Operator Manual
Contents
1. s Do not operate the genset when the vehicle is parked in a confined space such as a garage e Disable the automatic genset starting feature AGS of an inverter charger or other automatic starting device before storing the vehicle or park ing it in a garage or other confined space e The exhaust system must be installed in accor dance with the genset Installation Manual e Engine cooling air must not be used for heating the vehicle GENERATOR VOLTAGE IS DEADLY e Disable the automatic genset starting feature AGS of an inverter charger or other automatic starting device before servicing the genset e Generator electrical output connections must be made by a trained and experienced electrician in accordance with applicable codes Interconnecting the generator set and shore power can lead to electrocution or util ity line workers equipment damage and fire Use an approved switching device to prevent inter connections e Use caution when working on live electrical equipment Remove jewelry make sure clothing and shoes are dry stand on a dry wooden plat form or rubber insulating mat and use tools with insulated handles DIESEL FUEL IS COMBUSTIBLE s Do not smoke or turn electrical switches ON or OFF where fuel fumes are present or in areas sharing ventilation with fuel tanks or equipment Keep flames sparks pilot lights arc producing equipment and all other sources of ignition well away e Fuel lines must b2. Mechanical vibration and shock Vibration isolation of machines BEN eee acc 008 Information for the application of source isolation Reciprocating internal combustion engines Safety Part 1 Compression ignition engines BS EN 12601 2001 Sean internal combustion engine driven generating sets BS EN 1679 1 1998 13 2 Operation EXHAUST GAS IS DEADLY All en gine exhaust contains carbon monoxide an odorless colorless poisonous gas that can cause unconsciousness and death Symp toms of carbon monoxide poisoning include e Dizziness Headache or Throbbing Temples e Weakness or Muscular Twitching e Sleepiness or Confusion e Nausea or Vomiting IF YOU EXPERIENCE ANY OF THESE SYMPTOMS GET INTO FRESH AIR IMMEDI ATELY If symptoms persist seek medical atten tion Shut down the genset and do not operate it until it has been inspected and repaired Never sleep in the vehicle while the genset is running unless the vehicle has a work ing carbon monoxide detector The exhaust sys tem must be installed in accordance with the gen set Installation Manual Make sure there is ample fresh air when operating the genset in a confined area PRE START CHECKS Before the first start of the day and after every eight hours of operation inspect the genset as instructed under CONDUCTING GENERAL INSPECTIONS Page 14 Keep a log of maintenance and the hours run and perform any maintenance that may be due See Returning the
3. engine cooling and for protection from hazardous moving parts and hot exhaust manifolds Do not run the genset with the main tenance access covers off Contact with hazard ous moving parts and hot exhaust manifolds can cause severe personal injury Fill the recovery tank with coolant mixture to the COLD mark Checking Coolant Level Check coolant level in the recovery tank Figure 12 before the first startup of each day and fill to the COLD mark if necessary COOLANT RECOVERY TANK FILL CAP RECOVERY TANK FLUID LEVEL FIGURE 12 ENGINE COOLING SYSTEM PRESSURE CAP AND RECOVERY TANK 28 This page is intentionally blank 29 4 Troubleshooting TABLE 4 TROUBLESHOOTING lists the shutdown codes in numerical order along with step by step cor rective actions If you are unable to resolve the prob lem after taking the corrective actions suggested contact an authorized Cummins Onan dealer See How to Obtain Service Page 40 First note the following s Maintaining engine oil and coolant levels keep ing battery connections clean and tight watching the fuel gauge not overloading the genset keeping the air inlet and outlet openings clear etc will prevent most shutdowns When the genset and vehicle engine share a common fuel tank the fuel dip tubes are usually arranged so that the genset will run out of fuel first Marking the genset empty point on the fuel gauge will make it easier to tell when to stop the
4. s normal ground clearance is not being reduced by sloping ground curbs logs or other objects Repark the ve hicle if necessary and or remove any objects block ing the air inlet or air outlet CHECKING ENGINE OIL LEVEL Park the vehicle on level ground and shut off the gen set before checking engine oil level State and federal agencies have de termined that contact with used engine oil can cause cancer or reproduce toxicity Avoid skin contact and breathing of vapors Use rubber gloves and wash exposed skin Crankcase pressure can blow hot en gine oil out the fill opening causing severe burns Always stop the genset before removing the oil fill plug or drain Too much oil can cause high oil con sumption Too little oil can cause severe engine damage Keep the oil level between the high and low beads on the dipstick 1 Pull the plug and dipstick out of the oil fill neck Figure 6 The plug may be difficult to pull straight out It is easier if you tilt the plug in its socket while pulling out Wipe off the dipstick and thread it back into the fill neck and seat the plug which snaps into its socket Remove the plug and dipstick again and check the oil level on the dip stick 2 Add or drain oil as necessary See ENGINE OIL RECOMMENDATIONS Page 9 Keep the oil level between the high and low beads on the end of the dipstick as shown It is not necessary to add oil between oil changes if the oil has not dropped more th
5. snow banks high grass and brush and other vehicles can cause exhaust gases to accumulate in and around the vehicle Do not operate power ventilators or exhaust fans while the vehicle is standing with the genset running The ventilator or fan can draw exhaust gases into the vehicle Fuel System Check for leaks at hose tube and pipe fittings in the fuel supply system while the genset is running and while it is stopped Check flexible fuel hose sections for cuts cracks and abrasions Make sure the fuel line is not rubbing against other parts Replace worn or damaged fuel line parts before leaks occur Diesel fuel leaks can lead to fire Do not operate the genset if operation causes fuel to leak Prime the fuel system if the genset ran out of fuel Battery Connections Check the battery terminals for clean tight connec tions Loose or corroded connections have high elec trical resistance which makes starting harder See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Page 24 Mechanical Visually inspect genset for mechanical damage For generator sets with a sound shield install service doors before running the generator set to listen for unusual noises Check the genset mounting bolts Check to see that the generator set air inlet and outlet Openings are not clogged with debris or blocked Keep the generator set compartment clean To prevent overheating and to reduce fouling with dust and debris make sure the genset
6. Change engine oil more often See PERIODIC MAINTENANCE SCHEDULE Page 20 4 Keep containers of engine oil that have been opened tightly closed to keep out dust BREAKING IN A NEW ENGINE Proper engine break in on a new genset or on one with a rebuilt engine is essential for top engine per formance and acceptable oil consumption Run the genset at approximately 1 2 rated power for the first 2 hours and then 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 tem peratures that can be expected Change the oil if not appropriate for the ambient temperatures during break in See ENGINE OIL RECOMMENDATIONS Page 9 Check oil level twice a day or every 4 hours during the first 24 hours of operation and change the oil and oil filter after the first 50 hours of operation EXERCISING THE GENSET Exercise the genset at least 2 hours each month if use is infrequent Run the genset at approximately 1 2 rated power A single two hour exercise period is better than several shorter periods Exercising a genset drives off moisture re lubricates the engine replaces stale fuel and removes oxides from electrical contacts The result is better starting more reliable operation and longer engine life STORING THE GENSET Proper storage is essential for preserving top genset performance and reliability when the genset cannot be exercised regularly and will be
