Operator Manual
Contents
1. OIL FILTER OIL DRAIN VALVE ERVICE AC CESS DOORS FIGURE 5 OIL CHECK FILL DRAIN AND FILTER AIR CLEANER MAINTENANCE See Table 3 for frequency of maintenance The air cleaner element must be handled carefully and must never have oil applied to it Before changing the filter element squeeze the dust boot to release any trapped dust Install the new filter element as follows 1 Unclip the cover Figure 6 and pull the filter element out gently to reduce the amount of dust dislodged Gently twist or move the ele ment side to side to disengage the seal and pull it out 2 Clean the sealing surface and inside of the out let tube to keep dust and dirt from entering the engine 3 Examine the old filter element for dust on the clean air side of the element This could indi cate leakage on the sealing surface Correct as necessary 4 Inspect the new element for damage Do not install a damaged element Insert the new ele ment into the housing applying pressure at the outer rim of the element and not on its flexible center and secure the cover SPARK ARRESTOR CLEANING See Table 3 for frequency of maintenance Clean ing is necessary to maintain good performance and meet Forest Service requirements To clean the spark arrestor remove the 12. FUEL RETURN CONNECTION FILTER FUEL SUPPLY CONNECTION FIGURE 10 FUEL SYSTEM 16 Priming the Fuel System Priming the Low Pressure Side The fuel lift pump is usually able to prime the low pressure side during cranking If the engine does not start after two tries 15 second crankings with a two minute rest between crankings jumper the fuel lift pump directly to the 12 VDC cranking battery and let the pump run for a few minutes to make sure the fuel lines fuel filter and injection pump have been purged of all air The air and fuel are returned to the fuel tank There are no bleed screws to open Note If the genset has been mounted at an elevated location on the vehicle the vehicle manufacture probably has provided an auxiliary fuel pump and solenoid shutoff valve which must also be energized during priming Check with the vehicle manufacturer if it is not clear as to how the auxiliary pump and sole noid should be energized Priming the High Pressure Side This procedure should only be performed by a diesel mechanic The high pressure oil spray from an injector line fitting can penetrate the skin lead ing to possible blood poisoning Wear safety glasses and keep your hands away from the spray Do not delay getting proper medical attention if oil spray
3. IMPORTANT ENGINE INFORMATION CUMMINS POWER GENERATION 1400 73rd Ave NE Minneapolis MN 55432 Model No i Made in U S A S N AC Volts Amps Fuel Options Wiring Diagram Insulation NEMA Class F Ambient 40 C THIS ENGINE MEETS 1995 1999 CALIFORNIA EMISSION REGULATIONS FOR ULGE ENGINES REFER TO OPERATOR S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS 99 2495 URC Da BRETHREN I N L Ki gi RECORD MODEL AND SERIAL NUMBERS HERE MODEL NUMBER SERIAL NUMBER FIGURE 1 TYPICAL NAMEPLATE Se R DOROTA A Osu BAHIA 44 OOO RadLD ENGINE OIL RECOMMENDATIONS Use premium quality motor oil Look for the API American Petroleum Institute classification and use Class CF 4 or CF or better oil Also look for the SAE Society of Automotive Engineers viscosity grade Referring to Figure 2 choose the viscosity grade appropriate for the range of ambient temper atures expected before the next scheduled oil change Multi grade oils such as SAE 15W 40 are recommended for year round use fesse eiel aa tae 32 OF 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 0 OC 34 29 23 18 12 7 4 4 10 16 21 27 32 38 43 48 FIGURE 2 SAE VISCOSITY GRADE vs AMBIENT TEMPERATURE BATTERIES The genset requires a
4. Figure 5 to catch oil that drips out and then spin off the oil filter Clean the filter mounting surface making sure to remove the old gasket apply oil to the new filter gasket and spin the filter on until the gasket just touches the mounting pad Then tighten an additional 3 4 turn Refilling Engine Oil See ENGINE OIL REC OMMENDATIONS p 5 for the oil to use and Specifications for the amount Refill with the proper amount of oil start the engine and check for leak age around the filter gasket Tighten the filter only enough to stop leakage Shut off the genset re check the oil level and add oil as necessary Secure the access door Too little oil can lead to severe en gine damage and too much oil to high oil con sumption and foaming which can cause engine shutdown Keep the oil level between FULL and ADD Disposing of Used Oil and Oil Filter Dispose of the used oil and oil filter according to local environ mental regulations OIL FILL
5. the dealer coordinator or service manager at the nearest Cummins Onan distributor for assistance Before calling for service have the following in formation available 1 Complete model number and serial number 2 Date of purchase 3 Nature of the problem Improper service or replacement of parts can result in severe personal injury death and or equipment damage Service personnel must be qualified to perform electrical and or mechanical service Maintenance Record Use the following table to keep a record of all periodic and unscheduled maintenance and service See Peri odic Maintenance HOUR METER MAINTENANCE OR SERVICE PERFORMED READING Record the name address and phone number of your authorized Cummins Onan service center 25 Cummins Onan Cummins Power Generation 1400 73rd Ave NE Minneapolis MN 55432 USA Phone 1 763 574 5000 Toll free 1 800 888 6626 Fax 1 763 574 5298 Email www cumminsonan com contact www cumminsonan com Cummins Onan the C logo and Performance you rely on are trademarks of Cummins Inc 2009 Cummins Power Generation Inc All rights reserved
