CUMMINS onan 7.0 HGJAD, onan onan 7.0 HGJAE, onan 5.5 HGJAD, onan 7.0 HGJAF, onan 5.5 HGJAE Operator's Manual

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Redistribution or publication of this document by any means, is strictly prohibited.
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!!
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The engine exhaust from this product
of California to cause cancer, birth
defects or other reproductive harm.
gasoline warnings

Table of Contents

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SAFETY PRECAUTIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About this Manual 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Genset 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Recommendations 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Recommendations 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Batteries 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Control Panel 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Panel 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conducting Pre-Start Checks 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming Gasoline Fuel Systems 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Genset 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Genset 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Restarting the Genset 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Only Operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Restarting the Genset 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Lockout Switch 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting Circuit Breakers 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Utility Power 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Cold Weather 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Hot Weather 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating at High Altitude 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Dusty Environments 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Breaking In a New Engine 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercising the Genset 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storing the Genset 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conducting General Inspections 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Engine Oil Level 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Engine Oil and Oil Filter 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining Battery and Battery Connections 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Air Filter Element 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Spark Plugs 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Spark Arrestor 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INFORMATION FOR CALIFORNIA GENSET USERS 31. . . . . . . . . . . . . . . . . . . . . . . . . . .
HOW TO OBTAIN SERVICE 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE RECORD 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1

Safety Precautions

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Thoroughly read the OPERATOR’S MANUAL before operating the genset. Safe operation and top performance can be obtained only when equipment is operated and maintained properly.
The following symbols in this manual alert you to po­tential hazards to the operator, service person and equipment.
alerts you to an immediate hazard which will result in severe personal injury or death.
WARNING
practice which can result in severe personal injury or death.
CAUTION
practice which 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.
alerts you to a hazard or unsafe
alerts you to a hazard or unsafe
GENERAL PRECAUTIONS
Keep children away from the genset.
Do not use evaporative starting fluids. They are
highly explosive.
To prevent accidental or remote starting while working on the genset, disconnect the nega­tive (–) battery cable at the battery.
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.
Make sure all fasteners are secure and torqued properly.
Do not work on the genset when mentally or physically fatigued or after consuming alcohol or drugs.
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.
Used engine oil has been identified by some state and federal agencies as causing cancer or reproductive toxicity. Do not ingest, inhale, or contact used oil or its vapors.
Benzene and lead in some gasolines have been identified by some state and federal agencies as causing cancer or reproductive toxicity. Do not to ingest, inhale or contact gaso­line or its vapors.
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)
Genset installation and operation must comply with all applicable local, state and federal codes and regulations.
GENERATOR VOLTAGE IS DEADLY!
Generator electrical output connections must be made by a trained and experienced electri­cian in accordance with applicable codes.
The genset must not be connected to shore power or to any other source of electrical power. Back-feed to shore power can cause electric shock resulting in severe personal inju­ry or death and damage to equipment. An ap­proved switching device must be used to pre­vent interconnections.
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.
2
ENGINE EXHAUST IS DEADLY!
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Learn the symptoms of carbon monoxide poi­soning in this manual and never sleep in the vehicle while the genset is running unless the vehicle is equipped with a working carbon mon­oxide detector.
ments and other below-grade spaces. Prevent leaks and the accumulation of gas.
BATTERY GAS IS EXPLOSIVE
Wear safety glasses.
Do not smoke.
The exhaust system must be installed in accor-
dance with the genset Installation Manual. Engine cooling air must not be used for heating the working or living space or compartment.
Inspect for exhaust leaks at every startup and after every eight hours of running.
Make sure there is ample fresh air when operat­ing the genset in a confined area.
FUEL IS FLAMMABLE AND EXPLOSIVE
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 flame, sparks, pilot lights, arc-pro­ducing equipment and switches and all other sources of ignition well away.
Fuel lines must be secured, free of leaks and separated or shielded from electrical wiring.
Leaks can lead to explosive accumulations of
gas. Natural gas rises when released and can accumulate under hoods and inside housings and buildings. LPG sinks when released and can accumulate inside housings and base-
To reduce arcing when disconnecting or recon­necting battery cables, always disconnect the negative (–) battery cable first and reconnect it last.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
Do not wear loose clothing or jewelry near mov­ing parts such as PTO shafts, fans, belts and pulleys.
Keep hands away from moving parts.
Keep guards in place over fans, belts, pulleys,
and other moving parts.
HYDRAULIC FLUID UNDER PRESSURE
CAN CAUSE SEVERE PERSONAL INJURY
Always shut down the engine that drives the hy­draulic pump before loosening or tightening fit­tings.
The high pressure spray from a leak or fitting in a hydraulic line can penetrate the skin, leading to possible blood poisoning. Wear safety glasses. Do not delay getting proper medical attention if exposed to spray.
Commercial Mobile-1
3