7. Ex haust cold Oil Capacity with filter Cooling System Capacity DC SYSTEM Nominal Battery Voltage 12 volts 12 volts BII See 475 amps down to 0 F 17 C 475 amps down to 0 F 17 C S Amps 650 amps down to 20 F 29 C 650 amps down to 20 F 29 C Fuse F1 control start a REA 30 amp mini bayonet 30 amp mini bayonet WEIGHT 400 Ibs 181 kg SIZE L x W x H 34 5 x 22 9 x 20 3 in 876 x 581 2 x 514 4 mm SOUND LEVEL 68 dB A 10 ft 3m before installation and 1 2 load 1991 psi 13 73 mPa 1991 psi 13 73 mPa 0 0057 0 0073 inch 0 145 0 185 mm 0 0057 0 0073 inch 0 145 0 185 mm 2 quart 1 9 liter 2 quart 1 9 liter 3 0 quart 2 8 liter 3 0 quart 2 8 liter 38 This page is intentionally blank 39 6 How to Obtain Service When you call for service parts or product literature such as the Service Manual or Parts Catalog for your genset contact the nearest authorized Cum mins Onan distributor Cummins Onan has factory trained representatives to handle your requests for genset parts and service For information for con tacting our distributors worldwide go to internet site www cumminsonan com In North America Call 1 800 888 6626 to contact the nearest Cummins Onan distributor in the United States or Canada This automated service utilizes touch tone phones only Select OPTION 1 press 1 to be automatically connected to the dis
8. battery cable connections at the battery and at the genset 3 Recharge or replace the battery Refer to the battery manufacturer s recommendations THERE IS NO POWER WHEN THE GENSET IS RUNNING A line circuit breaker is OFF tripped or malfunctioning Corrective Action 1 Reset or turn ON the line circuit breaker on the genset Page 16 2 Reset or turn ON any other circuit breaker in the power supply system THE GENSET WILL NOT STOP RUNNING THE RUN LIGHT IS OFF The governor mechanism is stuck or binding Corrective Action Close the fuel supply valve if provided or squeeze off the fuel supply line and see an authorized Cummins Onan dealer 31 TABLE 4 TROUBLESHOOTING CONT Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions HIGH TEMPERATURE FAULT CODE NO 1 First level fault code engine coolant temperature exceeded 230 F 110 C Corrective Action 1 Check the engine coolant level and add coolant as necessary Page 28 2 Check for and remove any objects blocking the air inlet or outlet openings in the bottom and sides of the genset 3 Flush the coolant system to remove coolant passage fouling Page 27 LOW OIL PRESSURE FAULT CODE NO 2 First level fault code the low oil pressure cutoff sw
9. covers for proper engine cooling and for protection from hazardous moving parts and hot exhaust manifolds FILTER ELEMENT FILTER HOUSING FIGURE 9 REPLACING THE AIR FILTER ELEMENT 24 REPLACING FUEL FILTER See Table 3 for scheduled fuel filter replacement A dirty fuel filter may be the cause of a failure to start The fuel filter is accessible through the bottom access opening Figure 10 Diesel fuel is combustible and can cause severe personal injury or death Do not smoke near diesel fuel tanks or equipment Keep flames sparks pilot lights electrical switches arc producing equipment and all other sources of ignition well away Keep a type ABC fire extin guisher in the vehicle To prevent accidental or remote starting while working on the genset disconnect the negative battery cable at the battery Engine components drains filters hoses etc will be hot and can cause severe burns The use of protective gloves is recom mended Do not run the genset with the main tenance access covers off Contact with hazard ous moving parts and hot exhaust manifolds can cause severe personal injury 25 Removing the Fuel Filter Take care to spill as little fuel as possible when dis connecting the filter from the fuel line Close any shut off v
10. genset before running it out of fuel SHUTDOWN CODES The genset controller provides extensive diagnostics by causing the status indicator light on the Control Switch to blink in a coded fashion Following a fault shutdown the indicator light will repeatedly blink 1 2 3 or 4 blinks at a time e One blink indicates shut down due to high tem perature 30 e Two blinks indicate shutdown due to a loss of engine oil pressure Three blinks indicate a service fault Press Stop once to cause the two digit second level shut down code to blink Pressing Stop again will stop the blinking The two digit code consists of 1 2 3 4 or 5 blinks a brief pause and then 1 to 9 blinks The first set of blinks represents 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 jong pause repeat Four blinks indicate that cranking exceeded a preset time 20 seconds if ambient temperature is above 32 F 0 C 30 seconds if below with out starting Note shutdown code Nos 3 and 4 are first level faults Avoid interpreting them as second level shutdown code Nos 33 and 44 which have not been assigned as shutdown codes Restoring Shutdown Code Blinking The shut down code stops blinking after five minutes Press Stop three times within three seconds to restore blinking Note that the la
11. the loads exceeds genset power See Troubleshooting Page 30 To avoid overloading the genset and causing shut downs compare the sum of the loads that are likely to be used at the same time to the power rating of the genset It may be necessary to run fewer loads at the same time the sum of the loads must not be greater than genset rating Note that the genset may shut down due to overload when a large motor or air conditioner is started or cycles off and then on again even though the sum of the loads is less than genset rating The reason for this is that a motor s startup load is much larger than its running load It may be necessary to run fewer loads when large motors and air conditioners are cycling on and off Note also that maximum power decreases as altitude increases because air density decreases For every 1000 foot 305 m increase in elevation you can ex pect power to decrease approximately 3 percent Table 2 shows the results of typical calculations It may be necessary to run fewer loads at higher al titudes TABLE 2 POWER VS ALTITUDE Elevation above Sea A Maximum Power Level a u owe at below 500 ft 152 m 5000 W rated at 2500 762 M at 5500 ft 1676 m 4250 W 4250 W minus 150 W ev ery 1000 ft 305 m above 5500 ft 1676 m CONNECTING TO UTILITY POWER A vehicle with provisions for connecting utility power must have an approved device to keep the genset and utility from being interco
12. water and laundered before re use No special respiratory precautions are necessary in normal use DO NOT use as a solvent for removing dirt grease etc from skin STORAGE TRANSPORT Store and transport only in correctly marked con tainers Keep containers closed when not in use Keep cool out of sunlight and away from naked flames Electrical continuity is required between the transport and storage vessels during product trans fer Contain leak spill with sand earth or other suitable material and prevent entry of substance into drain age sewerage system water courses and land Dis pose of unwanted or absorbed substance through an authorized contractor to a licensed site Inform local and fire authorities should the product reach waterways drains etc EMERGENCY ACTION e Fire Extinguishing media Large fire Foam water fog Never use water jet Small fire foam dry powder AAAF CO sand earth Avoid making sparks Fire fighters to use self contained breathing apparatus Keep fire ex posed containers cool using water fog spray Prevent run off from entering waterway drains and drinking water supplies e Ingestion Do not induce vomiting Wash the mouth out with water and send to hospital immediately e Inhalation of vapour Remove from further exposure Obtain medical assistance immediately e Aspiration inhalation of liquid If following ingestion of gas oil vomiting occurs there is danger o