6. 8 inch pipe plug in the bottom of the muffler and run the genset for five min utes at full load Replace the plug when the muffler has cooled down See Figure 7 BATTERIES See Table 3 for frequency of maintenance Sealed maintenance free batteries are recommended Fol low the manufacturer s instructions for battery care Keep the terminals clean and tight Arcing at battery terminals or in a light switch or other equipment flames and sparks can ignite battery gas causing severe personal injury Ventilate the battery compart ment before connecting or disconnecting bat tery cables Disconnect the negative cable first and reconnect it last Wear safety glasses Do not smoke Switch lights ON and Off away from the battery 13 Yen 5 FIGURE 6 AIR CLEANER ASSEMBLY FIGURE 7 SPARK ARRESTOR WITH CLEANOUT PLUG ENGINE COOLING SYSTEM See Table 3 for frequency of maintenance Cooling System Overview The engine is cooled by a pressurized closed loop liquid cooling system Coolant is pumped through passages in the engine block and head and is cooled in a genset mounted radiator The radiator fan is arranged to either pull or push air through the radiator Recommended Coolant Mixture Use the best quality ethylene or propylene glycol antifreeze solution available It should be fully for mulated with rust inhibitors and coolant stabilizers but not with stop leak additives Use fresh water that is
7. C ENGINE CRANKS BUT DOES NOT START There are hazards present in troubleshooting that can cause equipment damage se vere personal injury or death Troubleshooting must be performed by qualified persons who know about the hazards of fuel electricity and machinery Read Safety Precautions and observe all instructions and precautions in this manual Possible Cause Corrective Action 1 Engine not getting fuel Open any closed shutoff valve Check fuel level and refill as necessary Prime the fuel system p 11 Check for fuel air leaks at all fittings and tighten as neces sary Replace the fuel filter p 16 2 Low engine temperature a Plug in repair or install engine coolant and engine oil heat ers Replace the engine oil if it is not of the recommended viscos ity for the ambient temperature 3 Low cranking voltage a Clean and tighten or replace the positive and negative battery cable connectors and cables at the battery and the genset Recharge or replace the battery Specific gravity for a fully charged battery is approximately 1 260 at 80 F 27 C 4 Blocked air inlet Service as necessary 19 FAULT SHUTDOWN There are hazards present in troubleshooting that can cause equipment damage se vere personal injury or death Troubleshooting must be performed by qualified persons who know about the hazards of fuel electricity and machinery Read Safety Precautions and observe all instruct
8. Do not use engine cooling air to heat the ve hicle interior e Make sure there is ample fresh air when oper ating the genset in a confined area MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH e Do not wear loose clothing or jewelry near mov ing parts such as PTO shafts fans belts and pulleys e Keep hands away from moving parts e Keep guards in place over fans belts pulleys etc mobile 5 BATTERY GAS IS EXPLOSIVE e Wear safety glasses and do not smoke while servicing batteries e When disconnecting or reconnecting battery cables always disconnect the negative bat tery cable first and reconnect it last to reduce arcing DO NOT OPERATE IN FLAMMABLE AND EXPLOSIVE ENVIRONMENTS Flammable vapor can cause a diesel engine to overspeed and become difficult to stop resulting in possible fire explosion severe personal injury and death Do not operate a diesel powered genset where a flammable vapor environment can be created by fuel spill leak etc unless the gen set is equipped with an automatic safety device to block the air intake and stop the engine The owners and operators of the genset are solely re sponsible for operating the genset safely Contact your authorized Cummins Onan dealer or distribu tor for more information Introduction ABOUT THIS MANUAL This manual covers operation and maintenance of the model HDKAL and HDKAS generator sets gen sets Study this manual carefully a
9. and maintenance The following symbols in this Manual alert you to potential hazards to the operator service personnel and equipment alerts you to an immediate hazard which will result in severe personal injury or death alerts you to a hazard or unsafe practice which can result in severe personal in jury or death alerts you to a hazard or unsafe practice which can result in personal injury or equipment damage Electricity fuel exhaust moving parts and batteries present hazards which can result in severe person al injury or death GENERAL PRECAUTIONS e Keep ABC fire extinguishers handy e Make sure all fasteners are secure and torqued properly e 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 e Let the engine cool down before removing the coolant pressure cap or opening the coolant drain Hot coolant under pressure can spray out and cause severe burns e Before working on the genset disconnect the negative battery cable at the battery to pre vent starting e Use caution when making adjustments while the genset is running hot moving or electri Cally live parts can cause severe personal inju ry 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 Do not work on the
10. low in minerals and corrosive chemicals Dis tilled water is best Unless prohibited by shipping regulations gensets are shipped with the recom mended 50 50 mixture of water and ethylene glycol which is good for 34 F 37 C Adjusting V Belt Tension See Table 3 for frequency of maintenance The V belt Figure 8 drives the coolant pump and battery charging alternator The radiator fan is mounted on the crankshaft pulley and therefore is not driven by the belt Accidental starting can cause se vere personal injury or death Disconnect the negative cable s at the battery ies to pre vent the engine from starting 1 Disconnect the negative cable s at the bat tery ies to prevent the engine from starting and remove the top belt guard 2 Loosen the alternator pivot bolt first and then the adjusting bracket bolt on top 3 Tighten belt tension by pivoting the alternator outwards Hold tension by tightening the adjus ting bracket bolt Apply 20 pounds 10 kg as shown to the middle of the pulley span and measure belt deflection which should be 0 4 inch 10 mm Tighten the alternator bolts when tension is correct 4 Secure the belt guard and reconnect the bat tery cables negative last 14 ADJUSTING BRACK ET BOLT 0 4 INCH 10 MM DEFLECTION AT 20 LBS 10 KG FIGURE 8 ADJUSTING V BELT TENSION Pressure Cap See Table 3 for frequency of replacement Replace the pres
