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1. 1 Look for mechanical damage and listen for unusual noises and vibrations 44 981 0183 Issue 11 2 2015 9 10 5 Maintenance 2 Check the generator set mounting bolts 3 Check to see that the generator set air inlet and outlet openings are not clogged with debris or blocked 4 Clean accumulated dust and dirt from the generator set Do not clean the generator set while it is running or still hot Protect the generator air cleaner control panel and electrical connections from water soap and cleaning solvents Replacing the Air Filter Element Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door or before working on the generator set use an insulated wrench to disconnect the negative cable from the battery to prevent accidental starting Engine components drains filters hoses etc can be hot and cause severe burns lacerations of the skin and liquid splash Use personal protective equipment when working with or around hazardous materials Examples of personal protective equipment include but are not limited to safety glasses protective gloves hard hats steel toed boots and protective clothing Refer to Section 5 1 on page 31 for scheduled air filter element replacement Under dusty operating conditions inspect and replace more often 1 Remove the front access cover 2 Unscrew the 2 wingnuts on the filter housing and pull away the air f
2. Check for signs of fuel and exhaust leaks and for damage to the exhaust system Replace access cover oco N Oo KR WD Turn off the air conditioner and other large appliances Priming the Fuel System The fuel system should be primed after the fuel filter is replaced or after the generator set runs out of fuel Position the control switch to STOP PRIME for 30 seconds The status indicator stays on while the pump is on 981 0183 Issue 11 23 4 Operation 2 2015 4 3 3 Starting the Generator Set 1 Visually inspect for fuel and exhaust leaks Do not start the generator set until any fuel or exhaust leak is repaired 2 Position and hold the control switch to START until the generator set starts The status indicator on the switch flashes while cranking It will stay on continuously when the generator set is running 3 If the generator set fails to start cranking will stop in approximately 30 seconds The status indicator will blink indicating an over crank fault Wait 5 seconds for the control to reset before trying again After 5 tries let the starter motor cool down for 30 seconds before trying again See Chapter 6 on page 49 if the generator set does not start after several tries The starter motor can be damaged by overheating Allow it to cool down for 30 seconds after every fifth crank 4 For top performance and engine life especially in colder weather let the engine warm up for 2 minutes before connect
3. Reliable generator set starting and starter service life depend upon adequate battery system capacity and maintenance Flames sparks or arcing at battery terminals light switches or other equipment can ignite battery gas causing severe personal injury Ventilate the battery area before working on or near a battery wear safety glasses and do not smoke Turn work light on or off away from the battery When performing maintenance procedures or when servicing a battery stop the generator set and disconnect the charger before disconnecting battery cables Using an insulated wrench disconnect the negative cable first and reconnect it last Refer to Section 5 1 on page 31 for the battery maintenance schedule and follow the battery manufacturer s instructions Have the battery charging system serviced if DC system voltage is consistently low or high Check the battery terminals for clean tight connections Loose or corroded connections have high electrical resistance which makes starting harder 1 Keep the battery case and terminals clean and dry 2 Keep the battery terminals tight 3 Remove battery cables with a battery terminal puller 4 Make sure which terminal is positive and which is negative before making battery connections always removing the negative cable first and reconnecting it last to reduce arcing Maintaining the Lubrication System Keep dirt water and other contaminants from enteri
4. 1 In North America 2 4 249utsidelNonlAmelllea cn oue nnn nnn nnn ner thu rnb n nnn nnn nnnm nen heure nnn 2 4 3 Information To Have Available ee ee ee ee ee ee memes S4 OVERVIEW x5 Ee Ge ele 3 1 Electromagnetic Compatibility Compliance ui esse enceinte ete Red Gee see ce 32 Information ot Seneratotsetlsers e TERES 3 3 Build Standards 3 4 Specifications 24 eDieseliModelsSpecilicatiolsieee RET 3 5 List of Acronyms 4 OPERATION erem 4 1 Key Component Locations 4 2 Control Panel 4 2 1g GeneratorssekeontroliPanelmeeee MR T 4 2 2 Remotexeontrolil2ameleet ae 4 3 Starting and Stopping the Generator Set EE ee ee ee Ee EE 4 3 1 Pre start Checks 4 3 2 Priming the Fuel Sy IMMER UC mL MEL 4 3 3 Starting the Generator Sel de e Raetia fein Dou ge Ludere diede des 4 3 4 Stopping the Generator Set ER rennen 4 4 Loading the Generator Set 981 0183 Issue 11 OO AA AA Co oo Donn a C Table of Contents 2 2015 4 4 1 Power Versus Altitude aa see Ee se Ee fee aden epe doe ER AE Ee NE as 26 4 5 Exercising tlie Generator S810 ae NE oe ne nc Meola Ke SEG d i dase De Ge se beg fud 27 4 6 Resetting Line Circuit Breakers ee ee ARE Be GR Re nien ee eke AR bee RE nan nnne ee De ee 27 4 7 Connecting Shore Powel ss Ee tete eene Re OER GE KERE Re ee cub n TRI een
5. 1400 73rd Ave NE Minneapolis MN 55432 USA Phone 1 763 574 5000 Toll free 1 800 888 6626 Fax 1 763 574 5298 Copyright 2015 Cummins Power Generation Inc All rights reserved Cummins Onan the C logo and Performance you rely on are trademarks of Cummins Inc
6. 5 13 Returning the Generator Set to Service Tee EE eee entente EER see Re 47 Os TROUBLES OG THING Ee alee ee ee cee rawness ER RR EG ee ee tenes 49 QV CIVIC UICE ee x ee 49 ZR av SS GI a EE Moo M c I Re cen m EI AA haces eR EE 49 6 2 1 Code 1 Engine Over Temperature inaron EER RA Ke Ee Ne EE hede Re RE 50 6 2 2 Code 2 Low Oil Pressure ER eU TU NUN ie 50 6 2 4 Code 3 Service Check EE EE EE UNUC HEURE 51 6 2 4 Code 4 OvepCrank c er e aan ae E rea 51 6 2 5 Code 12 Over Voltage Aren EE EE at E eer 51 6 2 0 Code 13 Under Voltage 5c SE EE Gesell We Ee 51 6 2 7 Gode 14 Over Frequency KEER RE RS ter ae o IO HR RE Ge Re qe ku bu DX Leon Dee ek denk 52 6 2 8 Code 15 Under Frequency eeu oH eee ta Ge Ge Ebr ce Pese bate ence dts 52 6 2 9 Code 19 Governor ACIUBtOF ss nere etse ipa Dep eg ng e Hole ge Reed Ge Ne gede 52 ii 981 0183 Issue 11 2 2015 Table of Contents 6 2 10 Code 22 Governor Actuator Overload RR ER ER RR AAR AA Re RA ede ee ee ee 6 2 11 Code 24 Faulty Temperature Sender ee es se Ge ke Gee ee Re be Gee ek 6 2 12 Code 27 Voltage Sense ELE EG ee Se Ge ee ee ee ke hee ute Fan ies maet gees 6 2 13 Code 29 High Battery Voltage 5 nere teneo AR eg Keel ee GEE 6 2 14 Code 32 Low Cranking Speed EE aa ae 6 2 15 Code 35 Gontfoli ardikalue EE N MM N 6 2 16 Codess6lEndinsistopped Ee ese n ER 6 2 17 Code 38 Over Current Field Overload EE esse ee EL ues 6 2 18 Code 41 Gen
7. Meter S O millimeter m Phase CSY VAC Volts Direct Current ooo l zE D e Z g kg h kW h S c a E ol o Zz i TU EAE o OD h h m i oO Volts Direct Current Watts Width O 981 0183 Issue 11 17 3 Overview 2 2015 This page is intentionally blank 18 981 0183 Issue 11 4 Operation 41 Key Component Locations The control panel and the components requiring attention during periodic maintenance see Section 5 1 on page 31 are located behind a removable access cover The figure below illustrates the components of a typical generator set There may be some variation depending on the generator set model To remove the access cover 1 Slide the cover latches up and pull the cover outward from the bottom 2 Lower the cover to remove it from the housing To replace the access cover 1 Position the tabs on the top of the cover into the openings on the housing 2 Slide the latches up and push the bottom of the cover in place 3 Hold the cover in place firmly and release the latches Operating the generator set with the access cover off can result in severe personal injury or equipment damage Hot components are exposed when the access cover is removed and generator set cooling air does not circulate properly Do not operate the generator set with the access cover removed 981 0183 Issue 11 19 4 Operation 2 2015 No Description
8. No Description AC Output and Remote Control Connections 8 Air in for cooling combustion and ventilation 2 Lifting Eye Cover 9 Access forcilandairfiters 6 Battery Connections 13 Access to Coolant PressureCap 7 Access below for oil and fuel filters and oil and coolant drain valves FIGURE 2 KEY COMPONENT LOCATIONS 20 981 0183 Issue 11 2 2015 4 Operation 4 2 Control Panel 4 2 1 Generator Set Control Panel Description 1 to Pressure Provides access to the coolant pressure cap Fill coolant here when refilling Cap the system E Oil Fill Cap and Dipstick Access Provides access to the oil fill cap and dipstick Check and fill engine oil here 3 Access to Coolant Recovery Provides access to the coolant recovery tank which allows space for coolant Tank expansion Replenish the normal loss of coolant here Coolant Level Sight Hole Use to view coolant level 5 Control Switch and Status Light The control switch is used to start and stop the generator set prime the engin fuel system and restore the fault code The status light is the LED in the control switch that blinks rapidly during preheat and cranking It stays on continuously after generator set is running If the generator set shuts down abnormally the indicator flashes a numerical code to indicate the cause of the shutdown see Chapter 6 on page 49 Line Circuit Breakers Protect the AC power leads connected to the generator set