13. DC control system and battery is normal If the indicator consistently stays above or below the normal zone see MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Page 24 ACCESS TO COOLANT PRESSURE CAP OIL FILL CAP amp DIPSTICK ACCESS TO COOLANT RECOVERY TANK COOLANT LINE CIRCUIT CONTROL SWITCH LEVEL SIGHT BREAKERS amp STATUS LIGHT HOLE FIGURE 4 OPERATOR S CONSOLE BUILD STANDARDS The generator set and its control system have been designed constructed and tested generally in accordance with the following Standards where applicable refer to Table 1 TABLE 1 BUILD STANDARDS BS EN 1037 1995 A1 2008 Safety of machinery Prevent of unexpected start up BS EN ISO 14121 1 2007 Safety of machinery Risk assessment Principles Safety of machinery Safety distance to prevent hazard zones be BS EN ISO 13857 2008 ing reached by upper and lower limbs l Safety of machinery Minimum gaps to avoid crushing parts on BS EN 349 1993 a1 2008 the human body Safety of machinery Human body dimensions Part 1 Prin BS EN 547 1 1996 A1 2008 ciples of determining the dimensions required for openings for whole body access into machinery Safety of machinery Human body dimensions Part 2 Prin BS EN 547 2 1996 A1 2008 ciples for determining the dimensions required for access open ings j Safety of machinery Human body dimensions Part 3 Anthro BS EN 547 3 1996 A1 2008 pomorphic data S
14. Dispose of it according to local reg ulations for hazardous substances 27 RADIATOR DRAIN COCK FIGURE 11 LOWER RADIATOR HOSE Cleaning the Cooling System Clean and flush the cooling system with radiator cleaning chemicals available at auto parts stores Follow the instructions for cleaning and flushing that come with the cleaning solution Refilling the Cooling System Close the radiator drain cock Pull the hose con nected to the pressure cap assembly out as far and as high as it will go Figure 12 Remove the pressure cap and fill the system using a funnel inserted into the fill hose to prevent coolant from entering the vent hose and blocking the escape of air as the system fills The system will seem full when it actually is not if the air cannot escape through the vent hose If the vent hose does get blocked pinch the overflow hose and blow the vent hose clear Start and operate the genset for a few minutes while keeping the fill open ing elevated to promote venting of air from the cool ant Shut down the genset and add coolant as neces PRESSURE CAP AND SYSTEM FILL OPENING sary Secure the pressure cap and fill the recovery tank to the COLD mark Coolant trapped in the vent hose will prevent the system from filling to its capacity which can lead to serious engine damage Secure the maintenance access covers for proper
15. Genset to Service Page 18 if the vehicle has been in storage Before each start 1 Make sure all vehicle CO detectors are working 2 Check for signs of fuel and exhaust leaks and damage to the exhaust system 3 To prevent overheating and to reduce fouling with dust and debris make sure the genset s nor mal ground clearance is not being reduced by sloping ground curbs logs or other objects Re 14 park the vehicle if necessary and or remove any objects blocking the air inlet or air outlet 4 Turn off air conditioners and other large equip ment PRIMING THE FUEL SYSTEM The fuel system should be primed after replacing the fuel filter or running the genset out of fuel To prime the fuel system hold the control switch down in its Stop position for at least 1 minute starts in 2 sec onds STARTING THE GENSET Start the genset from the genset control panel or re mote control panel inside the vehicle Excessive cranking can overheat and damage the starter motor Do not crank for more than 30 seconds at a time Wait at least 2 minutes before trying again 1 Visually inspect for fuel exhaust and coolant leaks Do not start the genset if there is a fuel ex haust or coolant leak and have it repaired Push and hold the switch at START until the gen set starts The status indicator light on the switch flashes during preheat and cranking It will come on solid when the starter disconnects indicating that t
16. Operator Manual Cummins Onan Performance you rely on Commercial Mobile Generator Set HDKBB Spec A F HDKBC Spec D F English Original Instructions 2 2010 981 0183 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 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 ic ats Scares RT NEAR R ke ee etal Be elias 1 2 INTRODUCTION eee ce eae 8 About jh anual se eee ns o 8 Modelde nin tic ieee eee a a 8 MOIS OR yee eerie paseo enn R SEO 9 Electromagnetic compatibility Aane 9a Z Saeeeemee te eieiereenenere 9 Enginer EmiSSionsiCompliance m nn ih T 9 BUCISCCOMUMGKICAUO Kose come Ami a T 9 Engine Oil Recommeridations Re sees eeeenceateeeeta sete nesses ne 9 StaingsBanenes a Remi nron et a ren co aeee 10 mcl Ca o MMM etre rss rr ree rere 10 perator Console WO eee a eee K 11 Remote Control Panel eee ee ee eee ee bee eee eee 11 Bild Standards EAS nh a a a a E a e 12 2 OPERA TONETTE EE EEE ee 14 Press PMCS a aono RE 14 Priming the Fuel System 2 he ideas daim ere 14 Starting the Genset nee ee
17. THE HAZARDS OF CARBON MONOXIDE Engine driven generators can pro duce harmful level of carbon monoxide that can injury or kill you ONLY YOU CAN PROTECT YOURSELF FROM CO POISONING Watch constantly for people near the exhaust of the generator set while it is running Make sure exhaust cannot enter the living quar ters through a window vent or door Make sure all CO detectors or audible alarms are working properly Pay attention to the signs of CO poisoning Check the exhaust system for corrosion ob struction and leaks each time you start the gen erator set and every eight hours if you run it con tinuously SUBSTANCE HAZARDOUS TO HEALTH Generator sets use substances and emit and create wastes that can cause health risks Generator set op erators must use appropriate personal protective equipment such as clothing gloves protective glasses goggles and respiration equipment when exposed to fuel oil coolant wet batteries grease cleaning agents or other substances exposed to lungs eyes or skin use appropriate containers for transport storage and disposal of waste sub stances Follow local regulations for disposal and re cycling ANTIFREEZE FLEETGUARD ES COMPLEAT EG PREMIX This antifreeze is also know as an ethylene glycol based coolant summer coolant coolant additive It is purple coloured viscous liquid with a mild chemical odour is soluble in water and harmful It contains eth ylene glyc
18. ad to severe personal injury or death and to damage to equipment and property Ser vice personnel must be qualified to perform elec trical and mechanical service Unauthorized modifications or replacement of fuel exhaust air intake or speed control system components that affect engine emissions are prohibited by law in the State of California MODEL IDENTIFICATION Be ready to provide the genset model and serial num bers on the nameplate when contacting Cummins Onan for parts service or information Figure 1 illus trates the nameplate and its location The gray boxes illustrate where to look for the model and serial num bers Record these numbers in the figure that they are easy to find when needed Each character in these num bers is significant The last character of the model number is the specification letter which is important for obtaining the right parts Genuine Cummins Onan replacement parts are recommended for best results Refer to the genset Parts Catalog IMPORTANT ENGINE INFORMATION CUMMINS POWER GENERATION 1400 73rd Ave NE Minneapolis MN 55432 Made in U S A Model No SIN AC V kVA Amps Pf Fuel Hz Options Wiring Diagram Insulation NEMA Class Ambient RECORD NUMBERS HERE MODEL NUMBER SERIAL NUMBER FIGURE 1 TYPICAL NAMEPLATE NOISE Generator sets emit noise As noise level and time of exposure increase risk of