11. 12 volt battery to power its control and starting circuits Reliable genset start ing and starter service life depend upon adequate battery system capacity and maintenance See Specifications for battery requirements and Peri odic Maintenance for battery care GENSET MOUNTED CONTROL PANEL Figure 3 illustrates the genset control panel Start Stop Preheat Switch S1 Starts the genset when held at Start and stops the genset when mo mentarily touched to Stop Holding the switch at Stop causes the glow plugs to preheat the combus tions chambers DC Control Breaker Protects the control circuits from shorts to ground Can be used as an emer gency stop switch Reset with handle Hour Meter Indicates the number of hours the gen set has run It cannot be reset Fault Reset Breaker Trips and shuts down the genset when there is a low oil pressure or high cool ant temperature fault condition Reset by pushing in the red button REMOTE CONTROL PANELS Remote control panels with a control switch and en gine gauges are available e s ee ee s ee ee l ee e e o ee ee a p ee ee r t SEE MANUAL FOR PREHEAT INSTRUCTION PUSH STOP 10 PREHEAT 20 SEC MAX PTT DC U F ON Control Lee pe pele es ed Brkr l o o o o TO OTAL HOURS QUARTZ FIGURE 3 GENSET CONTROL PANEL Operation AWARNING EXHAUST G
12. 73 L Starting System Remote 12 volt Generator Design Brush type Drip proof Construction Bearing Double Sealed Prelubricated Ball Bearing S Insulation System Rise Class F per NEMA Cooling Direct Drive Centrifugal Blower Detail MGI 1 65 and BS 2757 Insulating Varnish Conforms Damper Bar Improves Harmonics and Voltage to MIL 1 24092 Grade CB Class 155 C Waveforms Comm HDKAL HDKAS Only Exciter System Electronic Voltage Regulator GenSet Regulation No Load to Rated Load from No Load to Full Load is 1 Voltage t2 5 Random Voltage Variation Under These Performance Frequency 2 5 i Battery Charging 12 Volt Battery Charging DC Alternator 30 amp output Sound Level 76 dB a 3 m rated load Random Frequency Variation for Constant Loads Conditions is 1 Maximum Operating Ambient Temperature Efficient Radiator Cooling System Permits Operation at Ambient Temperatures up to 120 F 49 C Accessories Required Accessory e USDA Forest Service Approved Spark Arrester Muffler Optional Accessories Battery 12 volt 475 Cold Cranking Amps at O F 17 8 C e Remote Gauge Package with Start Stop Preheat Switch Voltage Meter Water Temperature Gauge Oil Pressure Gauge Hour Meter Standard on Comm HDKAL HDKAS Remote Circuit Breaker Kits Remote Wiring Harness 10 or 30 ft Engine Block Heater Comm HDKAL HDKAS Only RACOR Fuel Water Separator Comm HDKAL HDKAS Only e Remote DC Gauge Kit Comm H
13. 8 No oad Operation Ty gieeerssuen ies cise errs aimee en eye ee pore nena 8 Genset Exercise E AMO ee eee eee eee ewe eee bere ree eee eee 9 Genset Storage WM eee eee eee eens 9 Returning Genset to Service eee eee eee 9 PERIODIC MAINTENANCE SCHEDULE 0 0 ccc eee eee 10 MAINTENANCE PROCEDURES 0 0 eee e ete t eee eee 11 Seley oso a a 11 Changing Oil and Oil Filter 2 eee eee eee eee ees 12 Air Cleaner Maintenance 000 cece eee eee eee eens 13 Spark Arrestor Cle 1 a a eee 13 BE STOS n 00 60 0 0 lt c ti ie 12 Engine Cooling System eee eee eee eee eens 14 FUGISYSIOM e tla eect so eR omer peta eemae nee er reera T SE 16 TROUBLESHOOTING e eerie nese eee oe ae ee eee Beene eee 18 Eine eT Tle ToT e ae nn wes ere tec chore ree acne Oca ev gy ee ae 18 Engine Granks But Does NotStart 2 2 0 3 herd ioe Bee ee ee 19 REESI ONA ee ork cen oe tec gcc Neen ester ee erie HEN Au ane Beng 19 Engimei lacks Power orUnstable 32 20 2c ee ee ee 20 No Outp tVoltager e e ea a a a a 20 SPEGIFIGATIONS an a a ee ene PIES ee oe OE Se 22 INFORMATION FOR CALIFORNIA GENSET USERS 5 05 23 HOW TO OB TAIN SERVIC E eet a a dah ree ae RD Ere ae det ha 24 MAINTENANCE RECORDA E ie arty ete ees aha ok 25 Safety Precautions Thoroughly read the OPERATOR S MANUAL before operating the genset Safe operation and top performance can be obtained only by prop er operation
14. AS IS DEADLY Engine exhaust contains carbon monoxide a poisonous odorless and colorless gas that can cause unconsciousness and death Symptoms of carbon monoxide poisoning include e Dizziness Throbbing in Temples e Nausea e Muscular Twitching e Headache e Vomiting e Weakness e Trouble Thinking Clearly e Sleepiness GET EVERYONE OUT INTO FRESH AIR IMMEDIATELY IF ANYONE EXPERIENCES ANY OF THESE SYMPTOMS Seek medical attention if symptoms persist Never sleep in the vehicle when the genset is running unless the vehicle has an operating carbon monoxide detector Look and listen for leaks along the entire run of the exhaust system every time you start up the genset and every eight hours if the genset is being run continuously Shut down the genset immediately if there is a leak and do not run it until the leak has been repaired The installation of the exhaust system must be in accordance with the genset Installation Manual PRE START CHECKS Perform General Inspection p 11 Check for fuel exhaust oil and coolant leaks every eight hours if the genset is being run continuously Check the Maintenance Record and perform any maintenance due Periodic Maintenance Sched ule Also see GENSET BREAK IN if the genset is new and RETURNING THE GENSET TO SERVI CE if the vehicle has been in storage STARTING 1 Disconnect all loads from the genset 2 Preheat Hold the control switch in the PRE HEAT position for the following nu