9. flashes represents the 10s digit of the code After a brief pause the second digit of the code flashes representing the unit digit of the code This is followed by a long pause before repeating the flashing of the fault code For example Fault Code 36 appears as blink blink blink pause blink blink blink blink blink blink long pause repeat 2 Press STOP PRIME to stop flashing the fault code 981 0183 Issue 11 49 6 Troubleshooting 2 2015 6 2 1 6 2 2 50 4 flashes indicates that cranking exceeded 30 seconds without the engine starting Code 4 fault NOTICE Fault codes 33 and 34 are not assigned as fault codes Be careful of interpreting Fault Codes 3 and 4 as second level faults The fault code stops flashing after 5 minutes Pressing STOP PRIME 3 times within 5 seconds causes the fault code to resume flashing NOTICE The last fault logged continues to flash even though the condition that caused the shutdown has been corrected Code 1 Engine Over Temperature Indicates that during normal operation the engine coolant temperature exceeded 115 C 239 F for 10 seconds A Check Engine Coolant Level If coolant level is low add coolant as necessary and repair any leaks B Check for Blockages 1 If an air inlet or outlet opening on the bottom of the generator set is blocked remove objects 2 If dirt is fouling the radiation fins clean dirt out NOTICE Compressed air or washing wi
10. from overloads and equipment short circuits FIGURE 3 GENERATOR SET CONTROL PANEL 981 0183 Issue 11 21 4 Operation 2 2015 422 Remote Control Panel A remote control panel may be installed inside the vehicle Cummins Onan offers 3 remote control panel kits Control switch with status indicator Control switch with status indicator and an hour meter Control switch with status indicator and a DC voltmeter f N N Cummins Onan Cummins Onan Generator Cummins Onan Generator Generator Start Start Start Description Hold the switch in its Start position to crank and start the generator set Press the switch to the Stop position to stop the generator set Hold the switch in its 1 Control Switch Used to start and stop the generator set and to prime the engine fuel system Stop position to prime the fuel system Stays on continuously after generator set is running If the generator set shuts down abnormally the indicator flashes a numerical code to indicate the cause of the shutdown see Chapter 6 on page 49 Records the total running time of the generator set Cannot be reset 4 DC Voltmeter Displays voltage of the generator set If the voltage across the 12 VDC control system consistently stays above or below 12 VDC see Section 5 4 on page 33 Status Indicator LED in the control switch that blinks rapidly during preheat and cranking FIG
11. minutes NOTICE The Cummins Onan Warranty covers failures that are a direct result of defects in material or factory workmanship Generator damage service issues and or performance issues determined by Cummins Onan to be caused by bio diesel fuel blends not meeting the specifications outlined in the applicable Installation Operator and Service Manauls are not considered to be defects in material or workmanship and may affect your generator s warranty 5 6 3 Replacing the Fuel Filter Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door or before working on the generator set use an insulated wrench to disconnect the negative cable from the battery to prevent accidental starting 981 0183 Issue 11 39 5 Maintenance 2 2015 Engine components drains filters hoses etc can be hot and cause severe burns lacerations of the skin and liguid splash Use personal protective eguipment when working with or around hazardous materials Examples of personal protective eguipment include but are not limited to safety glasses protective gloves hard hats steel toed boots and protective clothing Diesel fuel is combustible and can cause severe personal injury or death Do not smoke near fuel tanks or fuel burning eguipment or in areas sharing ventilation with such eguipment Keep flames sparks pilot flames electrical arcs and switches and all other sources of ign
12. to obtain load in terms of kilowatts It is possible that the generator set circuit breaker may trip even though the sum of the steady state loads is less than the generator set power rating When a large motor or air conditioner is started last or cycles off and on the startup load is larger than its normal running load causing the load to temporarily exceed the generator set power rating Typical invisible charging loads During startup air conditioners need reserve power and can draw 3 4 times the typical 1400 2400 Watts needed to run Too much baseload can prevent air conditioners from starting Battery chargers are activated automatically and can draw a large load up to 3000 Watts Manage electrical loads by adjusting battery charge rates to best suit your needs Consult your inverter charger manual or manufacturer TABLE 5 TYPICAL APPLIANCE LOADS Appliance Average Required Wattage Amps Air Compressor hp 981 0183 Issue 11 25 4 Operation 2 2015 i Average Required Wattage Amps Microwave Convection Oven Radio Refrigerator Shaver Space Heater Stove VCR DVD Blu ray Player Washer Dryer Water Heater 250 1100 1 Battery chargers can be a source of significant load and will be on whether they are connected to shore power or the generator set Television 43 600 0 35 5 4 4 1 Power Versus Altitude The generator set is rated at standard barometric pressure humidity and air temp
13. 83 Issue 11 2 1 2 2 Introduction About this Manual This is the Operator Manual for the generator set or sets listed on the front cover Each operator should study this manual carefully and observe all of its instructions and safety precautions Keep this manual readily available for reference The information contained within the manual is based on information available at the time of printing In line with Cummins Power Generation policy of continuous development and improvement information may change at any time without notice The users should therefore make sure that before commencing any work they have the latest information available The latest version of this manual is available on QuickServe Online https qsol cummins com info index html The Operation Maintenance and Troubleshooting Chapters of this manual provide instructions necessary for operating the generator set and maintaining it at top performance The owner is responsible for performing maintenance in accordance with the information provided in Chapter 5 on page 31 This manual also includes generator set specifications and information on how to obtain service emissions regulation compliance and model identification See the Parts Manual for part identification numbers and required quantities Genuine Cummins Onan replacement parts are recommended for best results Related Literature Before any attempt is made to operate the generator set the operat
14. Cummins Onan osim Operator Manual Commercial Mobile Generator Set HDKBB Spec A H HDKBC Spec D H English Original Instructions 2 2015 981 0183 Issue 11 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 Conte nts 1 IMPORTANT SAFETY INSTRUGIONS mm a f EE EE EE 1 1 Overvi W a 1 2 Warning Caution and Not e Styles Used in This Manual eie ees see ee EE ee 1 3 General EIE Me MA ON EE a E e 1 4 Automatic Generator Start 1 5 Electrical Shock and Arc F eontiolibiazadsms Mame R M eee lash Can Cause Severe Personal Injury or Death 16 Generator voldgelsbeady ES Mii OM ORE TODOS T 1 7 Engine Exhaust Carbon Monoxide Is Deadly Es ee Re ee AA Ee AA ee TO pe el well amp oubi Lie mm M A OR N EE N ee 1 9 Battery Gas Is Explosive 1 10 Moving Parts Can Cause mol AIRES EE EE Re Severe Personal Injury or Death i e EE KEES RAK EA Ee Ne Aeneas Setwarming Labels ME AR EE EE EE Uc RUM 2 INTRODUCTION 2 1 About this Manual 2 2 Related Literature 2 3 Model Identification 2 5 l Nameplate IKOGatiOTi eeeeeeeeee eene tnn ne ener nnne rne Ee we Rd de ndn hann n 2 4 How to Obtain Service 2 4
15. Drive Coupling 1 Perform more often when operating in dusty conditions 2 Perform more often when operating in hot weather 3 Perform at least once a year 4 Perform every 75 hours when using high sulfur fuel 5 Perform at least once every two years 6 Perform at least once every five years 7 Must be performed by a qualified mechanic authorized Cummins Onan Service Representative 8 Perform every 250 hours when using B20 Bio diesel fuel 5 2 Consumable Parts The following is a list of consumables associated with the generator models covered in this manual TABLE 8 CONSUMABLE PARTS Fises iter 1 OmENgine o 5 O AF2614 Element Air Cleaner Primary A rats Element Air Cleaner Secondary 4 O ADMIDSIS FF5782 Fiter Fuel Skid Mou 3 iter Fut Rayoore O FSi06 iter Fuel Water Separator 2 Aoatwisewrao76 Fiter Water 2 5 3 General Inspection Check battery connections Section 5 4 on page 33 Check engine oil level Section 5 5 on page 33 1 2 3 Check engine coolant level Section 5 7 on page 41 4 Check fuel system Section 5 6 on page 37 32 981 0183 Issue 11 2 2015 9 4 9 9 5 5 1 5 Maintenance 5 Check exhaust system Section 5 8 on page 44 6 Check mechanical system Section 5 9 on page 44 Maintaining the Battery The generator set requires a 12 Volt battery to power its control and starting circuits
16. ESSSSIADD FIGURE 6 OIL FILL CAP AND DIPSTICK 5 5 2 Engine Oil Recommendations 34 Use API American Petroleum Institute classified engine oils according to the following guidelines n emissions regulated areas it is mandatory to use CF CF 4 CG 4 CH 4 or Cl 4 class oil with Low sulfur fuel sulfur content less that 500 ppm 0 0596 weight Ultra low sulfur fuel sulfur content less that 15 ppm 0 001596 weight n non emissions regulated areas use high sulfur fuel f sulfur content is between 500 ppm 0 05 weight and 5000 ppm 0 5 weight CF class oil is recommended f sulfur content is between 5000 ppm 0 596 weight and 10 000 ppm 1 096 weight use CF CF 4 CG 4 CH 4 or CI 4 class oil 981 0183 Issue 11 2 2015 5 Maintenance NOTICE If high sulfur fuel is used the oil and oil filter must be changed twice as often Look for the SAE Society of Automotive Engineers viscosity grade Choose the viscosity grade appropriate for the ambient temperatures expected until the next scheduled oil change Multigrade oils such as SAE 15W 40 are recommended for year round use TABLE 9 OIL VISCOSITY VS TEMPERATURE EXPECTED AMBIENT TEMPERATURES SAE VISCOSITY GRADE 0 C 32 F and higher 12 to 38 C 10 to 100 F 15W 40 OnaMax 18 to 27 C 0 to 80 F 10W 30 10W 40 5 5 3 Changing Engine Oil and Oil Filter Accidental or remote starting can cause severe personal injury
