System 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. TROUBLESHOOTING 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting With Table 4-1 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Code Blinking 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Restoring Fault Code Blinking 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. SPECIFICATIONS 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. MAINTENANCE RECORD 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
SAFETY PRECAUTIONS
Thoroughly read the OPERATOR’S MANUAL
before operating the genset. Safe operation and
top performance can only be obtained when
equipment is operated and maintained properly.
Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards shall remove, dismantle and
dispose of the generator set. See service manual.
The following symbols in this manual alert you to
potential hazards to the operator, service person
and equipment.
DANGER
which you must take steps to prevent severe
personal injury or death, as when you are in the
vicinity of High Voltage equipment.
WARNING
safe practice that can result in severe personal
injury or death.
CAUTION
safe practice that can result in personal injury
or equipment damage.
Electricity, fuel, exhaust, moving parts and batteries present hazards which can result in severe personal injury or death.
Used to alert you to a leathal hazard
Used to alert you to a hazard or un-
Used to alert you to a hazard or un-
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 negative (−) battery cable at the battery.
S Let the engine cool down before removing the
coolant pressure cap or opening the coolant
drain. Hot coolant under pressure can spray
out and cause severe burns.
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 You must be trained and experienced to make
adjustments while the genset is running—hot,
moving or electrically live parts can cause severe personal injury or death.
S Used engine oil has been identified by some
U. S. state and federal agencies as causing
cancer or reproductive toxicity. Do not ingest,
inhale, or contact used oil or its vapors.
S Ethylene glycol, used as engine antifreeze, is
toxic to humans and animals. Clean up spills
and dispose of used engine coolant in accordance with local environmental regulations.
S Keep multi-class ABC fire extinguishers
handy. Class A fires involve ordinary combustible materials 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.
GENERATOR VOLTAGE IS DEADLY
S Disable the automatic genset starting feature
of an inverter-charger or other automatic starting device before servicing the genset.
S Generator electrical output connections must
be made by a trained and experienced electrician in accordance with applicable codes.
WARNING
and shore power can lead to electrocution of
utility line workers, eqiupment damage and fire.
Use an approved switching device to prevent
interconnections.
S Use caution when working on live electrical
equipment. Remove jewelry, make sure clothing and shoes are dry, stand on a dry wooden
platform or rubber insulating mat and use tools
with insulated handles.
Interconnecting the gnerator set
iii
ENGINE EXHAUST IS DEADLY
S Inspect for exhaust leaks at every startup and
after every eight hours of running.
S Learn the symptoms of carbon monoxide poi-
soning in the Operator’s Manual.
S Never sleep in the vehicle while the genset is
running unless the vehicle is equipped with a
working carbon monoxide detector.
S Do not operate the genset when the vehicle is
in a confined space, such as a garage.
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
working or living spaces or compartments.
S Do not wear loose clothing or jewelry near
moving 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.
FLAMMABLE VAPOR CAN CAUSE A
DIESEL ENGINE TO OVERSPEED
WARNING
genset where a flammable vapor environment
can be created by fuel spill, leak, etc.
Flammable vapor can cause a diesel engine to
overspeed and become difficult to stop, resulting in
possible fire, explosion, severe personal injury and
death. The owners and operators of the genset are
solely responsible for operating the genset safely.
Do not operate a diesel-powered
DIESEL FUEL IS COMBUSTIBLE
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 equipment. Keep flames, sparks, pilot lights, arcproducing equipment and all other sources of
ignition well away.
S Fuel lines must be secured, free of leaks and
separated or shielded from electrical wiring.
BATTERY GAS IS EXPLOSIVE
S Wear splash−proof safety glasses.
S Do not smoke or permit flames or sparks to oc-
cur neat the battery at any time.
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 feature
of an inverter-charger or other automatic starting device before servicing the genset.
THE HAZARDS OF CARBON MONOXIDE
Engine−driven generators can produce harmful
levels of carbon monoxide that can injure or kill you.
The nature of boating is such that you can be
harmed by this poisonous gas despite good generator set maintenance and proper ventilation.
ONLY YOU CAN PROTECT YOURSELF
FROM CO POISONING!
S Watch constantly for swimmers when the gen-
erator set is running.
S Make sure exhaust cannot get under the deck,
between hulls or enter the living quarters
through a window, vent or door.