15. DKAL HDKAS Only Information for California Genset Users These gensets meet the requirements of Califor nia s Exhaust Emissions Standards for 1995 and later for Utility and Lawn and Garden Equipment Engines As a California user of these gensets please be aware that unauthorized modifications or replace ment of fuel exhaust air intake or speed control system components that affect engine emissions are prohibited Unauthorized modification removal or replacement of the genset label is prohibited You should carefully review Operator Owner Installation and other manuals and information you receive with your genset If you are unsure that the installation use maintenance or service of your genset is authorized you should seek assistance from an authorized dealer California genset users may use Table 4 as an aid in locating information related to the California Air Re sources Board requirements for emissions control TABLE 4 EMISSIONS CONTROL INFORMATION The California emissions control warranty statement is located in Genset Warranty Information the same packet of information as this manual when the engine is shipped from the factory Engine Fuel Requirements Engine Lubricating Oil Requirements Engine Emission Control System The engine is certified to operate on diesel fuel See FUEL REC OMMENDATIONS See ENGINE OIL RECOMMENDATIONS The engine emission control system consists of engine design
16. Every Month Every 2 Every PROCEDURE 8Hrs 50Hrs Years 5 years Inspect Genset Check Oil Level 9 Check Coolant Level iia SE ES 9 P a 9 e Check Fuel Level Clean Spark Arrestor x Clean Air Cleaner Dust Boot x5 Check Battery Check V Belt Tension Drain Water in Fuel Change Engine Oil and Oil Filter E L L Change Fuel Filter Change Air Cleaner Element Change Coolant a Adjust Valve Lash m Replace Pressure Cap E a x6 P k k k k k k l k l k l k l k l k l k l k Lisi slelal s lalsielelel a ee ee L ee es a a a aes ee E a ee ie i a Es ee ES Sees Replace Generator Bearing 1 Check for oil fuel coolant and exhaust system leaks 2 See battery manufacturer s recommendations 3 Check for slippage 4 Drain about one cup to remove water and sediment 5 Perform more often in dusty conditions 6 Must be performed by an authorized Cummins Onan dealer 10 Maintenance Procedures GENERAL INSPECTION Perform these checks and inspections every time the genset is started or every eight hours if the gen set is being run continuously Oil Level Check Crankcase pressure can blow out hot oil and cause severe burns Stop the engine before checking the oil level or opening the fill cap Shut down the genset to check engine oil level and wait a few minutes for the oil to drain down to the crankcase to get an accurate indication of oil level Keep t
17. Operator Manual Cummins Onan Performance you rely on Commercial Mobile Generator Set HDKAL HDKAS English 7 2009 981 0104 Issue 3 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 A WARNING A Do not use this genset on a boat Such use may violate U S Coast Guard regulations and can result in severe personal injury or death from fire electrocution or carbon monoxide poisoning Table of Contents SAFETY PRECAUTIONS 02 cdvncetaccnae eam Ra A R tes ae sdeede eins ean 2 INTRODUCTION x N Jai 54 nt a a Ee eto aO age area nt ASE Renee BES 4 About this Manual sae ee 4 Model Identification eee eee ae eee 4 Fuel Recommendations m e soe eee ee ee 4 Engine OiiRecommendationS22 5 0Fs ac ssee a Are 5 Tie Tie onek dies ooscpeecrneess 2 gfe gt gil ee eee o 5 Genset Mounted Control Panel 0 0 cece eee eee nee 5 Remote Gonttolinanclowse mas yee 5b a starrer 5 OPERATION 22 et ea E Se Ae te 9 TT 6 HPSEC aae TTE p co agc0 dod5ne ae 6 Starina stance E H T 6 SOP na teers E TT 7 EG GT eiS eE 7 Se h E 7 IGT GRIS OWEN Sas TTT 8 Resetting Line Circuit Breakers e e e eee bees eee eae ee 8 EngineiBrieak IM as s Sek Meeeueee see oee tener sass peers ee eecoaee trait teresa eee
18. eet 305 m that elevation increases above sea level See Table 2 for typical calcula tions It may be necessary to operate fewer ap pliances at higher altitudes TABLE 1 TYPICAL APPLIANCE LOADS Microwave Oven masser 1000600 aen 070 Eerie Brom 2050 Eeri Bene s20 Electric Drill Electric Broom Electric Blanket TABLE 2 MAXIMUM POWER VS ALTITUDE Elevation above Sea T Maximum Power Level a Owe at below 500 ft 152 m 7500 W rated at 2500 ft 762 m at 5500 ft 1676 m 7050 W 6375 W 6375 W minus 225 W every 1000 ft 305 m above 5500 ft 1676 m Appliance load and genset power are measured in terms of watt W or kilowatt kW where 1 kilowatt kW 1000 watt W CONNECTIONS TO UTILITY POWER A vehicle that has provisions for connection to utility power must be equipped with an approved transfer switch to keep the genset and utility power from be ing interconnected Backfeed to utility power can cause electrocution and damage to equipment Use an approved device to prevent the genset from be ing interconnected with utility power RESETTING LINE CIRCUIT BREAKERS If a circuit breaker in the main power distribution panel in the vehicle or on the genset Figure 4 trips there is either a short circuit or too much load Note that the genset will continue to run after a circuit breaker trips If a circuit breaker trips disconnect or turn off as many appliances as possible and res
19. engine Adit t High Idle Speed This is a service procedure requiring trained EIR Agyament personnel and proper tools See the Service Manual 23 and precision manufacture IFI How to Obtain Service When you need parts or service for your genset contact the nearest authorized Cummins Onan dealer or distributor Cummins Onan has factory trained representatives to handle your needs for genset parts and service To locate the nearest au thorized distributor 1 Check the North American Sales and Service Directory F 118 and the International Sales and Service Directory IN 1013 supplied with your genset These directories list authorized distributors who will assist you in locating the nearest authorized dealer 2 Consult the Yellow Pages Typically our distrib utors are listed under GENERATORS ELECTRIC ENGINES GASOLINE OR DIESEL or RECREATIONAL VEHICLES EQUIPMENT PARTS AND SERVICE 3 Call 1 800 888 0626 for the name and tele phone number of the nearest Cummins Onan distributor in the United States or Canada 24 This automated service utilizes touch tone phones only By calling this number you can also request a directory of authorized RV serv icing dealers RV Sales and Service Directory F 919 To get service contact the authorized dealer or dis tributor nearest you explain the problem and make an appointment If you have difficulty in arranging for service or resolving a problem please contact