19. afety of machinery Electrical equipment of machines General BS EN 60204 1 2006 A1 2009 requirements i Safety of machinery Ergonomic design principles Terminology BS EN 614 1 2006 A1 2009 and general principles k Safety of machinery Guards General requirements for the de AUS nee sign and construction of fixed and movable guards E Safety of machinery Basic concepts general principles for de T EEE sign Basic terminology methodology l Safety of machinery Basic concepts general principles for de BS EN ISO 12100 2 2003 A1 2009 sign Technical principles Ergonomics of the thermal environment Methods for the assess Be iG ee EE ment of human responses to contact with surfaces Hot surfaces 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 l Safety of machinery Indication marking and actuation Part 1 BS EN 61810212008 Requirements for visual auditory and tactile signals Safety of machinery Indication marking and actuation Part 2 0000022008 Requirements for marking Electromagnetic compatibility EMC Generic standards Immu BS EN 61000 6 1 2007 nity standard for residential commercial and light industrial envi ronments 12 Electromagnetic compatibility EMC Generic standards Emis BS EN 61000 6 3 2007 sion standard for residential commercial and light industrial en vironments
20. alve in the fuel line Use paper towels to clean the two fuel line fittings and absorb any fuel that spills To remove the filter disconnect the two fittings at the filter Use two flarenut wrenches on each fitting so as not to round the corners or stress the fittings Then re move the filter mounting nut and two 2 bracket mounting screws Dispose of the fuel filter and paper towels according to local regulations Installing the Fuel Filter Secure the bracket loosely to the new filter The filter and its bracket fit properly only one way Loosely secure the filter and bracket to the base with the two mounting screws and re connect the fuel fit tings Take care not to cross thread the fuel fittings Thread them in by hand and tighten one flat past seat ing Finally tighten the bracket and bracket mounting screws Prime the fuel system by holding the control switch down inits Stop position for at least 1 minute Priming is necessary to fill the new filter with fuel Secure the maintenance access covers for proper engine cooling and for protection from hazardous moving parts and hot exhaust manifolds FILTER DISCONNECT FUEL FILTER MOUNTING LINE TO ENGINE NUT DISCONNECT FUEL LINE FROM PUMP FILTER BRACKET FILTER BRACKET MOUNTING SCREWS FIGURE 10 FUEL FILTER 26 CHANGING COOLANT Refer to Table 3 for scheduled maintenance The en gine cooling system is filled with a 50 50
21. an 1 3 of the way between the high and low beads Approximately 1 pint 0 4 li ter can be added if the oil level is at the lower bead 22 3 Secure the oil fill plug which snaps into its sock et OIL FILL PLUG AND DIPSTICK KEEP OIL LEVEL BE TWEEN THESE TWO BEADS ON DIPSTICK ue FIGURE 6 CHECKING ENGINE OIL LEVEL CHANGING ENGINE OIL AND FILTER Refer to Table 3 for scheduled engine oil change Change oil more often in hot and dusty environments State and federal agencies have de termined 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 To prevent accidental or remote starting while working on the genset disconnect the negative battery cable at the battery Do not run the genset with the main tenance access covers off Contact with hazard ous moving parts and hot exhaust manifolds can cause severe personal injury Engine components drains filters hoses etc will be hot and can cause severe burns The use of protective gloves is recom mended 1 Run the genset until warm and shut it off Pull the oil dipstick Page 22 out a couple of inches 50 mm so that the oil will drain faster Remove the front and bottom access covers Figures 7 and 8 and direct the end of the drain hose into a container Open the drain valve to drain all of the old oil 5 Close the drai
22. ance In hot and dusty envi ronments some maintenance procedures should be performed more frequently as indicated by the foot notes in the table Keeping a log of maintenance per formed and hours run Page 42 will help you keep genset maintenance regular and provide a basis for supporting warranty claims Maintenance replacement or repair of emission con trol devices and systems may be performed by any engine repair establishment or individual However warranty work must be completed by an authorized Cummins Onan dealer TABLE 3 PERIODIC MAINTENANCE SCHEDULE MAINTENANCE FREQUENCY MAINTENANCE OPERATION After First 50 Hours Clean and Check Battery ae EEE 21 22 Eu ON ER CE Co CE CY Flush Coolant System Sn ne Check Generator Bearings Drive Belt Belt Tensioner amp 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 LE I 4 Perform every 75 hours when using high sulfur fuel See ENGINE OIL RECOMMENDATIONS Page 9 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 dealer 20 CONDUCTING GENERAL INSPECTIONS Inspect the genset before the first start of the day and after every eight hours of operation Oil Level Check engine oil level Page 22 Engine Coolant Syst
23. are hazardous containing COXx NOx and SOx compounds The vapour is explosive High vapour concentrations can cause respiratory irritation dizziness nausea and loss of consciousness Excessive and prolonged exposure to the mist can cause chronic inflammatory reaction of the lungs and form of pulmonary fibrosis Avoid strong oxidising agents e g chlorates which may be use in agriculture Gas oil is slightly irritating to the skin and has a de fatting action Toxicity following single exposure to high level of gas oil is of low order Prolonged re peated skin contact may de fat the skin resulting in possible skin irritation and dermatitis In some cases warty cancerous growths have occurred PROTECTIVE MEASURES Ensure good ventilation and avoid heat sources Ob servance of good housekeeping rules will ensure general safety Do not smoke Avoid breathing mist When working on or testing injection equipment special care is required to avoid perforation of skin by high pressure fuel Use eye protection in the event of suspected high pressure leak Adopt a high standard of personal hygiene In the case of skin contact wash well with soap and water Use glove and overalls and eye protection goggles if there is a risk of splashing Use oil impervious gloves and avoid contamination inside the gloves If overalls become contaminated discontinue use and clean thoroughly Contaminated clothing should be re moved soaked with
24. cal assistance e Eyes Flush copiously with water or preferably eye wash solution for at least five minutes Seek medical advice e Skin Wash thoroughly with soap and water and seek medical attention if irritation develops Change clothing if necessary and wash before re use e Spillage Soak up using an absorbent material and dis pose of this as directed under Storage Transport Section 5 1 3 GAS OIL This product is also known as Red Diesel Fuel Oil and type A1 or A2 It can be pale red or a clear liquid with a characteristic mild odour It contains catalyti cally cracked oil petroleum distillates quinizarin and gas oil maker dye red The catalytically cracked oil and petroleum distillates are potentially hazardous constituents The substance has an initial boiling point of 180 C a flash point greater than 56 C and a vapour pressure less than 0 7mm Hg at 20 C and has negligible solu bility in water It is used as a fuel for off road diesel powered ve hicles and stationary engines and can be found in fuel tanks pipes and injection systems The sub stance should not be used for any other purpose with out contacting the manufacturer or supplier In stallers operators and maintainers are likely to en counter this substance HAZARDOUS REACTIONS This liquid is flammable Avoid smoking heat sources such as welding and naked flames sparks and static electricity build up Thermal de composition products