17. Indicates that the engine stopped without receiving a command from the control A Check Fuel Level 1 If fuel level is low fill the fuel tank NOTICE The generator set fuel pickup tube could be higher up in the fuel tank than the vehicle engine pickup 981 0183 Issue 11 53 6 Troubleshooting 2 2015 6 2 17 6 2 18 6 2 19 6 2 20 6 2 21 6 2 22 54 2 Prime the engine fuel system by positioning the control switch to STOP PRIME for 30 seconds B Check Air Filter Element Replace the air filter if dirty C Check for Mechanical Damage Code 38 Over Current Field Overload Indicates low power factor loads A Reduce Load Reduce the number of connected appliances especially air conditioners and battery chargers Review load management in Loading the Generator Set B Check Appliances for Proper Operation Have air conditioners and other appliances checked for proper operation Code 41 Generator Rotor Indicates control is unable to sense field or output voltage A Contact Local Dealer or Distributor Code 42 Processor Indicates that a microprocessor ROM error occurred during self test A Contact Local Dealer or Distributor Code 43 Processor Indicates that a microprocessor RAM error occurred during self test A Contact Local Dealer or Distributor Code 45 Speed Sense Indicates the control is unable to sense quadrature frequency A Contact Local Dealer or Distribu
18. O 14121 1 2007 Safety of machinery Risk assessment principles BS EN ISO 13857 2008 Safety of machinery Safety distances to prevent hazard zones being reached by upper and lower limbs BS EN 349 1993 A1 2008 Safety of machinery Minimum gaps to avoid crushing parts on the human body BS EN 547 1 1996 A1 2008 Safety of machinery Human body dimensions Part 1 Principles for determining the dimensions required for openings for whole body access into machinery BS EN 547 2 1996 A1 2008 Safety of machinery Human body dimensions Part 2 Principles for determining the dimensions required for access openings BS EN 547 3 1996 A1 2008 Safety of machinery Human body dimensions Part 3 Anthropomorphic data BS EN 60204 1 2006 A1 2009 Safety of machinery Electrical equipment of machines General requirements BS EN 614 1 2006 A1 2009 Safety of machinery Ergonomic design principles Terminology and general principles BS EN 953 1997 A1 2009 Safety of machinery Guards General requirements for the design and construction of fixed and movable guards BS EN ISO 12100 1 2003 A1 2009 Safety of machinery Basic concepts general principles for design Basic terminology methodology BS EN ISO 12100 2 2003 A1 2009 Safety of machinery Basic concepts general principles for design Technical principles BS EN ISO 13732 1 2008 Ergonomics of the thermal environment Methods for the assessment of human responses to contact with surfaces Hot surfa
19. PM 3600 RPM Merge AE FUEL CONSUMPTION ENGINE 2 Cylinder In Line Water Cooled Indirect Injection IDI 4 Stroke Cycle Diesel 67 mm 2 64 in S trok 68 mm 2 68 in Stroke 0 479 cm 29 23 in 13 73 MPa 1991 psi Cooling System Capacity DC SYSTEM Nominal Battery Voltage 12 Volts 12 Volts 475 Amps down to 17 C 0 F 475 Amps down to 17 C 0 F 650 Amps down to 29 C 20 650 Amps down to 29 C 20 e Minimum Battery Capacity CCA Cold Cranking Amps F F Battery Recharging Installer must provide Installer must provide Maximum Regulated Charging Current 20 Amps 20 Amps INSTALLATION Weight 181 kg 400 Ibs 981 0183 Issue 11 15 3 Overview 2 2015 p HDKBB HDKBC Size Lx W x H 876 mm x 581 2 mm x 514 4 mm 34 5 in x 22 9 in x 20 3 in 68 dB A 3 m 10 ft before installation at half load 3 5 List of Acronyms TABLE 3 ACRONYM DEFINITIONS Carbon Monoxide S O Carbon Monoxide PG SA DC EEPROM EMC D National Fire Protection Agency Light emitting Diode National Pipe Thread Power Take Off RAM Read Only Memoy S O Rom o O Read Only Memory Recreational Vehicle RV Recreational Vehicle o O RVIA RV Industry Association 16 981 0183 Issue 11 2 2015 3 Overview Society of Automotive Engineers Unified National Coarse US U S United States Water Column TABLE 4 ACRONYMS FOR UNITS OF MEASUREMENT m B A bs p
20. URE 4 REMOTE CONTROL PANELS 22 981 0183 Issue 11 2 2015 4 3 4 3 1 4 3 2 4 Operation Starting and Stopping the Generator Set Pre start Checks EXHAUST GAS IS DEADLY Exhaust gases contain carbon monoxide an odorless colorless gas Carbon monoxide is poisonous and can cause unconsciousness and death Symptoms of carbon monoxide poisoning include e Dizziness Muscular twitching Weakness and sleepiness Throbbing in temples Headache Inability to think clearly Nausea Vomiting IF YOU OR ANYONE ELSE EXPERIENCES ANY OF THESE SYMPTOMS GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist seek medical attention Shut down the generator set and do not operate it until it has been inspected and repaired Never occupy the vehicle with the generator set running unless the vehicle is equipped with a working carbon monoxide detector However primary protection against inhaling carbon monoxide is proper installation of the exhaust system and daily every 8 hours inspection for visible and audible exhaust system leaks Perform pre start checks before the first start of the day and after every 8 hours of operation See Chapter 5 if the vehicle has been in storage 1 Make sure all vehicle CO detectors are working properly Remove access cover Inspect the generator set as instructed in Chapter 5 Perform any maintenance due Section 5 1 on page 31 Keep a maintenance log Chapter 7 on page 57
21. ces BS EN ISO 13849 1 2008 Safety of machinery Safety related parts of control systems BS EN ISO 13850 2006 Safety of machinery Emergency stop Principles for design BS EN 61310 1 2008 Safety of machinery Indication marking and actuation Part 1 Requirements for visual auditory and tactile signals BS EN 61310 2 2008 Safety of machinery Indication marking and actuation Part 2 Requirements for marking BS EN 61000 6 1 2007 Electromagnetic compatibility EMC Generic standards Immunity standard for residential commercial and light industrial environments BS EN 61000 6 3 2007 Electromagnetic compatibility EMC Generic standards Emission standard for residential commercial and light industrial environments BS EN 1299 1997 A1 2008 Mechanical vibration and shock Vibration isolation of machines Information for the application of source isolation BS EN 1679 1 1998 Reciprocating internal combustion engines Safety Part 1 Compression ignition engines BS EN 12601 2001 Reciprocating internal combustion engine driven generating sets Safety 14 981 0183 Issue 11 2 2015 3 Overview 34 Specifications 3 4 1 Diesel Model Specifications TABLE 2 DIESEL MODEL SPECIFICATIONS NNENEENNMI HDKBB HDKBC GENERATOR SET CONTROL Integrated Microprocessor Based Engine and Generator Controller GENERATOR 2 Bearing 2 Pole Rotating Field Poly Vee Belt Drive Power 1 0 power factor 4800 Watts 5000 Watts 3000 R
22. del Identification Each generator set is provided with a nameplate that contains the model and serial numbers This information is needed when contacting Cummins Onan for parts service and product information Every character of the model number is significant The last character of the model number is the specification letter which is important for obtaining the correct parts Record the generator set model and serial numbers in the figure below to have them available if needed 10 981 0183 Issue 11 2 2015 2 Introduction 2 3 1 Nameplate Location IMPORTANT ENGINE INFORMATION CUMMINS POWER GENERATION 1400 73rd Ave NE Minneapolis MN 55432 Model No Made in USA S N PH AC Volts kW Amps Pf RPM Fuel Hz Bat Options Wiring Diagram Insulation NEMA Class Ambient RECORD NUMBERS HERE MODEL NUMBER SERIAL NUMBER FIGURE 1 NAMEPLATE LOCATION 2 4 How to Obtain Service For generator set parts service and literature contact the nearest authorized Cummins Onan distributor You may go to the Internet site www power cummins com for information on contacting our distributors worldwide 2 4 4 In North America Call 1 800 8886626 for the nearest Cummins Onan distributor in the United States or Canada Press 1 option 1 to be automatically connected If you are unable to contact a distributor using the automated service consult the Yellow Pages Typically our dis
23. dule below for normal periodic maintenance In hot and dusty environments some maintenance procedures should be performed more frequently as indicated by the footnotes in the schedule Keeping a log of maintenance performed and hours run will help keep generator set maintenance regular and provide a basis for supporting warranty claims see Chapter 7 on page 57 Maintenance replacement or repair of emission control devices and systems may be performed by any engine repair establishment or individual However warranty work must be completed by an authorized Cummins Onan Service Representative 5 1 1 Periodic Maintenance Schedule TABLE 7 PERIODIC MAINTENANCE SCHEDULE MAINTENANCE FREQUENCY MAINTENANCE PROCEDURE 2 Ba After First Every Every 150 Every 500 Every 1000 H y 50 Hours Month Hours Hours Hours ours General Inspection X Check Engine Oil Level Clean Engine Coolant Level Clean and Check Battery Check Coolant Anti Freeze Protection Flush Coolant System Replace Coolant Pressure Cap 981 0183 Issue 11 31 5 Maintenance 2 2015 MAINTENANCE FREQUENCY MAINTENANCE PROCEDURE EO by After First Every Every 150 Every 500 Every 1000 Hou 50 Hours Month Hours Hours Hours Replace Engine V Belt Coolant Pump Replace Coolant Hoses and Thermostat adam M Adjust Engine Vawetash 0 0 er es WR EET EP N SG Service Fuel Injectors Check Generator Bearings Drive Belt Belt Tensioner and