Introduction

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ABOUT THIS MANUAL
This manual covers the operation and maintenance of the HGJAD, HGJAE and HGJAF Series of gener­ator sets (gensets). Each operator should study this manual carefully and observe all of its instructions and safety precautions. Keep this manual and the Installation Manual with the other vehicle manuals.
Operation, Periodic Maintenance and Trouble­shooting provide the instructions necessary for
operating the genset and maintaining it at top per­formance. The owner is responsible for performing maintenance in accordance with the PERIODIC MAINTENANCE SCHEDULE (Page 15). This man­ual also includes genset specifications, information on how to obtain service, and information for Califor­nia users.
7HGJAD–1910A
D000012345
WARNING
This genset is not a life support sys­tem. 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 an alarm system must be used if genset operation is criti­cal.
NAMEPLATE
Model and Serial Numbers: Have the model and serial numbers handy (gray boxes, Figure 1) when contacting an Onan dealer for parts, service or prod­uct information. Each character is significant. (The last character of the model number is the specifica­tion letter, which is important for obtaining the right parts.) Record these numbers in the boxes in Fig­ure 1 so that they are handy when you need them.
Genuine Onan replacement parts are recom­mended for best performance and safety.
Federal Emissions Compliance Period: The Federal Emissions Compliance Period referred to on the nameplate indicates the number of operating hours for which the engine has been shown to meet Federal emissions requirements. Category C = 250 hrs, B = 500 hrs, A = 1000 hrs.
[The engine family designation, engine displacement, state­ment of compliance with the applicable EPA and / or California emissions regulations, including the compliance period or category, appear in this block on the actual nameplate on the genset.]
RECORD NUMBERS HERE
MODEL NUMBER:
SERIAL NUMBER:
FIGURE 1. TYPICAL NAMEPLATE
4
TYPICAL GENSET
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Figure 2 illustrates a typical self-enclosed genset with the maintenance access cover removed.
CAUTION
Operating the genset with the ac­cess cover off can lead to overheating of com­ponents. Always secure the cover after starting the genset.
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      
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FIGURE 2. TYPICAL SELF-ENCLOSED GENSET
5
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FUEL RECOMMENDATIONS
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ENGINE OIL RECOMMENDATIONS
WARNING
Gasoline and LPG are highly flam­mable and explosive and can cause severe per­sonal injury or death. Do not smoke or turn elec­trical switches ON or OFF where fuel fumes, tanks or equipment are present or in areas sharing ventilation. Keep flames, sparks, pilot lights, arc-producing equipment and switches and all other sources of ignition well away. Keep a type ABC fire extinguisher in the vehicle.
Gasoline Models
Use clean, fresh unleaded gasoline having a mini­mum octane rating (Anti-Knock Index) of 87.
CAUTION
Do not use gasoline or gasoline ad­ditives containing methanol because methanol can be corrosive to fuel system components.
Avoid using leaded gasoline because of the ex­tra engine maintenance that will be required.
LPG Models
Use clean, fresh HD-5 grade liquified petroleum gas (LPG) or equivalent product consisting of at least 90 percent propane. Commercial liquified petroleum gas fuels may contain more than 2.5 percent butane which can result in poor fuel vaporization and poor engine starting in low ambient temperatures (below 32° F (0° C).
Satisfactory performance on low-pressure LPG models requires that the LPG vapor be supplied at a pressure within the range indicated in Specifica- tions.
WARNING
cause gas leaks which can lead to fire and se­vere personal injury or death. LPG supply pres­sure must be adjusted to Specifications by trained and experienced personnel.
High LPG supply pressure can
Use API (American Petroleum Institute) perfor­mance Class SJ, SH or SG engine oil, which may be in combination with performance Class CH-4, CG-4 or CF-4 (for example: SJ/CH-4). Also look for the SAE (Society of Automotive Engineers) viscosity grade. Referring to Table 1, choose the viscosity grade appropriate for the ambient temperatures expected until the next scheduled oil change.
Single-grade SAE 30 oil is preferable when temper­atures are consistently above freezing. Multigrade oils are better when wide temperature variations are expected.
TABLE 1. OIL VISCOSITY VS. TEMPERATURE
EXPECTED AMBIENT
TEMPERATURES
32° F (0° C) and higher 30
10° F to 100° F (–12° C to 38° C)
0° F to 80° F (–18° C to 27° C)
–20° F to 50° F (–28° C to 10° C) 5W-30
SAE VISCOSITY
GRADE
15W-40
TM
(OnaMax
10W-30 10W-40
)
STARTING BATTERIES
The genset has a 12 volt, direct current (DC) engine cranking and control system. See Specifications (Page 29) regarding minimum battery ratings for reliable genset cranking, especially in cold weather. Also see PERIODIC MAINTENANCE SCHEDULE (Page 15) and the battery manufacturer’s instruc­tions regarding battery maintenance. Reliable gen­set starting and starter service life depend upon adequate battery system capacity and proper main­tenance.
The genset provides up to 10 amps of regulated bat­tery charging current.
OnaMax is a trademark of Onan Corporation.
6
GENSET CONTROL PANEL
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The genset control panel (Figure 3) is located be­hind the maintenance access cover (Figure 2) and has the following features:
Control Switch – This switch is used to prime the fuel system, start and stop the genset and display the shutdown code. Hold the switch in its START position to crank and start the genset. Press the switch to its STOP position to stop the genset. Hold the switch in its STOP/PRIME position (starts in 2 seconds) to prime the fuel system (gasoline mod­els only). See Troubleshooting (Page 22) about dis- playing shutdown codes.
  