25. city and pass a minimum load level of 3100 grams as measured by ASTM D6078 or maximum scar diameter of 0 45 mm as mea sured by ASTM D6079 or ISO 12156 1 e B5 Bio Diesel fuel that meets industry specifi cations and quality is suitable for use with this genset ENGINE OIL RECOMMENDATIONS Oil Performance Class Use API American Petroleum Institute classified engine oils according to the following guidelines e Emissions Regulated Areas It is mandatory to use CF CF 4 CG 4 CH 4 or CI 4 class oil with low sulfur fuel sulfur content less than 500 ppm 0 05 weight or ultra low sulfur fuel sulfur content less than 15 ppm 0 0015 weight e Non Regulated Areas CF class oil is recom mended when using high sulfur fuel sulfur con tent between 500 ppm 0 05 weight and 5000 ppm 0 5 weight If CF 4 CG 4 CH 4 or CI 4 class oil is used the oil and oil filter must be changed twice as often as specified in the PE RIODIC MAINTENANCE SCHEDULE Page 20 s Non Regulated Areas Use CF CF 4 CG 4 CH 4 or CI 4 class oil when using high sulfur fuel sulfur content between 5000 ppm 0 5 weight and 10 000 ppm 1 0 weight The oil and oil filter must be changed twice as often as specified in the PERIODIC MAINTENANCE SCHEDULE Page 20 Oil Viscosity Look for the SAE Society of Automotive Engineers viscosity grade Referring to Figure 2 choose the vis cosity grade appropriate for the ambient temper atures expected unt
26. de in the control switch which blinks rapidly during preheat and crank ing After the genset starts up this light stays on con tinuously indicating that the genset is running and that the starter has disconnected If the genset shuts down this light blinks in coded fashion to indicate the nature of the fault shutdown see Troubleshooting Page 30 Rapid blinking before cranking starts indicates that the glow plugs are preheating the combustion cham bers The controller automatically varies the time based on engine temperature Line Circuit Breakers The line circuit breakers protect the AC power leads connected to the genset Coolant Pressure Cap The coolant pressure cap is under the access plate Fill coolant here when refilling the system Coolant Recovery Tank The recovery tank is mounted inside the genset and provides for coolant expansion The coolant level is visible through the sight hole on the front of the gen set The fill cap is under the access cover Replenish the normal loss of coolant here Oil Fill Cap and Dipstick Check and fill engine oil REMOTE CONTROL PANEL The vehicle probably has a control panel inside the vehicle for remote control of the genset Cummins Onan offers three remote control kits as follows e Remote switch status lamp e Remote switch status lamp and hour meter e Remote switch status lamp and DC voltmeter The DC voltmeter indicates whether voltage across the 12 V
27. e secured free of leaks and separated or shielded from electrical wiring MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH e Disable the automatic genset starting feature AGS of an inverter charger or other automatic starting device before servicing the genset e Do not wear loose clothing or jewelry near mov ing parts such as PTO shafts fans belts and pul leys e Keep hands away from moving parts e Keep guards in place over fans belts pulleys and other moving parts BATTERY GAS IS EXPLOSIVE e Wear splash proof safety glasses s Do not smoke or permit flames or sparks to occur near the battery at any time e To reduce arcing when disconnecting or recon necting battery cables always disconnect the negative battery cable first and reconnect it last FLAMMABLE VAPOR CAN CAUSE A DIESEL ENGINE TO OVERSPEED Do not operate a diesel powered gen set where a flammable vapor environment can be created by fuel spill leak etc Flammable vapor can cause a diesel engine to over speed and become difficult to stop resulting in pos sible fire explosion severe personal injury and death The owners and operators of the genset are solely responsible for operating the genset safely GENERAL PRECAUTIONS e Keep children away from the genset e Do not use evaporative starting fluids They are highly explosive e To prevent accidental or remote starting while working on the genset disconnect the nega ti
28. electrocution Caution Warning Indicates a risk of personal injury from equipment that may be subject to automatic starting or remote starting Caution Warning Indicates to read Operator manual for additional information Caution Warning of Belt and Rotating Part Hazard Indicates a risk of personal injury from entanglement in moving parts E anne EE Caution Warning of Pressure Hazard Indicates a risk of personal injury from pressurized fluids 1 Introduction ABOUT THIS MANUAL This is the Operator Manual for the generator sets gensets listed on the front cover Read and carefully observe all of the instructions and precautions in this manual Keep this manual with the other vehicle manuals Operation Periodic Maintenance and Trouble shooting provide the instructions necessary for op erating the genset and maintaining it at top perfor mance The owner is responsible for performing maintenance in accordance with the PERIODIC MAINTENANCE SCHEDULE Page 20 This genset is not a life support sys tem It can stop without warning Children per sons with physical or mental limitations and pets could suffer personal injury or death A personal attendant redundant power or an alarm system must be used if genset operation is critical This generator set is not ignition protected and shall not be used in a flammable vapor environment Improper service or replacement of parts can le
29. em CAUTION Operating the genset when coolant level is low can cause serious engine damage Check the coolant level and look for coolant leaks around the bottom of the genset and on the ground below Minor leaks that can be replenished by daily additions of coolant to the recovery tank should be re paired by a qualified service technician as soon as possible Larger leaks are cause for shutting down the genset until it can be repaired Exhaust System 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 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 gen set again 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 Check all CO monitors to assure proper operation Do not park the vehicle in high grass or brush Contact with the exhaust system can cause a fire 21 Park the vehicle so that the genset exhaust gases can disperse away from the vehicle Barriers such as walls
30. ensed battery system voltage greater than 19 volts Corrective Action 1 Check battery bank connections and reconnect if necessary so that the 12 volt batteries serving the genset are connected in parallel 12 volt rather than in series 24 volt 2 Select a lower battery booster charge rate LOW CRANKING SPEED FAULT CODE NO 32 Cranking speed less than 100 rpm 2 5 Hz generator for more than 12 seconds Corrective Action 1 Have the vehicle propulsion engine running while trying to start the genset The battery charging alternator may be able to maintain starting voltage high enough to get the genset started Clean and tighten the battery cable connections at the battery and at the genset Recharge or replace the battery Refer to the battery manufacturer s recommendations Replace engine oil with oil of proper viscosity for ambient temperatures High oil viscosity can slow down cranking speed 34 TABLE 4 TROUBLESHOOTING CONT Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions CONTROL CARD FAULT CODE NO 35 Microprocessor EEPROM error during self test Corrective Action See an authorized Cummins Onan dealer ENGINE STOPPED FAULT CODE NO 36 The genset stopped without a command from the control