S Make sure all CO detectors and 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
generator set and every eight hours if you run
it continuously.
Mobile-8
iv
SUBSTANCE HAZARDOUS TO HEALTH
PROTECTIVE MEASURES
Generator sets use substances, and emit and
create wastes that can cause health risks. Generator set operators must use appropriate personal
protective equipment (such as clothing, gloves,
protective glasses/goggles, and respiration equipment) when exposed to fuel, oil, coolant, wet batteries, 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 disposal and recycling.
ANTIFREEZE (FLEETGUARD − ES
COMPLEAT/EG PREMIX)
This antifreeze is also know as an ethylene glycol
based coolant; summer coolant; coolant additive. It
is purple coloured, viscous liquid, with a mild chemical odour, is soluble in water and harmful. It contains ethylene glycol, and diethylene glycol. Ethylene glycol is a potentially hazardous constituent.
The substance has a boiling point of 107° C, and a
flash point of 121° C.
It is used as an engine coolant additive, and can be
found in engine cooling systems, and head exchangers. Installers, operators and maintainers are
likely to encounter this substance.
HAZARDOUS REACTIONS
Ethylene glycol is combustible when exposed to
heat or flame and can react vigorously with oxidants. Moderate explosive hazard in form of vapour
when exposed to heat or flame. Hazardous products resulting from combustion or decomposition
include carbon monoxide, carbon dioxide and acrid
smoke. Self−contained breathing apparatus must
be worn in the event of fume build up.
Avoid strong oxidizing agents − incompatible with
sulfuric acid, nitric acid, caustics and aliphatic
amines.
It may cause neurological signs and symptoms,
and kidney damage. It is also a skin and eye irritant.
Very toxic in particulate form upon inhalation.
Harmful if swallowed, lethal dose for humans reported to be 100ml.
Refrain from eating, drinking or smoking when using the product. Adopt a high standard of personal
hygiene. In case of skin contact, wash immediately
with soap and water.
Ensure good ventilation and avoid heat sources.
Avoid breathing mist, if there is a risk of vapour, or
particulate, use a suitable organic vapour mask.
Eye protection, gloves, overalls, impervious apron
should be used. Avoid contamination inside the
gloves. If overalls become contaminated, discontinue use and clean thoroughly.
STORAGE/TRANSPORT
Store and transport only in correctly marked containers. Keep containers closed when not in use.
Keep cool, out of sunlight, away for naked flames
and strong acids, do not freeze. Store well away
from food−stuffs and drinking water. Take special
care to avoid discharge into drains, sewers and water−courses.
Contain leak/spill with sand, earth or non−combustible, absorbent material to prevent entry of substance into drainage/sewerage system, water−
courses and land. Eliminate all ignition sources,
use plastic shovel to transfer to suitable container
and dispose of unwanted or absorbed substance
through and authorised contractor to a licensed
site.
EMERGENCY ACTION
S Fire
Extinguishing media: CO
foam, dry powder, or water spray.
Fire fighters to use self contained breathing
apparatus. Keep fire exposed containers cool.
Prevent run−off from entering waterways,
drains and drinking water supplies.
S ngestion
Toxic by ingestion. If swallowed induce vomiting only
control centre. Delayed treatment may result in
fatality.
S Inhalation (of vapour)
Remove from further exposure. In case of irritation to lungs or throat, seek medical advice.
S Aspiration (inhalation of liquid)
Obtain immediate medical assistance.
S Eyes
Flush copiously with water or preferably eye−
under the advice of a Doctor or poison
alcohol resistant
2,
v
wash solution for at least five minutes. Seek
medical advice.
S Skin
Wash thoroughly with soap and water, and
seek medical attention if irritation develops.
Change clothing if necessary and wash before
re−use.
S Spillage
Soak−up using an absorbent material and dispose of this as directed under Storage/Transport (Section 5.1.3)
GAS OIL
This product is also known as Red Diesel, Fuel Oil,
and type A1 or A2. It can be pale red or a clear liquid
with a characteristic mild odour. It contains catalytically cracked oil, petroleum distillates, quinizarin,
and gas oil maker dye red. The catalytically cracked
oil and petroleum distillates are potentially hazardous constituents.