24. e often 3 Change engine oil more often 981 0183 Issue 11 2 2015 4 10 4 Operation Care of New or Rebuilt Engine Proper engine break in on a new generator set or on one with a rebuilt engine is essential for top engine performance and acceptable oil consumption Run the generator set at approximately 1 2 rated power for the first 2 hours and at 3 4 rated power for 2 more hours Proper engine oil and oil level are especially critical during break in because of the higher engine temperatures that can be expected Change the oil if the oil is not appropriate for the ambient temperatures during break in See Section 5 5 on page 33 for engine oil recommendations Check oil level twice a day or every 4 hours during the first 24 hours of operation and change the oil after the first 50 hours of operation 981 0183 Issue 11 29 4 Operation 2 2015 This page is intentionally blank 30 981 0183 Issue 11 5 Maintenance Only authorized and competent personnel who are familiar with the eguipment and its operation should carry out maintenance 5 1 Periodic Maintenance Accidental starting can cause severe personal injury or death Turn off the AGS whenever performing maintenance or service when the vehicle is stored between uses is awaiting service or is parked in a garage or other confined area Periodic maintenance is essential for top performance and long generator set life Use the Periodic Maintenance Sche
25. e properly grounded to cause the line circuit breakers to trip when short circuits occur Electrical appliances and tools must be used and maintained in accordance with their manufacturer s instructions and safety precautions Proper grounding is needed to reduce the risk of electric shock and fire Connecting Shore Power Interconnecting the generator set and shore power can lead to electrocution of utility line workers equipment damage and fire Use an approved switching device to prevent interconnections A vehicle with provisions for connecting utility power must have an approved device to keep the generator set and utility from being interconnected See the generator set Installation Manual for more information Operating in Weather Extremes Pay particular attention to the following items when operating the generator set in cold or hot weather 1 Make sure nothing blocks airflow to and from the generator set 2 Make sure engine oil viscosity is appropriate for the ambient temperature See Section 5 5 on page 33 for engine oil recommendations 3 Keep the generator set clean 4 Perform maintenance due See Section 5 1 on page 31 Operating in Dusty Environments Pay particular attention to the following items when operating the generator set in dusty environments 1 Do not let dirt and debris accumulate inside the generator set compartment Keep the generator set clean 2 Perform air filter element maintenance mor
26. en identified by some state and federal agencies to cause cancer or reproductive toxicity Do not breathe in or come into contact with exhaust gases Carbon monoxide is a poisonous gas Inhalation of this gas can cause severe personal injury or death Adhere to the following bullet points to make sure carbon monoxide is not being inhaled by occupants of the vehicle as well as others working on or around the generator set Inspect for exhaust leaks and test and confirm that all carbon monoxide detectors are working in accordance with the manufacturer s instructions or owner s manual prior to every startup and after every 8 hours of running Never occupy the vehicle while the generator set is running unless the vehicle is equipped with a working carbon monoxide detector Never operate the generator set when the vehicle is in a confined space such as a garage basement or building of any kind Make sure the exhaust system is installed in accordance with the generator set installation manual Never use engine cooling air for heating a working or living space compartment Carbon Monoxide CO is odorless colorless tasteless and non irritating It cannot be seen or smelled Exposure even to low levels of CO for a prolonged period can lead to asphyxiation lack of oxygen Mild effects of CO poisoning include headache dizziness drowsiness fatigue 981 0183 Issue 11 2 2015 1 Important Safety Instructions ch
27. erator ROT osaan A EE oo Re Re ee E ee ee ee ee ooo 62 9uodert2tiprocessoMee AA SS sos Rees S 02 20 Code 258 PAROLES YSIS01 MI ec ees ES OPA Corels 4s speed sense E 6 2 22 Code 48 Generator Field Sense ER RR ER RE Ee ek ee Re ee de dee ee ee ee ee 6 223 Godel54 verBime M R ee RERO 6 3 Symptom Based O39 Tes tatussindicatemNotwWorkingtss Seec re e meu tet eM E 5 3 2 stammgibaueries RumBown 299 cr EE are 6 3 3 S arten Engages Bisengages ees IU 6 3 4 No Power Generator Set Running Status Light ON ee ee AR ee T MAINTENANCE RECORD 981 0183 Issue 11 52 52 52 53 53 53 53 54 54 54 54 54 54 55 55 55 55 55 56 57 Table of Contents 2 2015 This page is intentionally blank iv 981 0183 Issue 11 1 Important Safety Instructions 1 1 Overview Thoroughly read the Operator Manual before operating the generator set It contains important instructions that should be followed during operation and maintenance Safe operation and top performance can only be achieved when equipment is properly operated and maintained The owners and operators of the generator set are solely responsible for its safe operation Generator set operation maintenance and installation must comply with all applicable local state and federal codes and regulations Electricity fuel exhaust moving parts and batteries present hazards which can result in severe personal injury or dea
28. erature reference ISO 3046 Low barometric pressure high altitude or high ambient temperature decreases engine power As ambient temperature increases rated generator set engine power decreases approximately 1 for every 5 5 C 10 F above 25 C 77 F Power decreases approximately 3 5 of rated power each 305 m 1000 ft of increase in elevation Refer to the table below for typical elevation generator set power calculations NOTICE It may be necessary to run fewer appliances at higher altitudes and ambient temperatures TABLE 6 POWER VERSUS ALTITUDE Elevation Above Mean Sea Level Maximum Generator Set Power Up to 152 m 500 ft 5000 Watts rated 762 m 2500 ft 4700 Watts 1676 m 5500 ft 4250 Watts Above 1676 m 5500 ft 4250 Watts minus 150 Watts each 305 m 1000 ft 1 Does not take into account the effect circuit breakers may have in limiting maximum power 26 981 0183 Issue 11 2 2015 4 5 4 6 4 Operation Exercising the Generator Set Exercise the generator set at least 2 hours each month if use is infrequent Run the generator set at approximately 1 2 rated power A single 2 hour exercise period is better than several shorter periods Exercising a generator set drives off moisture relubricates the engine replaces stale fuel in fuel lines and removes oxides from electrical contacts and generator slip rings The result is better starting longer engine life and greater reliab
29. est pain confusion More extreme symptoms include vomiting Seizure loss of consciousness 1 8 Diesel Fuel Is Combustible Diesel fuel is highly combustible Adhere to the following bullets to avoid igniting fuel and fuel vapors 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 all other sources of ignition well away from fuel lines and sources Fuel lines must be secured free of leaks and separated or shielded from electrical wiring Flammable vapor can cause a diesel engine to over speed and become difficult to stop resulting in possible fire or explosion and severe personnel injury or death Do not operate a diesel powered generator set where a flammable vapor environment can be created by fuel spill leak etc 1 9 Battery Gas Is Explosive Battery gas is highly explosive and may cause personal injury or death if ignited Take the proper precautions to avoid personal injury For personal safety wear appropriate PPE when working on or around the generator set To make sure battery gas is not ignited do not smoke around the generator set To reduce arcing when disconnecting or reconnecting battery cables always disconnect the negative battery cable first and reconnect it last 1 10 Moving Parts Can Cause Severe Personal Injury or Death Moving
30. ge ee Ke ee e Ee Re es 28 4 8 Operating in Weather Extremes EE E vis ken a EE 28 4 9 Operating in Dusty Basitoniiei MO ee NE 28 4 10 Care of News r buie R aaa EE 29 5 MAINTENSTEPES E WON iB ee af 31 5 1 Periode Maintenance rc aee ees EE TS 31 51 Periode Maintenance schedule c 3 Ame ae o oo 31 Emile N EA N OO EE EE 32 bres Generali speciem ees eee DU E EE 32 c MEITENE UNS Ben AT BA o aa oem 33 9 9 Maintaining the Lubrication Systerngas AM e rete iE 33 9 AO bee EE Eee EE Pn OL T LM UE 33 S oveninell ecommerntations es erc c ER EE cane 34 Soro Changing Erigine Oil andOil Filter EE EE M OR 35 olie diie Fuel System 39 EE N EN Ee Ee 37 Ou AR SE OE 37 5102 Fiel Recommendations ei es ske ee ek GE EE EE Gee AE Ge Ge Ge sd ee nnn Ge 38 96 3 Replacing ii MT GE ennemi tnmen kn kannaa ENEN mme ke uu cn 39 5 7 Maintaining the Comite Stem see Re Ee ek nene eren nnne tnn nennen nete nnne naa nena 41 Gh 0 Meel 5 0 sa Re ee ee 41 5 7 2 Coolant eve 42 MAR EERDER n nnnK nue innen 42 5 7 4 Draining and Cleaning Cooling System eene 42 nose Cooling SYSteM EE Ee nnne 44 28 Elias io AE n GE RES 44 5 9 Mecnanieal System ER cet eec A a Sets cM ees tete ME ee ee ee 44 540 Replacing the Ar Filler Elemente oerte etre eet tuu uei ee oe 45 Bd eleamngtressparieAImester eene N Rd ee EE e t Mee Ae E td 46 ost2 stonngdneGeneratonsels ER RE T AR eee lA E ereE 47