  
Status Indicator Light – This light is an LED (light emitting diode) in the control switch which blinks rapidly during cranking and comes on solid when the starter disconnects, indicating that the genset is running. If the genset shuts down abnormally, the light will blink a code to indicate the cause of the shutdown. See Troubleshooting (Page 22).
Line Circuit Breakers – The line circuit breakers protect the AC power leads connected to the genset from overloads and equipment short circuits.
Hour Meter – The hour meter records genset oper- ating time in hours. It cannot be reset. See the Peri­odic Maintenance Schedule (Page 15).
REMOTE CONTROL PANEL
The vehicle probably has a control panel inside the vehicle for remote control of the genset. Onan offers three remote control kits as follows:


FIGURE 3. GENSET CONTROL PANEL
FIGURE 4. REMOTE SWITCH
 

Remote switch / status lamp (Figure 4).
Remote switch / status lamp and hour meter
(Figure 5).
Remote switch / status lamp and DC voltmeter
(Figure 6).
The DC voltmeter indicates whether voltage across the 12 VDC control system and battery is normal. If the indicator consistently stays above or below the normal zone, see MAINTAINING THE BATTERY AND BATTERY CONNECTIONS (Page 19).
FIGURE 5. REMOTE SWITCH / HOUR METER
FIGURE 6. REMOTE SWITCH / DC VOLTMETER
7