20. et the circuit breaker Push the circuit breaker OFF to reset it and then ON to reconnect the circuit If the circuit breaker trips right away either the electrical dis tribution system has a short or the circuit breaker is faulty Call a qualified electrician If the circuit breaker does not trip reconnect a com bination of appliances that does not overload the genset or cause the circuit breaker to trip An ap pliance that causes a circuit breaker to trip right away probably has a short Electrical appliances must be properly grounded and in good working condition Electrical shock can cause severe personal injury or death Read and follow the appliance manufacturer s instructions and warnings ENGINE BREAK IN Change the oil and oil filter after the first 50 hours of operation See Maintenance Procedures NO LOAD OPERATION Keep no load operation to a minimum During no load operation combustion chamber tempera tures drop to the point where fuel does not burn completely causing slobbering and white smoke Always have some load connected when the gen set is run for long periods LINE CIRCUIT BREAKER RESET HANDLES FIGURE 4 GENSET MOUNTED LINE CIRCUIT BREAKERS GENSET EXERCISE If use is infrequent r
21. genset when mentally or physically fatigued or after consuming alcohol or drugs Carefully follow all applicable local state and federal codes GENERATOR VOLTAGE IS DEADLY Generator output connections must be made by a qualified electrician in accordance with ap plicable codes The genset must not be connected to the public utility or any other source of electrical power Connection could lead to electrocution of utility workers damage to equipment and fire An ap proved switching device must be used to pre vent interconnections Use caution when working on live electrical equipment Remove jewelry make sure cloth ing and shoes are dry and stand on a dry wood en platform on the ground or floor FUEL IS FLAMMABLE AND EXPLOSIVE e Keep flames cigarettes sparks pilot lights electrical arc producing equipment and switches and all other sources of ignition well away from areas where fuel fumes are present and areas sharing ventilation Fuel lines must be secured free of leaks and separated or shielded from electrical wiring Use approved non conductive flexible fuel hose for fuel connections at the genset ENGINE EXHAUST IS DEADLY e Learn the symptoms of carbon monoxide poi soning in this manual e Never sleep in the vehicle while the genset is running unless the vehicle has a working car bon monoxide detector e The exhaust system must be installed in accor dance with the genset Installation Manual e
22. he oil level between FULL and ADD on the dipstick Figure 5 See ENGINE OIL REC OMMENDATIONS p 5 for the oil to use Too little oil can lead to severe en gine damage and too much oil to high oil con sumption and foaming which can cause engine shutdown Keep the oil level between FULL and ADD Coolant Level Check Replenish the normal loss of coolant by keeping the level in the coolant recovery tank between COLD and HOT See COOLING SYSTEM for the recom mended mixture of antifreeze and if it is necessary to refill the system Exhaust Leaks Look and listen for exhaust system leaks while the genset is running Shut down the genset if a leak is found and have it repaired before operating the genset Look for openings or holes between the genset compartment and vehicle cab or living space if the genset engine sounds louder than usual Have all such openings or holes closed off or sealed to pre vent exhaust gases from entering the vehicle Replace dented bent or severely rusted sections of the tailpipe and make sure the tailpipe extends at least 1 inch 25 4 mm beyond the perimeter of the vehicle Park the vehicle so that the genset exhaust gases can disperse away from the vehicle Barriers such as walls snow banks high grass brush and other 11 vehicles can cause exhaust gases to accumulate in and around the vehicle To avoid drawing exhaust gases into the vehicle do not turn on power ventilators or exhaust fan
23. ions and precautions in this manual Possible Cause Corrective Action 1 Low engine oil pressure Check engine oil level repair any leaks and fill to the proper level p 12 2 High engine temperature a Check engine coolant level repair any leaks and fill to the proper level p 14 b Check V belt tension p 14 c Clean and service the cooling system as required to restore full cooling capacity p 14 ENGINE LACKS POWER OR UNSTABLE There are hazards present in troubleshooting that can cause equipment damage se vere personal injury or death Troubleshooting must be performed by qualified persons who know about the hazards of fuel electricity and machinery Read Safety Precautions and observe all instructions and precautions in this manual Possible Cause Corrective Action 1 Inadequate fuel delivery a Check for fuel air leaks at all fittings and tighten as neces sary b Replace the fuel filter p 16 2 Contaminated fuel Connect the fuel lift pump to a container of fuel of known quality Replace the contents of the fuel supply tank if there is a noticeable difference in performance 20 NO OUTPUT VOLTAGE There are hazards present in troubleshooting that can cause equipment damage se vere personal injury or death Troubleshooting must be performed by qualified persons who know about the hazards of fuel electricity and machinery Read Safety Precautions and observe all instructions and precautions in this