31. etd ee eee eee eee 14 Stoppingithe Genset nad aca ac ee a eee enna eer aa beer ee ae 14 ALLO Malic Staring anid StOPPIN Gian es N 15 Sace Tee pS GT on nian ne cecin EE Cr gaits eee 15 Connecting to Utility Rowen RS cee ER NN eke ene See rie 15 Resetting Circ itiBreakers arrar a a ER A ee ner ee 16 ODA ES aT G G TTG ER ER coe ere aa ea ae 17 peratingiimMot Weathers a a Gen cn oc 17 Operating at MAd Cr tee ce yet Se tity BUEN eee 17 Operating in Dusty Environments 17 Breaking ina New Engine 2 5 2 600 cel eed eee eee eee eee 17 Exercising the Gensere a See dan Ser a ga od a ed Be 17 Storing bile fer Sct aed mu dati lan Telus on ner 18 3 PERIODIC MAINTENANCE 20 Conducting General Inspections 21 Checking Engine Oil Level 22 Changing Engine Oil and Filter 23 Maintaining Battery and Battery Connections 24 Replacing Air Filtegil mener eee 24 BEGEWE FUS RARE RER 25 GH ROMARC CORNE Oe 7 27 ATROUBEESTOOMNG eaters 7 0h Me T 30 Bore CRG AINIO Nomura RER A et enamine eee 38 Sym OO VNINGS VC TT a WS clo cdutoutaus au cane 40 pOK TT RIII e SSC 30 ho odd nbus wed eaounyauedow 42 SAFETY PRECAUTIONS Thoroughly read the OPERATOR S MANUAL be fore operating the genset Safe operation and top performance can only be obtained when equip ment is
32. f aspiration into the lungs This would cause intense local irritation and chemical pneumonitis that can be fatal Obtain immediate medical assistance e Eyes Irrigate copiously with water or preferably eye wash solution for at least five minutes If irritation persists seek medical advice e Skin Wash thoroughly with soap and water Change clothing if necessary If high pressure injection has occurred prompt surgical attention is required e Spillage Absorb using sand earth or other suitable ma terial Dispose of unwanted or absorbed flam mable material as directed under Storage Transport Section 5 7 3 LUBRICATION OIL PREMIUM BLUE E 15W40 Also known as oil lube oil sump oil new oil is dark viscous liquid with a slight characteristic odour The base oil contains distillates petroleum sol vent dewaxed heavy paraffinic It is not classified as dangerous according to Directive 1999 45 EC and its amendments and is not classified according to the EU regulations It has a boiling point greater than 150 C a flash point Open Cup of 220 C Cleveland and is insoluble in cold water It is used in engine lubricant oil systems sump pan and filters make up tanks and piping systems as a lubrication oil for use in wide range of diesel engines operating under severe conditions Installers opera tors and maintainers are likely to encounter this prod uct HAZARDOUS REACTIONS This product is stable although sli
33. ghtly re active with oxidising agents Results of decomposition are car bon oxides CO COs and water Although harmful if swallowed or aspirated breathed in repeated or prolonged exposure is not known to aggravate medical conditions Used oil may contain harmful combustion by prod ucts and unburnt fuel that will cause skin reactions as detailed for fuel Particular care must be taken if oil form a severely overheated engine is handled use impervious gloves lab coat and safety glasses Do not breathe vapour spray PROTECTIVE MEASURES Ensure good ventilation and avoid heat sources Adopt a high standard of personal hygiene In case of skin contact wash thoroughly with soap and water Use safety glasses impervious gloves and lab coat Avoid contamination inside the gloves If overalls be come contaminated discontinue use and clean thor oughly No special respiratory precautions are necessary n normal use Do no breathe vapour spray when han dling hot materials STORAGE TRANSPORT Store and transport only in correctly marked con tainers Keep containers tightly sealed when not in use Keep in a cool well ventilated area out of sun light and away from naked flames Store well away from food stuffs and drinking water Wear splash goggles full suit boots and gloves Ab sorb leak spill with an inert material and dispose of unwanted or absorbed substance through an autho rized contractor to a licensed site Finis
34. h cleaning by spreading water on the contaminated surface and al low to evacuate through the sanitary system EMERGENCY ACTION e Fire Extinguishing media Large fire Use water spray fog or foam Do not use water jet Small fire Use dry chemical powder or CO Fire fighters to use self contained breathing ap paratus and full turnout gear Keep fire exposed containers cool Ingestion Do not induce vomiting Obtain medical advice immediately Inhalation of vapour Remove from further exposure Obtain medical attention Aspiration inhalation of liquid Obtain immediate medical assistance Eyes Flush copiously with water or preferably eye wash solution for at least fifteen minutes Obtain medical advice Skin Wash thoroughly with soap and water Obtain medical advice if irritation develops Change clothing if necessary and wash before re use Spillage Absorb with an inert material and dispose of this as directed under Storage Transport Generator Set Warning Labels Warning signs are provided on the generator set at or near the point of risk To avoid injury always take the necessary precautions as indicated on the sample signs shown below Caution Warning Indicates a risk of personal injury Caution Warning of Temperature Hazard Indicates a risk of personal injury from high temperature Caution Warning of High Voltage Hazard Indicates a risk of personal injury from electric shock
35. he genset is running Depending on how cold it is preheat can take up to 15 seconds ex tending the time that the light blinks See Troubleshooting Page 30 if the genset does not start after several tries For top performance and engine life especially in colder weather let the engine warm up for two minutes before connecting loads STOPPING THE GENSET Turn off air conditioners and other large loads and let the genset run for two minutes to cool down Then push the switch to STOP AUTOMATIC STARTING AND STOPPING The vehicle may be equipped with an inverter char ger or other automatic genset starting device AGS Always follow the instructions and safety precautions provided by the manufacturer of the automatic start ing device when enabling automatic genset starting EXHAUST GAS is deadly MOVING PARTS and ELECTRICITY can cause severe per sonal injury or death To reduce exposure to these hazards always disable automatic genset starting before e Sleeping unless vehicle CO detector is enabled e Parking vehicle in garage or confined space e Parking vehicle for storage e Servicing genset e Servicing batteries e Servicing electrical appliances e Fueling vehicle LOADING THE GENSET The genset can power AC motors air conditioners AC DC converters and other loads How much load can be powered depends upon the genset power rat ing The genset will shut down or its circuit breakers will trip if the sum of
36. hearing damage in creases The Specifications page in the Operator manual states noise level for this generator set Se lect and use personal hearing protection appropriate for your exposure to generator set noise Note for use in countries where compliance to the EU Noise directive is required This generator set has not been evaluated and is not marked for use in open air Install the generator set in accordance with the Instal lation manual Obey local noise restrictions when you operate the generator set ELECTROMAGNETIC COMPATIBILITY Generator sets emit and receive electromagnetic ra dio frequency energy If the generator set affects op eration of nearby devices or nearby devices affect generator set operation increase the distance be tween them Note for use in countries where compliance to the EMC directive is required This generator set has been evaluated for use in residential commercial and light industrial environments ENGINE EMISSIONS COMPLIANCE Labels that state compliance with applicable engine emissions regulations are located on the side of the engine valve cover and in the lower left hand corner on the front of the genset Refer also to the FEDERAL EMISSION DESIGN AND DEFECT LIMITED WAR RANTY FOR C I ENGINES DIESELS that was shipped in the same package as the Operator Manu al FUEL RECOMMENDATIONS Diesel fuel is combustible and can cause severe personal injury or death Do not smoke near fue