31. ges Indicates cranking voltage dips below 6 Volts 981 0183 Issue 11 55 6 Troubleshooting 2 2015 A Use Vehicle to Start Generator Set Run the vehicle propulsion engine while trying to start the generator set the battery charging alternator may be able to maintain starting voltage high enough to start the generator set B Check Battery 1 Clean and tighten the positive and negative battery cable connections at the battery and at the generator set 2 Recharge or replace the battery Refer to the battery manufacturer s recommendations C Change Battery Cables Increase battery cable size or run parallel cables 6 3 4 No Power Generator Set Running Status Light On Indicates line circuit breaker is OFF or tripped due to short circuit or overload A Check Line Circuit Breakers 1 Turn on or reset the line circuit breaker on the generator set 2 Turn on or reset the line circuit breaker on the main distribution panel in the vehicle 56 981 0183 Issue 11 T Maintenance Record TABLE 10 MAINTENANCE RECORD Record all and unscheduled maintenance service See Periodic Maintenance section DATE METER MAINTENANCE OR SERVICE PERFORMED READING Record the name address and phone number of your authorized Cummins Onan service center 981 0183 Issue 11 57 7 Maintenance Record 2 2015 This page is intentionally blank 58 981 0183 Issue 11 Cummins Onan Cummins Power Generation
32. gh as it will go and fill the system with coolant 4 When the coolant level reaches the fill opening start and operate the generator set for a few minutes and shut it down 5 Add more coolant if necessary 6 Secure the pressure cap 5 8 Exhaust System 1 Look and listen for exhaust system leaks while the generator set is running Shut down the generator set if a leak is found and have it repaired before operating 2 Look for openings or holes between the generator set compartment and vehicle cab or living space if the generator set engine sounds louder than usual Have all such openings or holes closed off and sealed to prevent exhaust gases from entering the vehicle 3 Replace dented bent or severely rusted sections of the tailpipe and make sure the tailpipe extends at least 25 4 mm 1 in beyond the perimeter of the vehicle 4 Park the vehicle so that generator set exhaust gases disperse away from the vehicle Barriers such as walls snow banks high grass brush and other vehicles can cause exhaust gases to accumulate in and around the vehicle 5 Do not operate power ventilators or exhaust fans while the vehicle is standing with the generator set running The ventilator or fan can draw exhaust gases into the vehicle 6 Check all CO monitors to assure proper operation 5 9 Mechanical System Compressed air pressure washers and steam cleaners can cause severe eye injury Always wear safety glasses when using
33. hazard Keep the generator set clean and repair any oil leaks promptly 2 981 0183 Issue 11 2 2015 1 Important Safety Instructions NOTICE Keep multi class ABC fire extinguishers handy Class A fires involve ordinary combustible materials such as wood and cloth Class B fires involve combustible and flammable liquid fuels and gaseous fuels Class C fires involve live electrical equipment Refer to NFPA No 10 in applicable region 1 4 Automatic Generator Start Control Hazards Accidental starting can cause severe personal injury or death Turn off the AGS whenever performing maintenance or service when the vehicle is stored between uses is awaiting service or is parked in a garage or other confined area Unexpected starting may occur if the generator set is equipped with an inverter charger or other Automatic Generator Start AGS control This may cause exposure to Unexpected generator starting Moving parts hazards Electric shock Exhaust carbon monoxide CO 1 5 Electrical Shock and Arc Flash Can Cause Severe Personal Injury or Death Electrical shocks and arc flashes can cause severe personal injury or death Adhere to the following guidelines Only qualified service personnel certified and authorized to work on power circuits should work on exposed energized power circuits All relevant service material must be available for any electrical work performed by certified service personnel Expos
34. ility Resetting Line Circuit Breakers If a generator set line circuit breaker or a circuit breaker in the power distribution panel trips either a short circuit has occurred or too many loads were connected NOTICE The generator set continues to run if its circuit breaker trips If a circuit breaker trips 1 Disconnect or turn off as many electrical loads as possible 2 Reset the circuit breaker 3 If the circuit breaker trips right away either the appliance or electrical load has a short or the circuit breaker is faulty Call a qualified electrician NOTICE It may be necessary to push the circuit breaker OFF to reset it and ON to reconnect the circuit 4 If the circuit breaker does not trip right away reconnect loads one by one making sure not to overload the generator set or cause a circuit breaker to trip If a circuit breaker trips right away when an appliance is connected that appliance or circuit probably has a short Generator Set Transfer Breaker Switch AC Shore Distribution Panel FIGURE 5 CIRCUIT BREAKER CONNECTIONS 981 0183 Issue 11 27 4 Operation 4 7 4 8 4 9 28 2 2015 Short circuits in electrical equipment can cause fire and electrical shock leading to severe personal injury or death Electrical equipment and its grounding must be maintained properly to protect against short circuits Electrical equipment must be used and maintained properly and b
35. ilter housing and air filter element 3 Wipe the air filter element sealing surfaces clean and install new air filter element into the housing and slide back into position 4 When installing the new air filter element turn the wingnuts hand tight 5 Replace the front access cover 981 0183 Issue 11 45 5 Maintenance 2 2015 No Description Air Filter Element Air Filter Housing FIGURE 12 AIR FILTER ELEMENT 5 11 Cleaning the Spark Arrester A hot muffler can cause severe burns Let the muffler cool down before removing or installing spark arrester cleanout plugs or screens Grass or brush in contact with the exhaust system can cause fire Do not park the vehicle in high grass or brush Refer to Section 5 1 on page 31 for scheduled spark arrester muffler cleaning meets U S Forest Service requirements Cleaning is required for maximum generator set performance 1 Remove the cleanout plug from the muffler 2 Start and load the generator set to near full power Let the generator set run for about 5 minutes to expel the soot in the muffler 3 Stop the generator set allow the muffler to cool and reinstall the plug 46 981 0183 Issue 11 2 2015 5 Maintenance FIGURE 13 SPARK ARRESTER CLEANOUT PLUG 5 12 Storing the Generator Set Proper storage is essential for preserving top generator set performance and reliability If the generator se
36. ilter if dirty C Check Exhaust System If exhaust system is blocked remove blockage Code 24 Faulty Temperature Sender Indicates the control sensed open sender A Contact Local Dealer or Distributor Code 27 Voltage Sense Indicates the control is unable to sense output voltage 981 0183 Issue 11 2 2015 6 Troubleshooting A Contact Local Dealer or Distributor 6 2 13 Code 29 High Battery Voltage Indicates that voltage across the battery system is greater than 19 Volts A Check Battery 1 Check battery bank connections and reconnect if necessary so that the 12 Volt batteries serving the generator set are connected in parallel 12 Volt rather than in series 24 Volt 2 Select a lower battery boost charge rate 6 2 14 Code 32 Low Cranking Speed Indicates that cranking speed is less than 180 RPM for more than 2 seconds A Check Battery 1 Clean and tighten the positive and negative battery cable connections at the battery and at the generator set 2 Recharge or replace the battery Refer to the battery manufacturer s recommendations B Replace Engine Oil Replace engine oil with oil of proper viscosity for the ambient temperature NOTICE High oil viscosity can slow down cranking speed 6 2 15 Code 35 Control Card Failure Indicates that a microprocessor EEPROM error occurred during self test A Contact Local Dealer or Distributor 6 2 16 Code 36 Engine Stopped
37. imit diesel fuel sulfur content to a maximum of 500 ppm 0 0596 weight Use Grade 2 D S500 or 2 D S15 diesel fuel When the ambient temperature is below 10 C 14 F use Grade 1 D S500 or 1 D 15 diesel fuel NOTICE Beginning in the year 2010 US EPA regulations limit diesel fuel sulfur content to a maximum of 15 ppm 0 0015 weight Do not use diesel fuel with a sulfur content greater than 10 000 ppm 1 0 weight Diesel fuel must meet the ASTM D975 standard for lubricity and pass a minimum load level of 3100 grams as measured by ASTM D6078 or maximum scar diameter of 0 45 mm as measured by ASTM D6079 or ISO 12156 1 5 6 2 1 Bio diesel Fuels B5 B20 B5 bio diesel fuel that meets industry specifications and quality is suitable for use with this generator set Before using bio diesel fuel blends above B5 and up to B20 the following conditions must be verified The vehicle propulsion engine is capable of using B20 when sharing the same fuel tank The OEM has installed a B20 compatible fuel line from the fuel tank to the generator set The OEM has installed a water separator in the fuel line just before the generator set 38 981 0183 Issue 11 2 2015 5 Maintenance For bio diesel blends above B5 and up to B20 Cummins Onan recommends that the fuel meet the specifications outlined in ASTM D7467 The bio diesel component of this fuel blend must meet ASTM D6751 or EN14214 and the petroleum diesel co