24. manual Possible Cause Corrective Action 1 Line circuit breaker Off Find out why the circuit breaker was turned Off make sure it is safe to reconnect power and then throw the circuit break er On 2 Line circuit breaker Tripped Shut down the genset and have service performed as neces sary to clear the short circuit or ground fault that caused trip ping Then Reset the circuit breaker and start the genset 21 Specifications Co ntrol e Unit Mounted Drip Proof Vibration Isolated e AC Controls S stem Console e Voltage Regulator See Generator Detail y e DC Controls 12 Volt System One or Two Circuit Breakers e Start Stop Preheat Switch e Sealed Remote Connector for Start Stop Preheat Switch Gauge Package e Manual Reset Fault Relay Indicating Engine Shutdown for High Coolant Temperature Low Oil Pressure Engine Design 4 Cycle Liquid cooled Diesel Engine Fuel Injection Pump Bosch K mini S Cylinders Inline Vertical 3 Combustion Chamber Spherical Detail Bore l Fuel Consumption No 2 Diesel Fuel gph lph HDKAL 3 07 in 78 mm No Load Half Load Full Load ca HDKAS 2 83 IN 72 MM HDKAL 0 24gph 0 49gph 0 85 gph roke 0 90 Iph 1 85 Iph 3 2 Iph HDKAL 3 09 in 78 4 mm 7 P 7 I 2 90 ingo mm HDKAS 0 23 gph 0 48 gph 0 8 gph Displacement HDKAL 68 53 in 1124 cm3 0 87 Iph 1 74Iph 3 03 Iph HDKAS 54 8 in 898 cm3 Compression Ratio 24 to 1 Lube Oil Capacity 5 39 qt 5 1 L Cooling System Capacity 1 25 gal 4
25. mber of sec onds depending on ambient temperature 10 seconds above 50 F 10 C 15 seconds 0 F to 50 F 17 to 10 C 20 seconds below 0 F 17 C Preheat times longer than 20 seconds can damage the glow plugs 3 Start Immediately after PREHEAT push the control switch to START and hold it there until the engine starts The starter will automatically disconnect as the engine starts up Do not crank for more than 15 seconds at a time Wait two minutes before trying again See Troubleshooting if the engine does not start on the second try Excessive cranking can over heat and damage the starter Do not crank for more than 15 seconds at a time and wait two minutes before trying again Connect the electrical loads after the genset has warmed up for a few minutes Check for fuel exhaust oil and coolant leaks and complete General Inspection p 11 Check the engine gauges regularly if pro vided while the genset is running e Oil Pressure Gauge Normal engine oil pressure is 28 64 psi 194 442 kPa at normal operating temperature e DC Voltmeter Normal DC system voltage is 12 5 15 volts depending on battery condition and state of charge s Coolant Temperature Gauge Normal engine coolant temperature is 160 195 F 71 91 C depending on load and ambient temperature STOPPING Before stopping let the genset cool down by run ning at no load for three to five minutes Then
26. nd observe all of its instructions and precautions Using the genset properly and maintaining it regularly will promote longer genset life better performance and safer operation Each operator should become thor oughly familiar with this manual Keep this manual in a convenient location for quick reference MODEL IDENTIFICATION When you call for service or parts have the genset model number and serial number ready Figure 1 For ready reference record these numbers in the boxes shown FUEL RECOMMENDATIONS Diesel fuel is combustible and can cause severe personal injury or death Do not smoke near fuel tanks or fuel burning equip ment 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 type ABC fire extinguisher handy Use clean fresh No 2 diesel fuel ASTM 2 D when the outdoor ambient temperature is above freezing and No 1 diesel fuel ASTM 1 D when below freezing The fuel should have a Cetane number of at least 45 for reliable starting Note Only low sulfer diesel or Ultra Low Sulfur Die sel ULSD fuel that meets the ASTM D975 or EN 590 standard for lubricity may be used with this engine The 1 to 2 percent less energy content of the fuel can have a slight effect on maximum engine power Note B5 Bio Diesel fuel that meets industry specifi cations and quality is suitable for use with this en gine
27. nnot be avoided FUEL SOLENOID To drain the filter remove the plug Figure 10 col lect the water and sediment about 1 2 cup 120 ml in a suitable container and dispose of properly Re install the plug securely Replacing the Filter Element See Table 3 for fre quency of maintenance Replace the filter sooner if the engine lacks power or surges 1 Drain the filter as explained above and spin off the element 2 Clean the contact surface of the base 3 Lubricate the new element and its gasket and fill the element with clean diesel fuel 4 Spin the new element onto the base and hand tighten 5 Start and run the genset and check for fuel leakage Tighten the filter only enough to stop leakage See Priming the Fuel System if the genset does not start FUEL INJECTION PUMP
28. ns of mechanical damage Check the engine gauges regularly if provided while the genset is running See Operation for nor mal gauge readings Keep the genset clean Do not clean the genset while it is running Protect the generator control panel and electrical connections from cleaning sol vents Remove the generator endbell cover and use compressed air to blow dust out of the generator and radiator core Wear safety glasses when using compressed air to prevent eye injury CHANGING OIL AND OIL FILTER State and federal agencies have de termined that contact with used engine oil can cause cancer or reproductive toxicity Take care to limit skin contact and breathing of vapors Use protective gloves and wash exposed skin See Table 3 for frequency of maintenance Crankcase pressure can blow out hot oil and cause severe burns Stop the engine before checking the oil level or opening the fill cap Draining Engine Oil To drain the engine oil run the engine until thoroughly warm and stop it Open either the side or bottom service access door to get at the oil drain valve and oil filter Figure 5 Drain OIL DIPSTICK BOTH SIDES the oil into a suitable container and close the valve when the oil has completely drained Changing Oil Filter To change the oil filter place a container under the oil filter