37. hen short cir cuits occur Short circuits in electrical equipment and tools can cause fire and electrical shock leading to severe personal injury or death Read and follow the equipment and tool manufactur er s instructions and warnings regarding use maintenance and proper grounding LINE CIRCUIT BREAKER S FIGURE 5 LINE CIRCUIT BREAKERS 16 OPERATING IN COLD WEATHER Make sure the engine oil viscosity is appropriate for the cold weather temperatures See ENGINE OIL RECOMMENDATIONS Page 10 Be sure to change the oil if a sudden drop in temperature occurs OPERATING IN HOT WEATHER Pay particular attention to the following items when operating the genset in hot weather 1 Make sure nothing blocks airflow to and from the genset 2 Make sure engine oil viscosity is appropriate for the ambient temperatures See ENGINE OIL RECOMMENDATIONS Page 9 3 Keep the genset clean 4 Perform maintenance due See PERIODIC MAINTENANCE SCHEDULE Page 20 OPERATING AT HIGH ALTITUDE For the effect of altitude on maximum power see LOADING THE GENSET Page 15 OPERATING IN DUSTY ENVIRONMENTS Pay particular attention to the following items when operating the genset in dusty environments 1 Do not let dirt and debris accumulate inside the genset compartment Keep the genset clean 2 Perform air cleaner maintenance more often See PERIODIC MAINTENANCE SCHEDULE Page 20 17 3
38. idle for more than 120 days Storing the Genset 1 Push the genset line circuit breaker OFF Page 16 Change the engine oil and attach a tag indicating oil viscosity See ENGINE OIL REC OMMENDATIONS Page 9 Disconnect the battery cables negative cable first from the starting battery and store the bat tery according to the battery manufacturer s rec ommendations See MAINTAINING THE BAT TERY AND BATTERY CONNECTIONS Page 24 Plug the exhaust tail pipe to keep out dirt mois ture bugs etc Close the fuel supply valve if so equipped 18 Returning the Genset to Service 1 Check the oil tag on the genset and change the oil if the viscosity indicated is not appropriate for the temperatures expected See ENGINE OIL RECOMMENDATIONS Page 9 Reconnect the starting battery negative cable last See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Page 24 Remove the plug from the exhaust tailpipe Change the air filter element if it is dirty Page 24 Open the fuel supply valve if so equipped Inspect the genset See CONDUCTING GEN ERAL INSPECTIONS Page 14 Push the genset line circuit breaker ON Page 16 when the genset is ready to power ap pliances This page is intentionally blank 19 3 Periodic Maintenance Periodic maintenance is essential for top perfor mance and long genset life Use Table 3 as a guide for normal periodic mainten
39. il the next scheduled oil change Multi grade oils such as SAE 15W 40 are recom mended for year round use 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 1 4 10 16 21 27 32 38 43 48 FIGURE 2 OIL VISCOSITY VS TEMPERATURE ACCESS TO COOLANT PRESSURE CAP OIL FILL CONTROL 7 SWITCH e H COOLANT LEVEL CHECK ACCESS FOR OIL amp AIR FILTERS AIR IN FOR COOLING COM BUSTION amp VENTILATION AC OUTPUT amp REMOTE CONTROL CONNECTIONS STARTING BATTERIES The genset requires a 12 volt battery to power its con trol and starting circuits Reliable genset starting and starter service life depend upon adequate battery system capacity and maintenance See Specifi cations Page 38 for battery requirements and MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Page 24 for battery care TYPICAL GENSET Figure 3 illustrates a typical genset LIFTING EYE COVER HOT AIR OUT END amp BOTTOM EXHAUST TAILPIPE EXIT END BACK amp BOTTOM CONNECTIONS ACCESS BELOW FUEL FILTERS AND OIL amp COOLANT DRAIN VALVES BATTERY CONNECTIONS FIGURE 3 TYPICAL GENSET 10 OPERATOR CONSOLE The console Figure 4 has the following features Control Switch This switch is used to start and stop the genset prime the engine fuel system and restore the fault code blinking status light Status Light This is an LED light emitting dio
40. itch is open Corrective Action 1 Check the engine oil level and add oil as necessary Page 22 2 Drain the excess oil if the oil level is above the Full mark on the dipstick The oil will foam if the level is too high and result in possible loss of oil pressure SERVICE CHECK CODE NO 3 First level fault code a second level fault occurred Corrective Action Check the second level fault code by momentarily pressing Stop The second lev el fault will be one of the following in this table OVERCRANK FAULT CODE NO 4 First level fault code Cranking without starting exceeded 20 to 30 seconds depending on ambient Corrective Action 1 Check the fuel level and refill as necessary Note The genset fuel pickup is probably higher than the vehicle engine fuel pickup 2 Check for fuel air leaks at all fuel fittings and tighten as necessary Prime the engine fuel system by holding the control switch at Stop for one minute 3 Check the engine air filter Page 24 and remove any blockage 4 Check for mechanical damage 5 Replace the fuel filter Page 26 OVERVOLTAGE FAULT CODE NO 12 The controller is not able to regulate to rated voltage Corrective Action See an authorized Cummins Onan dealer 32 TABLE 4 TROUBLESHOOTING CONT Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels elec
41. l tanks or fuel burning equipment or in areas sharing ventilation with such equip ment Keep flames sparks pilot flames electri cal 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 perfor mance and long engine life e The specifications for the type and sulfur content ppm weight of the diesel fuel used must comply with all emissions regulations applicable in the areas where the genset is to be operated e Diesel fuels meeting ASTM D975 or EN 590 specifications are recommended Use Grade 1 D diesel fuel where ambient temperatures are below 14 F 10 C A minimum Fuel Cetane Rating of 45 is recommended Where ambient temperatures are below 4 F 20 C or the elevation is above 5000 ft 1500 m a minimum Cetane Rating of 50 is recommended e Current US EPA regulations for Non Road en gines limit diesel fuel sulfur content to a maxi mum of 500 ppm 0 05 weight Therefore use Grade 2 D S500 or 2 D S15 diesel fuel Where ambient temperatures are below 14 F 10 C use Grade 1 D S500 or 1 D S15 diesel fuel Note that beginning in year 2010 US EPA regulations for Non Road engines will limit diesel fuel sulfur content to a maximum of 15 ppm 0 0015 weight e Do not use diesel fuel having a sulfur content greater than 10 000 ppm 1 0 weight e Diesel fuel must meet the ASTM D975 standard for lubri
42. ler Corrective Action Check the fuel level and refill as necessary Note The genset fuel pickup is probably higher than the vehicle engine fuel pickup Check for fuel air leaks at all fuel fittings and tighten as necessary Prime the engine fuel system by holding the control switch at Stop for one minute Check the engine air filter Page 24 and remove any blockage Check for mechanical damage Replace the fuel filter Page 26 FIELD OVERLOAD FAULT CODE NO 38 Field voltage exceeded 150 VDC Corrective Action 1 Reduce the number of air conditioners running at the same time and other appliances that cause low power factor 2 Have the air conditioners and other appliances checked for proper operation A locked compressor rotor can cause very low power factor SHORTED ROTOR FAULT CODE NO 41 The rotor circuit is shorted to ground Corrective Action See an authorized Cummins Onan dealer PROCESSOR FAULT CODE NO 42 Microprocessor ROM error during self test Corrective Action See an authorized Cummins Onan dealer PROCESSOR FAULT CODE NO 43 Microprocessor RAM error during self test Corrective Action See an authorized Cummins Onan dealer 35 TABLE 4 TROUBLESHOOTING CONT Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perf