38. ing appliances 5 See Chapter 6 on page 49 if the generator set shuts down and the status indicator blinks indicating a fault 4 3 4 Stopping the Generator Set 1 Turn off the air conditioner and other large appliances 2 Run generator set for 2 minutes to allow for cool down 3 Press the control switch in its STOP position 4 4 Loading the Generator Set The power rating kW on the generator set nameplate determines how much electrical load motors fans heaters air conditioners and other appliances the generator set can power If the sum of the loads exceeds the generator set power rating the generator set will shut down or its line circuit breakers will trip NOTICE It may be necessary to run fewer appliances at the same time the sum of the loads must not be greater than the generator set power rating To avoid shutdowns due to generator set overload use the electrical ratings on the nameplates of equipment if available to compare the sum of the electrical loads that are likely to be used at the same time to the generator set power rating Refer to the table below for typical appliance ratings 24 981 0183 Issue 11 2 2015 4 Operation Appliance load and generator set power are measured in terms of Watts W or kilowatts KW where 1 kilowatt kW 1000 Watts W If the equipment is marked in Amps and Volts only multiply the Amps times the Volts to obtain the load in Watts Divide Watts by 1000
39. ipment damage Do not operate the generator set with the cover or service doors removed Coolants under pressure can cause severe scalding Do not open a radiator or heat exchanger pressure cap while the engine is running Let the engine cool down before removing the coolant pressure cap Turn the cap slowly and do not open it fully until the pressure has been relieved Hot metal parts can cause severe burns Avoid contact with the radiator turbo charger and exhaust system Starting fluids such as ether can cause explosion and generator set engine damage Do not use Ethylene glycol used as engine coolant is toxic to humans and animals Clean up coolant spills and dispose of used antifreeze in accordance with local environmental regulations Used engine oils have been identified by some state and federal agencies to cause cancer or reproductive toxicity Do not ingest breathe the fumes or contact used oil when checking or changing engine oil To prevent accidental or remote starting while working on the generator set disconnect the negative battery cable at the battery using an insulated wrench Unsecured or loose fasteners can cause equipment damage Make sure all fasteners are secure and properly torqued Oily rags and other material can cause fire and restrict cooling Keep the generator set drip pan and compartment clean Accumulated grease and oil can cause overheating and engine damage presenting a potential fire
40. ition well away Keep a multiclass fire extinguisher handy Refer to Section 5 1 on page 31 for scheduled fuel filter replacement Replace the fuel filter if the engine lacks power 1 Let engine cool down to prevent igniting any fuel that may be spilled when disconnecting the fuel filter 2 Remove the fuel line from the fuel filter Plug the fuel line to prevent fuel leakage and vapor accumulation 3 Disconnect the negative cable at the battery to prevent the engine from starting 4 Disconnect the two fittings at the fuel filter using two flarenut wrenches so as not to round the corners or stress the fittings 5 Remove the filter mounting nut and two 2 bracket mounting screws 6 Remove old fuel filter 7 Loosely secure the bracket to the new fuel filter 8 Loosely secure the new fuel filter and bracket to the base with the two mounting screws 9 Reconnect the fuel fittings making sure to thread them in by hand to prevent cross threading Tighten one flat past seating 10 Tighten the bracket and bracket mounting screws 11 Prime the engine for at least 1 minute to fill the new fuel filter Check for leaks as the generator set runs for several minutes 12 Tighten the connections if necessary 13 Connect the negative cable at the battery 14 Dispose of the old filter in accordance with local environmental regulations 40 981 0183 Issue 11 2 2015 5 Maintenance No Dese
41. ly wipe off the filter mounting surface Remove the gasket if it does not come off with the filter 6 Apply a film of oil to the new filter gasket and spin the new filter on by hand until the gasket just touches the mounting pad Tighten 1 2 to 3 4 of a turn Too little oil can cause severe engine damage Too much oil can cause high oil consumption Keep the oil level between the high and low beads or markings on the dipstick 7 Refill with 1 9 liters 2 qts of oil Check the oil level and add or drain oil as necessary 8 Screw the oil fill cap on securely 9 Reconnect the negative battery cable 10 Run the generator for a few minutes shut it down and recheck for proper oil level and leaks 11 Dispose of the used oil and oil filter in accordance with local environmental regulations Oooo ponme b OODAIDIOIEE FIGURE 7 OIL FILTER FRONT ACCESS 36 981 0183 Issue 11 2 2015 5 Maintenance INo Description Oil Drain Valve Oil Filter Oil Drain Hose IN EEN FIGURE 8 OIL DRAIN VALVE DRAIN HOSE AND FILTER BOTTOM ACCESS 5 6 Maintaining the Fuel System Keep dirt water and other contaminants from entering the fuel system and corroding or clogging fuel system components 5 6 1 Fuel System Diesel fuel leaks can lead to fire Do not operate the generator set if operation causes fuel to leak 1 Check for leaks at the hose tube and pipe fitting
42. mponent must meet ASTM D975 Blended bio diesel fuels should be pre blended and not made by customers Market applications contain properties that can affect engine operating characteristics lt is hightly recommended that use of these bio diesel fuel blends be avoided or exercised with extra care Use standard fuels in applications that experience seasonal usage storage for periods exceeding 90 days and extreme temperatures or humidity The following bio diesel fuel properties can affect engine performance Poor oxidation stability can accelerate fuel oxidation Fuel oxidation reduces generator performance This effect is accelerated at increased ambient temperatures Properties change at temperatures below 5 C 23 F Necessary precautions must be taken when operating the generator with bio diesel blends in low ambient temperatures Fuel heater Hose insulation Additional anti gel fuel additives Bio diesel fuel blends are an excellent medium for microbial growth Microbes cause fuel system corrosioin and premature filter plugging The effectiveness of all commerically available conventional anti microbial additives when used in bio diesel fuel is not known Consult your fuel and additive supplier for assistance If bio diesel fuel is used for seasonal applications stored more than 90 days the generator must be purged before storage by running the engine on pure diesel fuel meeting ASTM D975 for a minimum of 30
43. ne fuel system by positioning the control switch to STOP PRIME for 30 seconds E Replace Fuel Filter Code 12 Over Voltage Indicates the control is unable to maintain rated voltage A Contact Local Dealer or Distributor Code 13 Under Voltage Indicates the control is unable to maintain rated voltage 981 0183 Issue 11 51 6 Troubleshooting 2 2015 6 2 7 6 2 8 6 2 9 6 2 10 6 2 11 6 2 12 52 A Reduce Load Reduce the number of connected appliances especially air conditioners and battery chargers Review load management in Loading the Generator Set Code 14 Over Frequency Indicates the engine governor is unable to maintain rated frequency A Contact Local Dealer or Distributor Code 15 Under Frequency Indicates the engine governor is unable to maintain rated frequency A Reduce Load Reduce the number of connected appliances especially air conditioners and battery chargers Review load management in Loading the Generator Set Code 19 Governor Actuator Indicates the control sensed an open or shorted circuit A Contact Local Dealer or Distributor Code 22 Governor Actuator Overload Indicates the duration of operation is near full duty cycle beyond design limit A Reduce Load Reduce the number of connected appliances especially air conditioners and battery chargers Review load management in Loading the Generator Set B Check Air Filter Element Replace the air f
44. ng the lubrication system and corroding or clogging lubrication components Oil Level Park the vehicle on level ground and stop the generator set before checking engine oil level Engine components drains filters hoses etc can be hot and cause severe burns lacerations of the skin and liquid splash Use personal protective equipment when working with or around hazardous materials Examples of personal protective equipment include but are not limited to safety glasses protective gloves hard hats steel toed boots and protective clothing 981 0183 Issue 11 33 5 Maintenance 2 2015 Crankcase pressure can blow hot engine oil out the fill opening causing severe burns Always stop the generator set before removing the oil fill cap State and federal agencies have determined that contact with used engine oil can cause cancer or reproductive toxicity Avoid skin contact and breathing of vapors Use rubber gloves and wash exposed skin Too little oil can cause severe engine damage Too much oil can cause high oil consumption Keep the oil level between the high and low beads or markings on the dipstick Unscrew the oil fill cap dipstick Wipe off the dipstick and thread back into the fill neck Remove the dipstick to check oil level Add or drain oil as necessary Keep the oil level between the full and add marks oa fF OO N Insert the dipstick and screw the oil fill cap back on securely FULLEE