29. penetrates your skin 1 Loosen the high pressure fittings at the nozzles Use two wrenches to keep from twist ing the return fittings Use flare nut wrenches to keep from rounding the shoulders 2 Crank the genset until fuel appears at the loos ened fittings and then snug up each fitting The engine should start and run when the first fitting is snugged 3 Shut down the engine and torque the fittings to 19 25 lb ft 25 34 N m USE TWO FLARE NUT WRENCHES TO LOOSEN THESE FITTINGS TO BLEED HIGH PRESSURE INJECTOR LINES WEAR SAFETY GLASSES AND KEEP FINGERS OUT OF SPRAY DO NOT LOOSEN THESE FITTINGS FIGURE 11 PRIMING THE HIGH PRESSURE FUEL INJECTION SYSTEM 17 Troubleshooting The following troubleshooting tables are designed to help you think through genset problems The problem could be as simple as an empty fuel tank closed fuel shutoff valve or tripped circuit breaker If you fail to resolve the problem after taking the cor rective actions suggested see How to Obtain Ser vice Troubleshooting time can be saved if abnormal en gine gauge readings were noted before shutdown that is whether shutdown was due to low oil pres sure or to high engine temperature Note that shut down occurs when oil pressure falls below 14 psi 97 kPa or engine temperature reaches 222 F 106 C FAULT CODE BLINKING At fault shutdown the statu
30. s Filling a hot engine with cold water can cause cracks in the manifold head and block Follow the manufacturer s instructions for cleaning and flushing Filling the System Close all drain valves and se cure all hose clamps and fill the system through the fill opening holding the fill hose vertical The system will fill only as fast as the air can escape Start and run the engine for a minute to dislodge air pockets and shut it down Add as much coolant as neces sary to fill up the tube and secure the pressure cap Low coolant level can cause severe engine damage Make sure the system is full RAISE HOSE VERTICAL AND REMOVE CAP TO CHECK COOLANT LEVEL RECOVERY TANK LOCATED NEAR GENSET FIGURE 9 COOLING SYSTEM FUEL SYSTEM Fuel Handling Precautions Keep dirt water and other contaminants from enter ing the fuel system and damaging corroding or clogging fuel injection components The genset has a water separator type of fuel filter A primary source of water in fuel which can clog fuel passages by freezing and cause corrosion by form ing sulfuric acid with the sulfur in the fuel is the con densation of humid air on the walls of the fuel tank Keeping fuel tanks as full as possible reduces con densation by reducing the area on which condensa tion can take place Fuel Filter Draining Water and Sediment See Table 3 for frequency of maintenance Drain more often if fuel quality is poor or condensation ca
31. s indicator light will re peatedly blink sets of 1 2 3 or 4 blinks e One blink indicates shutdown due to high en gine coolant temperature e Two blinks indicate shutdown due to a loss of engine oil pressure e Three blinks indicate a service fault Press Stop once to cause the two digit second level shutdown code to blink Pressing Stop again will stop the blinking The two digit code con sists of 1 2 3 4 or 5 blinks a brief pause and then 1 to 9 blinks The first set of blinks repre sents the tens digit and the second set of blinks the units digit of the shutdown code number For example shutdown code No 36 appears as blink blink blink pause blink blink blink blink blink blink long pause repeat e Four blinks indicate that cranking time ex ceeded 35 seconds e Fault Code Nos 1 2 3 and 4 are first level faults Pay close attention to the pause sequence to avoid interpreting first level faults as second level Fault Codes Nos 11 22 33 or 44 e To avoid the possibility of anyone misinterpreting Code Nos 3 and 4 as Code Nos 33 and 44 the lat ter have not been assigned faults RESTORING FAULT CODE BLINKING The fault code stops blinking after five minutes Press Stop three times within three seconds to re store fault code blinking Note The last fault logged will blink even though the condition that caused the shutdown may have been corrected ENGINE DOES NOT CRANK There are hazard
32. s present in troubleshooting that can cause equipment damage se vere personal injury or death Troubleshooting must be performed by qualified persons who know about the hazards of fuel electricity and machinery Read Safety Precautions and observe all instructions and precautions in this manual Possible Cause Corrective Action 1 Faulty remote circuit Try starting at the genset control panel If the genset starts have the remote circuit repaired as necessary 2 Fault shutdown Perform maintenance or have service performed as neces sary to clear the fault condition Push the red button on the fault reset breaker on the genset mounted control panel to reset the control panel ENGINE DOES NOT CRANK There are hazards present in troubleshooting that can cause equipment damage se vere personal injury or death Troubleshooting must be performed by qualified persons who know about the hazards of fuel electricity and machinery Read Safety Precautions and observe all instructions and precautions in this manual Possible Cause Corrective Action 3 Tripped DC control breaker Reset the control breaker handle Have the genset serviced if it keeps tripping 4 Low cranking voltage a Clean and tighten or replace the positive and negative battery cable connectors and cables at the battery and the genset b Recharge or replace the battery Specific gravity for a fully charged battery is approximately 1 260 at 80 F 27
33. s when the genset is running and the vehicle is standing still EXHAUST GAS IS DEADLY Do not operate the genset if there is an exhaust leak or any danger of exhaust gases entering or being drawn into the vehicle Do not park the vehicle in high grass or brush Contact with the exhaust sys tem can cause a fire Fuel System Inspection Check for leaks at all fuel line fittings and gaskets Replace fuel hose that has been abraded or cut and install new hose in such a way that it will not become kinked rub against other parts or come in contact with sharp edges hot surfaces or wiring Fuel leaks can lead to fire Repair leaks immediately Do not run the genset if it causes fuel to leak Prime the fuel system if the genset ran out of fuel or a fuel filter was replaced See FUEL SYSTEM Battery Inspection Check for clean tight battery connections Loose and corroded connections make for hard starting because of high electrical resistance See BAT TERIES Arcing at battery terminals or in a light switch or other equipment flames and sparks can ignite battery gas causing severe personal injury Ventilate the battery compart ment before connecting or disconnecting bat tery cables Disconnect the negative cable first and reconnect it last Wear safety glasses Do not smoke Switch lights ON and Off away from the battery Mechanical Inspection Check for unusual noises and vibrations loose gen set mounts and sig