The substance has an initial boiling point of 180°C,
a flash point greater than 56°C, and a vapour pressure less than 0.7mm Hg at 20°C and has negligible
solubility in water.
It is used as a fuel for off−road diesel powered vehicles and stationary engines, and can be found in
fuel tanks, pipes and injection systems. The substance should not be used for any other purpose
without contacting the manufacturer or supplier. Installers, operators and maintainers are likely to encounter this substance.
HAZARDOUS REACTIONS
This liquid is flammable. Avoid smoking, heat
sources, such as welding and naked flames,
sparks and static electricity build−up. Thermal decomposition products are hazardous, containing
, NOX and SOX compounds.
CO
X
The vapour is explosive. High vapour concentrations can cause respiratory irritation, dizziness,
nausea, and loss of consciousness. Excessive and
prolonged exposure to the mist can cause chronic
inflammatory reaction of the lungs and form of pulmonary fibrosis.
Avoid strong oxidising agents, e.g. chlorates which
may be use in agriculture.
Gas oil is slightly irritating to the skin and has a de−
fatting action. Toxicity following single exposure to
high level of gas oil is of low order. Prolonged, repeated skin contact may de−fat the skin resulting in
possible skin irritation and dermatitis. In some
cases warty, cancerous growths have occurred.
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 laundered before re−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 containers. 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 transfer.
Contain leak/spill with sand, earth or other suitable
material, and prevent entry of substance into drainage/sewerage system, water−courses and land.
Dispose of unwanted or absorbed substance
through an authorised 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.
vi
Small fire − foam/dry powder, AAAF, CO2,
sand, earth.
Avoid making sparks. Fire fighters to use self−
contained breathing apparatus. Keep fire exposed 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.
lubrication oil for use in wide range of diesel engines operating under severe conditions. Installers,
operators and maintainers are likely to encounter
this product.
HAZARDOUS REACTIONS
This product is stable although slightly re−active
with oxidising agents. Results of decomposition are
carbon oxides (CO, CO
) and water.
2
S Inhalation (of vapour)
Remove from further exposure. Obtain medical assistance immediately.
S Aspiration (inhalation of liquid)
If, following ingestion of gas oil, vomiting occurs, 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 irritation 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 material. Dispose of unwanted or absorbed flammable material as directed under Storage/
Transport (Section 5.7.3).
LUBRICATION OIL − PREMIUM BLUE E
15W40
Also known as oil, lube oil, sump oil, new oil is dark,
viscous liquid with a slight, characteristic odour.
The base oil contains: distillates (petroleum), solvent−dewaxed heavy paraffinic. It is not classified
as dangerous 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 150°C, a flash
point Open Cup of 220°C (Cleveland), and is insoluble in cold water.
It is used in engine lubricant oil systems, sump pan
and filters, make−up tanks and piping systems as a
Although harmful if swallowed or aspirated
(breathed in), repeated or prolonged exposure is
not known to aggravate medical conditions.
Used oil may contain harmful combustion by−products 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 breathe vapour/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 water.
Use safety glasses, impervious gloves and lab
coat. Avoid contamination inside the gloves. If
overalls become contaminated, discontinue use
and clean thoroughly.
No special respiratory precautions are necessary n
normal use. Do no breathe vapour/spray when
handling hot materials.
STORAGE/TRANSPORT
Store and transport only in correctly marked containers. Keep containers tightly sealed when not in
use. Keep in a cool, well ventilated area, out of sunlight 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 an inert material and dispose
of unwanted or absorbed substance through an authorised contractor to a licensed site. Finish cleaning by spreading water on the contaminated surface and allow to evacuate through the sanitary
system.
vii
EMERGENCY ACTION
S Fire
Extinguishing media:
Large fire − Use water spray, fog or foam. Do
not use water jet.
Small fire − Use dry chemical powder or CO
Fire−fighters to use self contained breathing
apparatus and full turnout gear. Keep fire ex-
2
posed containers cool.
S Ingestion
Do not induce vomiting, Obtain medical advice
immediately.
S Inhalation (of vapour)
Remove from further exposure. Obtain medical attention.
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.
viii
1. Introduction
ABOUT THIS MANUAL
This is the Operator’s Manual for the generator sets
(gensets) listed on the front cover. Read and carefully observe all of the instructions and precautions
in this manual. Keep this manual and the genset
Installation Manual with the other vehicle manuals.