45. or death Before removing a panel or access door or before working on the generator set use an insulated wrench to disconnect the negative cable from the battery to prevent accidental starting Engine components drains filters hoses etc can be hot and cause severe burns lacerations of the skin and liquid splash Use personal protective equipment when working with or around hazardous materials Examples of personal protective equipment include but are not limited to safety glasses protective gloves hard hats steel toed boots and protective clothing State and federal agencies have determined that contact with used engine oil can cause cancer or reproductive toxicity Avoid skin contact and breathing of vapors Use rubber gloves and wash exposed skin Refer to Section 5 1 on page 31 for the engine oil change schedule Change oil more often in hot or dusty environments 1 Run the generator set under load until it is up to operating temperature stop it and disconnect the negative battery cable at the battery Crankcase pressure can blow hot engine oil out the fill opening causing severe burns Always stop the generator set before removing the oil fill cap 2 Remove the oil fill cap 3 Place a pan underneath the oil drain hole and open the drain valve Let all oil drain from the engine 981 0183 Issue 11 35 5 Maintenance 2 2015 4 Close the drain valve 5 Spin off the oil filter and thorough
46. or should take time to read all of the manuals supplied with the generator set and to familiarize themselves with the warnings and operating procedures A generator set must be operated and maintained properly if you are to expect safe and reliable operation The Operator manual includes a maintenance schedule and a troubleshooting guide The Health and Safety manual must be read in conjunction with this manual for the safe operation of the generator set e Health and Safety Manual 0908 01 10 The relevant manuals appropriate to your generator set are also available the documents below are in English Operator Manual for Commercial Mobile Generator Set HDKBB Spec A G and HDKBC Spec D G 0981 0183 Installation Manual for Commercial Mobile Generator Set HDKBC Spec A G and HDBKC Spec D G 0981 0650 Generator Set Service Manual for Commercial Mobile Generator Set HDKBB Spec A G and HDKBC Spec D G 0981 0535 981 0183 Issue 11 9 2 Introduction 2 2015 Recommended Spares List RSL for Commercial Mobile Generator Set HDKBB Spec A RSL 517 HDKBB Spec B G A043T385 and HDKBC Spec D G A043T640 Parts Manual for Commercial Mobile Generator Set HDKBB Spec A G and HDKBC Spec D G 0981 0273 Standard Repair Times BJ Family 0900 0621 Service Tool Manual A043D529 Failure Code Manual F1115C Warranty Manual A040W374 Global Commercial Warranty Statement A028U870 2 3 Mo
47. parts can cause severe personal injury or death and hot exhaust parts can cause severe burns Make sure all protective guards are properly in place before starting the generator set 981 0183 Issue 11 5 1 Important Safety Instructions 2 2015 Hot moving and electrically live parts can cause severe personal injury or death Keep children away from the generator set Hot moving and electrically live parts can cause severe personal injury or death Only trained and experienced personnel should make adjustments while the generator set is running Moving parts can catch on loose items such as clothing or jewelry Do not wear loose clothing or jewelry near moving parts such as PTO power take off shafts fans belts and pulleys Moving parts can entangle appendages such as fingers Keep the protective guards in place over fans belts pulleys and other moving parts and keep hands away from all moving parts 1 11 CARB 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 The California Air Resources Board CARB has requirements regarding modification amp repair of fuel system amp exhaust components 1 12 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
48. rals and corrosive chemicals A 50 50 mixture is recommended for all climates and is suitable for temperatures down to 37 C 34 F 5 7 4 Draining and Cleaning Cooling System Hot coolant spray can cause severe burns Let the engine cool before releasing the pressure cap or removing the drain plug 42 981 0183 Issue 11 2 2015 5 Maintenance Let the engine cool before removing the pressure cap 1 Relieve any remaining pressure by turning the cap slowly without pushing down 2 When the pressure has been relieved push down on the cap and turn it the rest of the way to withdraw it Ethylene glycol antifreeze is considered toxic Dispose of it according to local regulations for hazardous substances 3 Remove the bottom access cover 4 Open the radiator drain cock and drain the coolant into a suitable container Flush and clean the cooling system before refilling Radiator cleaning chemicals are available at local auto parts stores Follow cleaning and flushing instructions on the product No Description Ned Description Bottom Access Cover Radiator Drain Cock FIGURE 11 LOWER RADIATOR HOSE 981 0183 Issue 11 43 5 Maintenance 2 2015 5 7 5 Refilling Cooling System 1 Install the coolant drain plug using pipe thread sealant 2 Tighten it just enough to prevent leaks when the generator set is running and has warmed up 3 Pull the hose connected to the pressure cap assembly out as far and hi
49. ripion No scription 3 FiterMoundngNut iter Bracket o FIGURE 9 FUEL FILTER 5 7 Maintaining the Cooling System The engine cooling system is filled with a 50 50 mixture of ethylene glycol antifreeze and water when the generator set leaves the factory The mixture is suitable for temperatures down to 37 C 34 F 5 7 1 Cooling System Operating the generator set when coolant level is low can cause serious engine damage Check the engine coolant level and look for coolant leaks around the bottom of the generator set and on the ground below Minor leaks that can be replenished by daily additions of coolant to the recovery tank should be repaired by a qualified service technician as soon as possible Larger leaks are cause fo shutting down the generator set until it can be repaired 981 0183 Issue 11 41 5 Maintenance 2 2015 No Description Description Pressure Cap and System Fill Opening Fill Hose Coolant Recovery Tank Fill Cap Vent Hose 6 Recovery Tank Fluid Level FIGURE 10 COOLING SYSTEM 5 7 2 Coolant Level Check coolant level in the recovery tank before the first startup of each day and fill to the COLD mark if necessary 5 7 3 Coolant Recommendations Use the best quality ethylene glycol antifreeze available Antifreeze should be fully formulated with rust inhibitors and coolant stabilizers Mixed with fresh distilled water that is low in mine
50. s in the fuel supply system while the generator set is running and while it is stopped 2 Check flexible fuel hoses sections for cuts cracks abrasions and loose hose clamps 3 Make sure the fuel line does not rub against other parts of the vehicle or generator set 4 Replace worn or damaged fuel line parts before leaks occur 981 0183 Issue 11 37 5 Maintenance 2 2015 5 6 2 Fuel Recommendations Diesel fuel is combustible and can 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 multi class ABC fire extinguisher handy High quality diesel fuel is necessary for good performance and long engine life The specifications for the type and sulfur content ppm and weight percentage of the diesel fuel used must comply with all emissions regulations applicable in the areas where the generator set is to be operated Diesel fuels meeting ASTM D975 or EN 590 specifications are recommended Use Grade 1 D diesel fuel When the ambient temperature is below 10 C 14 F a minimum Cetane number of 45 is recommended When the ambient temperature is below 20 C 4 F or elevation is above 1500 m 5000 ft a minimum Cetane number of 50 is recommended Current US EPA regulations for non road engines l
51. sample signs shown below Caution or Warning Indicates a risk of personal injury Caution or Warning of Temperature Hazard Indicates a risk of personal injury from high temperature Caution or Warning of High Voltage Hazard Indicates a risk of personal injury from electric shock or electrocution 6 981 0183 Issue 11 2 2015 1 Important Safety Instructions Caution or Warning of Engine Coolant Pressure Hazard Indicates a risk of personal injury from hot pressurized engine coolant Caution or Warning Indicates to read Operator Manual for additional information Caution or Warning of No Step Indicates a risk of personal injury or eduipment damage from stepping on equipment Caution or Warning of Combustion or Explosion Hazard Indicates a risk of personal injury from explosion Caution or Warning of Belt and Rotating Part Hazard Indicates a risk of personal injury from entanglement in moving parts Caution or Warning of Chemical ingestion or burn Hazard Indicates a risk of personal injury or asphyxiation from poisonous fumes or toxic gases Caution or Warning of High Voltage or Current Source Hazard Indicates a risk of personal injury from electrical shock or electrocution Caution or Warning of Fan and Rotating Part Hazard Indicates a risk of personal injury from entanglement in moving parts 981 0183 Issue 11 7 1 Important Safety Instructions 2 2015 This page is intentionally blank 8 981 01
52. t is not going to be exercised on a regular basis and not be used for more than 120 days the generator set should be prepared for storage Carbon monoxide is deadly and can accumulate to dangerous levels in garages and other confined spaces Disable the automatic generator starting feature before storing the vehicle 1 Disable the automatic generator set starting feature 2 Change the engine oil and attach a tag indicating the oil grade viscosity 3 Disconnect the battery cables negative cable first from the starting battery and store the battery according to the battery manufacturer s recommendations 4 Position the line circuit breaker to OFF 5 13 Returning the Generator Set to Service 1 Check the oil tag on the generator set and change the oil if the viscosity indicated is not appropriate for the temperatures expected Reconnect the starting battery negative cable last Replace the air filter element Use new air filter element if it is dirty Inspect the generator set EE EE N Prime the generator set fuel system by positioning the control switch to STOP PRIME for 30 seconds The status indicator stays on while the pump is on 6 Start the generator set 7 Position the line circuit breaker to ON when the generator set is ready to power loads 981 0183 Issue 11 47 5 Maintenance 48 This page is intentionally blank 2 2015 981 0183 Issue 11 6 1 6 2 Troubleshooting Overvie