Operation

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WARNING
Exhaust gases contain carbon monoxide, an odorless, colorless gas. Carbon monoxide is poisonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning include:
Dizziness Throbbing in Temples Nausea
Muscular Twitching Headache Vomiting
Weakness and Sleepiness Inability to Think Clearly
IF YOU OR ANYONE ELSE EXPERIENCES ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the genset and do not op­erate it until it has been inspected and repaired.
Never sleep in the vehicle with the genset running unless the vehicle is equipped with a working car­bon monoxide detector. Primary protection against inhaling carbon monoxide, however, is proper installation of the exhaust system, daily (every eight hour) inspection for visible and audible exhaust system leaks.
CONDUCTING PRE-START CHECKS
Before the first start of the day and after every eight hours of operation, inspect the genset as instructed under CONDUCTING GENERAL INSPECTIONS (Page 16). Keep a log of maintenance and the hours run and perform any maintenance that may be due. See Returning the Genset to Service (Page 14) if the vehicle has been in storage.
Before each start:
1. Make sure all vehicle CO detectors are wor­king.
2. Check for signs of fuel and exhaust leaks and for damage to the exhaust system.
3. To prevent overheating and to reduce fouling with dust and debris, make sure the genset’s normal ground clearance is not being reduced by sloping ground, curbs, logs or other objects. Repark the vehicle if necessary and/or remove any objects blocking the air inlet or air outlet.
4. Turn off air conditioners and other large loads.
5. If the genset is equipped with an hydraulic pump, check and refill the oil reservoir as nec­essary.
PRIMING GASOLINE FUEL SYSTEMS
If a gasoline genset ran out of fuel prime the fuel sys­tem by holding the control switch at STOP/PRIME
EXHAUST GAS IS DEADLY!
for 30 seconds. (The status indicator light will stay on solid while the pump is on.)
STARTING THE GENSET
Start the genset from the genset control panel or re­mote control panel inside the vehicle (Page 7).
1. Push and hold the switch at START until the genset starts. The status indicator light on the switch flashes while cranking. It will come on solid when the starter disconnects, indicating that the genset is running. (Because the genset control has to “wake up,” a slight delay might be noticed before anything seems to happen. On models with fuel injection, the delay could be up to 3 seconds to pressurize the fuel injectors.)
2. The genset control will discontinue cranking if the genset does not start within 30 seconds and will cause the status indicator light to blink shut­down code No. 4. Wait 5 seconds for the con­trol to reset before trying again. See Trouble- shooting (Page 22) if the genset does not start after two or three tries.
CAUTION
starter motor by continued attempts to start. Find out why the genset is not starting and repair as necessary.
3. For top performance and engine life, especially in colder weather, let the engine warm up for two minutes before connecting appliances.
Do not risk burning out the
8
4. Check for fuel and exhaust leaks. Stop the gen-
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set immediately if there is a fuel or exhaust leak and have it repaired.
5. See Troubleshooting (Page 22) if the engine shuts down and the status indicator light blinks.
6. Always secure the access cover after starting the genset at the genset control panel.
WARNING
Operating the genset with the access cover off can lead to severe burns and overheating of components. Always secure the cover after starting the genset.
STOPPING THE GENSET
Turn off air conditioners and other large loads and let the genset run for two minutes to cool down be­fore stopping. This reduces backfiring and run-on. Then press the switch to STOP to stop the genset.
can be powered depends upon the genset power rating. The genset will shut down or its circuit break­ers will trip if the sum of the loads exceeds genset power.
To avoid overloading the genset and causing shut­downs, compare the sum of the loads that are likely to be used at the same time with the power rating of the genset. It may be necessary to run fewer
loads at the same time—the sum of the loads must not be greater than genset rating.
Note that the genset may shut down due to over­load—even though the sum of the loads is less than genset rating—when a large motor or air conditioner is started last or cycles off and then on again. The reason for this is that a motor’s startup load is much larger than its running load. It may be necessary to
run fewer loads when large motors and air con­ditioners are cycling on and off.
RESTARTING THE GENSET
See Troubleshooting (Page 22) if the genset shuts down abnormally.
ENGINE ONLY OPERATION
Shutdowns due to generator failure are bypassed when the genset is restarted within one (1) minute. While operating in this mode, the status indicator lamp flashes at a high frequency. This feature al­lows the engine to run so that hydraulic systems powered by the engine can be operated though AC output has failed.
GENSET LOCKOUT SWITCH
The vehicle may be equipped with a genset lockout switch in the cab and/or boom bucket that can be used to prevent unauthorized starting of the genset. The switch(s) must be in their unlocked positions to start the genset.
LOADING THE GENSET
The genset can power AC motors, air conditioners, AC/DC converters and other loads. How much load*
Note also that air density decreases as altitude in­creases, causing rated genset engine power to de­crease—approximately 3.5 percent each increase of 1000 feet (305 m) above the maximum elevation at which the engine can maintain rated power (Table 2). It may be necessary to run fewer loads
at higher altitudes.
De-rating for temperature usually is not necessary because the engine can maintain rated power in ambient air temperatures of up to 120° F (49° C).
TABLE 2. POWER VS. ALTITUDE
Genset Rated
7000 watts up to
3000 ft (914 m)
6755 watts @
4000 ft (1219 m)
6510 watts @
5000 ft (1524 m)
Subtract 245 watts
each additional 1000 ft (305 m)
1. – This table does not take into account the effect circuit breakers may have in limiting maximum genset power. Also, power decreases even though the altitude adjust knob is set correctly (Page 11).
7.0 kW
1
Genset Rated
6500 watts up to
3000 ft (914 m)
6272 watts @
4000 ft (1219 m)
6044 watts @
5000 ft (1524 m)
Subtract 228 watts
each additional 1000 ft (305 m)
6.5 kW
1
Genset Rated
5500 watts up to 5000 ft (1524 m)
5307 watts @
6000 ft (1829 m)
5114 watts @
7000 ft (2134 m)
Subtract 193 watts
each additional 1000 ft (305 m)
5.5 kW
1
* Load and genset power are measured in terms of watts (W) or kilowatts (kW), where 1 kilowatt (kW) = 1000 watts (W).
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