This is the Service Manual for the generator sets
(gensets) listed on the front cover.
Operation, Periodic Maintenance and Troubleshooting provide the instructions necessary for op-
erating the genset and maintaining top performance. The owner is responsible for performing
maintenance in accordance with the PERIODIC
MAINTENANCE SCHEDULE (p. 3-1).
WARNING
tem. It can stop without warning. Children, persons with physical or mental limitations, and
pets could suffer personal injury or death. A personal attendant, redundant power or alarm system must be used if genset operation is critical.
This genset is not a life support sys-
numbers is significant. The last character of the
model number is the specification letter, which is important for obtaining the right parts. Genuine
Onan® replacement parts are recommended for
best results. Refer to the genset Parts Catalog.
[The engine family designation, engine displacement, statement of compliance with applicable EPA and / or California
emissions regulations appear in this block on the actual nameplate on the genset.]
WARNING
This generator set is not “ignition
protected” and shall not be used in a flammable
vapor environment.
WARNING
Improper service or replacement of
parts can lead to severe personal injury or death
and to damage to equipment and property. Service personnel must be qualified to perform
electrical and mechanical service.
Unauthorized modifications or replacement of
fuel, exhaust, air intake or speed control system
components that affect engine emissions are
prohibited by law in the State of California.
NAMEPLATE
Be ready to provide the genset model and serial
numbers on the nameplate when contacting Onan
for parts, service or information. Figure 1-1 illustrates the nameplate and its location. The gray
boxes illustrate where to look for the model and serial numbers.
FIGURE 1-1. TYPICAL NAMEPLATE
MODEL NUMBER: ___________________________
SERIAL NUMBER: ___________________________
Record these numbers in Figure 1-2 so that they are
easy to find when needed. Each character in these
FIGURE 1-2. RECORD NUMBERS HERE
1-1
HOW TO OBTAIN SERVICE
Information to Have Ready
When you call for service, parts, or product literature
(such as the Service Manual or Parts Catalog) for
your genset, contact the nearest authorized distributor. Onan has factory-trained representatives to
handle your requests for genset parts and service.
In North America
Call 1-800-888-ONAN to contact the nearest Cummins/Onan or Onan-only distributor in the United
States or Canada. (This automated service utilizes
touch-tone phones only). Select OPTION 1
(press 1) to be automatically connected to the distributor nearest to you.
If you are unable to contact a distributor using the
automated service, consult the Yellow Pages. Typically, our distributors are listed under:
GENERATORS − ELECTRIC,
ENGINES − GASOLINE OR DIESEL, or
RECREATIONAL VEHICLES − EQUIPMENT,
PARTS AND SERVICE.
If you have difficulty in arranging service or resolving a problem, please contact the Service Manager
at the nearest Cummins/Onan distributor for assistance.
Outside North America
If you are outside North America, call Onan Corporation at 1−763−574−5000 from 7:30 AM to
4:00 PM, Central Standard Time, Monday through
Friday, or fax 1−763−528−7229.
Before calling for service, have the following information available:
1. The complete genset model number and serial
number. See About This Manual (Page 1-1).
2. The date of purchase
3. The nature of the problem. See Section 4. Trou-
bleshooting.
NOISE
Generator sets emit noise. As noise level and time
of exposure increase, risk of hearing damage increases. The Specifications page n the Operator
manual states noise level for this generator set. Select and use personal hearing protection appropriate 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 evaluated and is not marked for use in
open air. Install the generator set in accordance with
the Installation manual. Obey local noise restrictions when you operate the generator set.
ELECTROMAGNETIC COMPATIBILITY
Generator sets emit and receive electromagnetic
(radio frequency) energy. If the generator set affects operation of nearby devices, or nearby devices affect generator set operation, increase the
distance between them.
This generator set has been evaluted for use in industrial environments.
1-2
EMISSIONS
genset is authorized, you should seek assistance
from an approved Onan dealer.
You should carefully review Operator (Owner),
Installation manuals and other information you receive with your genset. If you are unsure that the
installation, use, maintenance or service of your
TABLE 1-1. EMISSIONS CONTROL INFORMATION TABLE
The California emissions control warranty statement is located in
Emissions Warranty Information
Engine Valve Clearance (Lash) See Section 5. Specifications.