34. sure cap as recommended to maintain opti mal engine cooling and minimal coolant loss Coolant Recovery Tank Replenish the normal loss of coolant by keeping the level in the recovery tank between COLD and HOT Use the recommended mixture of antifreeze See Changing Coolant if it is necessary to fill the system Changing Coolant Hot coolant is under pressure and can cause severe burns when loosening the pressure cap Let the engine cool before loos ening the pressure cap Accidental starting can cause se vere personal injury or death Disconnect the negative cable s from the battery ies to pre vent the engine from starting Draining the System Let the engine cool down disconnect the negative cable s at the bat tery ies to prevent the engine from starting re move the system pressure cap and open the block CYLINDER BLOCK COOLANT DRAIN VALVE RADIATOR COOLANT DRAIN VALVE LOCATED UNDER THIS CORNER OF RADIATOR and radiator drain valves Figure 9 Collect used coolant in containers for proper disposal Ethylene glycol antifreeze is con sidered toxic Dispose of it according to local regulations for hazardous substances Cleaning and Flushing the System Use radiator cleaning chemicals to clean and flush the cooling system before new coolant is added Follow the manufacturer s instruction
35. touch the control switch momentarily to STOP Failure to let the engine cool down before stopping can lead to engine damage Let the genset run three to five minutes at no load before stopping POWERING APPLIANCES The genset can power AC motors air conditioners AC DC converters and other appliances How much appliance load can be serviced 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 rating To avoid overloading the genset and causing shut downs compare the sum of the loads of the ap pliances that are likely to be used at the same time to the power rating of the genset Use Table 1 or the ratings on the appliances themselves if so marked to obtain the individual appliance loads It may be necessary to run fewer appliances at the same time so that the sum of the loads is not greater than genset rating Note that the genset may shut down due to over load even though the sum of the loads is less than genset rating when a large motor or air conditioner is started last or cycles off and then on again The reason for this is that motor startup load is much larger than running load It may be necessary to run fewer appliances when large motors and air conditioners are cycling on and off Note that air density decreases as altitude in creases decreasing engine power Power de creases approximately 3 percent of rated power ev ery 1000 f
36. un the genset at approximately 1 2 rated power for an hour every week Exercising the genset results in better starting longer engine life and increased genset reliability by driving off moisture re lubricating the engine using up fuel before it becomes stale and removing oxides from electrical contacts One longer period during which the engine and generator warm up thoroughly is better than several shorter periods GENSET STORAGE If the genset will be inactive for more than 30 days and it is impractical to have someone exercise it prepare it for storage as follows 1 Run the genset until it has thoroughly warmed up and shut it down Crankcase pressure can blow out hot oil and cause severe burns Stop the engine before checking the oil level or opening the fill cap 2 Change the oil and oil filter while still warm and attach a tag to the dip stick indicating the oil vis cosity grade See CHANGING OIL AND OIL FILTER in Maintenance Procedures Arcing at battery terminals or in a light switch or other equipment flames and sparks can ignite battery gas causing severe personal injury Ventilate the battery compartment before connecting or discon necting battery cables Disconnect the negative cable first and reconnect it last Wear safety glasses Do_ not smoke Switch lights ON and Off away from the battery Disconnect the battery cables negative cables first and store the battery ies in accor dance
37. with the manufacturer s recommenda tions Hot coolant is under pressure and can cause severe burns when loosen ing the pressure cap Let the engine cool before loosening the pressure cap Check the coolant level and add coolant as necessary Test the coolant mixture if freezing temperatures are possible and change if nec essary See ENGINE COOLING SYSTEM in Maintenance Procedures Clean the genset and lightly oil parts that can rust RETURNING GENSET TO SERVICE Check the tag on the dipstick and change the oil if the viscosity is not suitable for present and anticipated ambient temperatures Reconnect the battery ies negative cables last and service as necessary in accordance with the manufacturer s instructions Prime the fuel system p 17 4 Perform PRE START CHECKS and start and run the genset according to STARTING Per form maintenance or service as required be fore placing the genset in service Periodic Maintenance Schedule Periodic maintenance is essential for top genset AWARNING Accidental starting can cause se performance and long service life Use Table 3 as a vere personal injury or death Disconnect the guide follow Maintenance Procedures and record negative cable s at the battery ies to pre maintenance performed in Maintenance Record vent starting while working on the genset TABLE 3 PERIODIC MAINTENANCE SCHEDULE FREQUENCY Every Every Every6 Every i Day
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