53. th Only trained and experienced personnel with knowledge of fuels electricity and machinery hazards should perform generator set installation or adjustment procedures or remove dismantle or dispose of the generator set 1 2 Warning Caution and Note Styles Used in This Manual The following safety styles and symbols found throughout this manual indicate potentially hazardous conditions to the operator service personnel or equipment DANGER Indicates a hazardous situation that if not avoided will result in death or serious injury Indicates a hazardous situation that if not avoided could result in death or serious injury Indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE Indicates information considered important but not hazard related e g messages relating to property damage 1 3 General Safety Precautions Operation of equipment is unsafe when mentally or physically fatigued Do not operate equipment in this condition or after consuming any alcohol or drug 981 0183 Issue 11 1 1 Important Safety Instructions 2 2015 Maintaining or installing a generator set can cause severe personal injury Wear personal protective eguipment such as safety glasses protective gloves hard hats steel toed boots and protective clothing when working on eguipment Running the generator set without the cover or service door can cause severe personal injury or equ
54. th water can be helpful in removing debris from heat exchangers Do not allow copious amounts of water to enter generator set components A pressure washer is NOT advised for cleaning heat exchangers C Reduce Load Reduce the number of connected appliances especially air conditioners and battery chargers Review load management in Loading the Generator Set Code 2 Low Oil Pressure Indicates that the low oil pressure cutoff switch did not open A Check Engine Oil Level 1 If the dipstick indicates oil is low add oil 2 If oil is above the full mark on dipstick drain excess oil 981 0183 Issue 11 2 2015 6 2 3 6 2 4 6 2 5 6 2 6 6 Troubleshooting Code 3 Service Check See second level fault code Code 4 Over Crank Indicates that cranking exceeded 30 seconds without engine starting A Check Fuel Level 1 If fuel level is low fill the fuel tank NOTICE The generator set fuel pickup tube could be higher up in the fuel tank than the vehicle engine pickup 2 Prime the engine fuel system by positioning the control switch to STOP PRIME for 30 seconds B Check Air Filter Element Replace the air filter if dirty C Replace Engine Oil Replace engine oil with oil of proper viscosity for the ambient temperature NOTICE High oil viscosity can slow down cranking speed D Check Fuel Fittings 1 Tighten any fuel fitting if there is a fuel or air leak 2 Reprime the engi
55. tor Code 48 Generator Field Sense Indicates the control is unable to sense field voltage 981 0183 Issue 11 2 2015 6 Troubleshooting A Contact Local Dealer or Distributor 6 2 23 Code 57 Over Prime Indicates that priming exceeded 3 minutes A Check Control Switch Check for and remove any object that may be holding either control switch remote or generator set in the STOP PRIME position 6 3 Symptom Based Diagnosis of some problems involves observing system operation 6 3 1 Status Indicator Not Working Indicates that there could be faulty connections or no battery voltage A Check Other Control Switch Try the generator set control switch if the remote control switch start doesn t work and vice versa B Check Battery 1 Clean and tighten the positive and negative battery cable connections at the battery and at the generator set 2 Recharge or replace the battery Refer to the battery manufacturer s recommendations 6 3 2 Starting Batteries Run Down Indicates problem with batteries connections charging system or parasitic loads A Check Battery 1 Clean and tighten the positive and negative battery cable connections at the battery and at the generator set 2 Recharge or replace the battery Refer to the battery manufacturer s recommendations B Battery Charging System Install or service a battery charging system in the vehicle 6 3 3 Starter Engages Disenga
56. tributors are listed under generators electric 2 4 2 Outside North America If you are outside North America refer to www cumminspower com and select Distributor Locator or send an email to ask powergen cummins com 2 4 3 Information To Have Available model number 981 0183 Issue 11 11 2 Introduction 2 2015 serial number date of purchase nature of the problem see Chapter 6 on page 49 12 981 0183 Issue 11 3 Overview 3 1 Electromagnetic Compatibility Compliance 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 When used in countries where compliance to the EMC directive is required This generator set has been evaluated for use in the residential commercial and light industrial environments 3 2 Information for Generator Set Users This generator set meets the requirements of California Air Resources Board CARB as stated on the nameplate As a user of this generator set please be aware that unauthorized modifications or replacement of fuel exhaust air intake or speed control system components that affect engine emissions are prohibited Unauthorized modification removal or replacement of the generator set label is prohibited Carefully review Operator Owner Installation and other manuals and information you receive
57. ure to energized power circuits with potentials of 50 VAC or 75 VDC or higher poses a significant risk of electrical shock and electrical arc flash Refer to standard NFPA 70E or equivalent safety standards in corresponding regions for details of the dangers involved and for safety requirements 1 6 Generator Voltage Is Deadly Improperly connected generator electrical output connections can cause equipment damage severe personal injury or death Electrical connections must be made by a trained and experienced electrician in accordance with applicable codes 981 0183 Issue 11 3 1 Important Safety Instructions 2 2015 1 7 Improper installations can cause equipment damage severe personal injury or death All installations must be conducted by trained and experienced personnel in accordance with the installation instructions and all applicable codes Back feed to shore power can cause electrocution and damage to equipment The generator set must not be connected to shore power or to any other source of electrical power An approved switching device must be used to prevent interconnections Live electrical equipment can cause electrocution 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 Engine Exhaust Carbon Monoxide Is Deadly Substances in exhaust gases have be
58. w Hot engine parts can cause severe burns Always allow the engine to cool down before performing any maintenance or service The following paragraphs provide fault code faults and symptom based faults If a problem is not resolved after taking the corrective actions suggested contact a local dealer or distributor See Section 2 4 on page 11 NOTICE Maintaining engine oil level keeping battery connections clean and tight watching the fuel gauge not overloading the generator set etc will prevent most shutdowns NOTICE When the generator set and vehicle engine share a common fuel tank the fuel dip tubes are usually arranged so that the generator set will run out of fuel first Marking the generator set empty point on the fuel gauge will make it easier to tell when to stop the generator set before running it out of fuel Fault Codes The generator set control contains extensive diagnostics to detect shutdown faults Following a fault shutdown the control indicates the fault code by flashing the numeric code on the status indicator in the control switch Determine the fault code as follows e 1 flash indicates a high engine coolant temperature 2 flashes indicates a low oil pressure fault Code 2 fault 3 flashes indicates a service fault Code 3 fault 1 Press STOP PRIME on the control switch once to have the 2 digit service fault code flash The 2 digit code consists of two sets of flashes The first set is of
59. with the generator set If unsure that the installation use maintenance or service of the generator set is authorized seek assistance from an approved Cummins Onan dealer Generator set users may use the following table as an aid in locating information related to the CARB requirements for emissions control TABLE 1 EMISSIONS CONTROL INFORMATION The emissions control warranty statement is located in the same Generator Set Warranty Information packet of information as this manual when the generator set is shipped from the ponunt I lEngmeVavelash Valve Lash See Section 3 4 on page 5 Section 3 4 on page 15 The engine is certified to operate on diesel fuel engingirugissouirements See Section 5 6 on page 37 for fuel recommendations Engine Lubricating Oil Requirements See Section 5 5 on page 33 for engine oil recommendations High idle speed This is a service procedure requiring trained pole Ie ate SUH personnel and proper tools See the Service Manual Ya The engine emissions control system consists of engine design and Engine Emission Control System precision manufacture IFI 3 3 Build Standards The generator set and its control system have been designed constructed and tested generally in accordance with the following Standards where applicable 981 0183 Issue 11 13 3 Overview 2 2015 Standard Title BS EN 1037 1995 a1 2008 Safety of machinery Prevention of unexpected start up BS EN IS

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