Engine Fuel Requirements
Engine Lubricating Oil Requirements See ENGINE OIL RECOMMENDATIONS (Page 2-1).
Engine Adjustments
Engine Emission Control System
the same packet of information as this manual when the genset is
shipped from the factory.
The engine is certified to operate on diesel fuel. See FUEL RECOMMENDATIONS (Page 2-1).
High Idle Speed. This is a service procedure requiring trained
personnel and proper tools. See the Service Manual.
The engine emission control system consists of engine design
and precision manufacture. (IFI)
California genset users may use Table 1-1 as an aid
in locating information related to the California Air
Resources Board requirements for emissions control.
1-3
TYPICAL GENSET
Figure 1-3 illustrates the fuel, battery, remote control and AC output connection points, the flow of
cooling and ventilating air and the maintenance and
service access panels of a typical genset. Not
shown are the combustion air inlet and oil drain
openings in the base.
AC OUTPUT AND REMOTE
CONTROL CONNECTIONS
COOLING & VENTILATING AIR IN HOT AIR OUT
MAINTENANCE
ACCESS
CONTROL
PANEL
BATTERY
CONNECTIONS
FUEL
CONNECTIONS
EXHAUST
CONNECTIONS
FIGURE 1-3. TYPICAL GENSET
1-4
2. Operation
RECOMMENDED FUEL
WARNING
cause severe personal injury or death. Do not
smoke near fuel tanks or fuel-burning equipment or in areas sharing ventilation with such
equipment. Keep flames, sparks, pilot flames,
electrical arcs and switches and all other
sources of ignition well away. Keep a multiclass fire extinguisher handy.
Use clean, fresh No. 2 diesel fuel (ASTM 2-D) when
the outdoor ambient temperature is above freezing,
and No. 1 diesel fuel (ASTM 1-D) when below freezing. The fuel should have a Cetane number of at
least 45 for reliable starting.
Diesel fuel is combustible and can
RECOMMENDED COOLANT
Use the best quality ethylene glycol antifreeze solution available. It should be fully formulated with rust
inhibitors and coolant stabilizers. Use fresh water
that is low in minerals and corrosive chemicals. Distilled water is best.
See Section 5. Specifications for coolant capacity.
RECOMMENDED ENGINE OIL
FIGURE 2-1. OIL VISCOSITY VS. TEMPERATURE
Use API (American Petroleum Institute) performance Class CH-4 engine oil or better. Also look for
the SAE (Society of Automotive Engineers) viscosity grade. Referring to Figure 2-1, choose the viscosity grade appropriate for the ambient temperatures expected until the next scheduled oil change.
Multi-grade oils such as SAE 15W-40 are recommended for year-round use.
See Section 5. Specifications for oil capacity.
STARTING BATTERIES
The genset requires a 12 volt battery to power its
control and starting circuits. Reliable genset starting
and starter service life depend upon adequate battery system capacity and maintenance.
See MAINTAINING THE BATTERY AND BATTERY
CONNECTIONS (p. 3-6) and Section 5. Specifi-
cations for minimum required battery ratings.
2-1
CONTROL PANEL
The control panel (Figure 2-2) has the following features:
(Rapid blinking before cranking starts indicates that
the glow plugs are preheating the combustion
chambers. The genset controller automatically varies the time based on engine temperature.)
Control Switch − This switch is used to start and
stop the genset, prime the engine fuel system and
restore the fault code (blinking status light).
Status Lamp − This is a lamp in the control switch
that blinks rapidly during preheat and cranking. It
stays on continuously while the genset is running. If
the genset shuts down, it will blink a numerical code
to indicate the nature of the fault shutdown (see
Section 4. Troubleshooting).
LINE CIRCUIT
BREAKER(S)
Line Circuit Breaker(s) − The line circuit breakers
protect the AC power leads connected to the genset.
Coolant Recovery Tank Fill Cap − The recovery
tank provides for coolant expansion. Replenish the
normal loss of coolant by filling here.
Hour Meter − The hour meter records the total run-
ning time of the genset. It cannot be reset.
COOLANT RECOVERY
TANK FILL CAP
CONTROL SWITCH
&STATUS LAMP
COOLANT RECOVERY
TANK FLUID LEVEL
HOUR METER
FIGURE 2-2. CONTROL PANEL
2-2
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