43. lls impervious apron should be used Avoid contamination inside the gloves If overalls become contaminated discon tinue use and clean thoroughly STORAGE TRANSPORT Store and transport only in correctly marked con tainers Keep containers closed when not in use Keep cool out of sunlight away for naked flames and strong acids do not freeze Store well away from food stuffs and drinking water Take special care to avoid discharge into drains sewers and wa ter courses Contain leak spill with sand earth or non combus tible absorbent material to prevent entry of sub stance into drainage sewerage system water courses and land Eliminate all ignition sources use plastic shovel to transfer to suitable container and dispose of unwanted or absorbed substance through and authorized contractor to a licensed site EMERGENCY ACTION e Fire Extinguishing media CO alcohol resistant foam dry powder or water spray Fire fighters to use self contained breathing ap paratus Keep fire exposed containers cool Pre vent run off from entering waterways drains and drinking water supplies e Ingestion Toxic by ingestion If swallowed induce vomiting only under the advice of a Doctor or poison con trol centre Delayed treatment may result in fatal ity e Inhalation of vapour Remove from further exposure In case of ir ritation to lungs or throat seek medical advice e Aspiration inhalation of liquid Obtain immediate medi
44. mixture of ethylene glycol and water at the factory which is suit able for temperatures down to 34 F 37 C Recommended Coolant Mixture Use the best quality ethylene glycol antifreeze solu tion available It should be fully formulated with rust inhibitors and coolant stabilizers Use fresh water that is low in minerals and corrosive chemicals Dis tilled water is best Hot coolant spray can cause severe burns Let the engine cool before releasing the pressure cap or opening the drain cock Replacing the Pressure Cap Replace the pressure cap Figure 12 every two years seals deteriorate and leak Proper cooling system pressure 14 psi is essential for optimal en gine cooling and minimal coolant loss Draining the Cooling System To prevent accidental or remote starting while working on the genset disconnect the negative battery cable at the battery Engine components drains filters hoses etc will be hot and can cause severe burns The use of protective gloves is recom mended Let the engine cool before removing the pressure cap Relieve any remaining pressure by turning the pressure cap slowly without pushing down To re move the cap push down and turn it the rest of the way Then remove the bottom access cover Fig ure 11 open the radiator drain cock and drain the coolant into a suitable container Approximately 1 6 quarts 1 5 L will drain Ethylene glycol antifreeze is con sidered toxic
45. n valve Spin off the oil filter and clean the filter mounting surface on the engine block Remove the old gasket if it remains The oil filter is easier to re move through the front access opening Make sure the gasket is in place on the new filter and apply a thin film of clean oil to the gasket Spin the new filter on until the gasket just touches the block Turn it an additional 1 2 to 3 4 turn Do not over tighten Refill with 2 quarts 1 9 liters of oil and check the level Page 22 Secure the maintenance access covers for prop er engine cooling and for protection from hazard ous moving parts and hot exhaust manifolds 23 10 Dispose of the used oil and oil filter according to local environmental regulations OIL FILTER FIGURE 7 OIL FILTER ACCESS THROUGH FRONT OIL DRAIN VALVE OIL DRAIN HOSE Z OIL FILTER FIGURE 8 OIL DRAIN VALVE DRAIN HOSE AND FIL TER ACCESS THROUGH BOTTOM MAINTAINING BATTERY AND BATTERY CONNECTIONS Refer to Table 3 for scheduled battery maintenance and follow the battery manufacturer s instructions Have the battery charging system serviced if DC sys tem voltage is consistently low or high Always Arcing at battery terminals or in light switches or other equipment and flame
46. nnected See the genset Installation Manual for more information Interconnecting the genset and the public utility or any other power source can lead to electrocution of utility line workers equipment damage and fire Use an approved switching de vice to prevent interconnections Equipment load and genset power are measured in terms of watts W or kilowatts kW where 1 kilowatt kW 1000 watts W 15 RESETTING CIRCUIT BREAKERS If a circuit breaker in the main power distribution pan el of the vehicle or on the genset Figure 5 trips ei ther a circuit shorted or too many loads were running Note that the genset will continue to run after a circuit breaker trips If a circuit breaker trips disconnect or turn off as many loads as possible and reset the circuit breaker Push the circuit breaker to OFF to reset it and then to ON to reconnect the circuit If the circuit breaker trips right away either the electrical distribution system has a short or the circuit breaker is faulty Call a quali fied electrician If the circuit breaker does not trip reconnect the loads one by one up to a total load that does not overload the genset or cause the circuit breaker to trip If a circuit breaker trips right away when an ap pliance is connected the load equipment probably has a short Electrical equipment and tools must be used and maintained properly and be properly grounded to cause the line circuit breakers to trip w
47. ol and diethylene glycol Ethylene glycol is a potentially hazardous constituent The substance has a boiling point of 107 C anda flash point of 121 C It is used as an engine coolant additive and can be found in engine cooling systems and head ex changers Installers operators and maintainers are likely to encounter this substance HAZARDOUS REACTIONS Ethylene glycol is combustible when exposed to heat or flame and can react vigorously with oxidants Mod erate explosive hazard in form of vapour when ex posed to heat or flame Hazardous products resulting from combustion or decomposition include carbon monoxide carbon dioxide and acrid smoke Self contained breathing apparatus must be worn in the event of fume build up Avoid strong oxidizing agents incompatible with sulfuric acid nitric acid caustics and aliphatic amines It may cause neurological signs and symptoms and kidney damage It is also a skin and eye irritant Very toxic in particulate form upon inhalation Harm ful if swallowed lethal dose for humans reported to be 100ml PROTECTIVE MEASURES Refrain from eating drinking or smoking when using the product Adopt a high standard of personal hy giene In case of skin contact wash immediately with soap and water Ensure good ventilation and avoid heat sources Avoid breathing mist if there is a risk of vapour or particulate use a suitable organic vapour mask Eye protection gloves overa
48. orm genset service See Safety Precautions SPEED SENSE FAULT CODE NO 45 Controller unable to sense quadrature frequency Corrective Action Check the fuel level and fill as necessary Then prime the engine fuel system by holding the control switch at Stop for one minute and try restarting OVERPRIME FAULT CODE NO 57 Prime mode exceeded 3 minutes Corrective Action Check for and remove any object that may be holding either control switch remote or local in the prime stop position 36 This page is intentionally blank 37 5 Specifications HRB SSCS GENSET CONTROLLER Integrated Microprocessor Based Engine and Generator Controller GENERATOR Two Bearing Two Pole Rotating Field Poly Vee Belt Drive LL i 7 ma 230V 1 Ph 120V 1 Ph 120 240V 1 Ph or 120 240V 3 Ph 2 pole 25 A 1 pole used 2 pole 25 A 1 Ph or 3 pole 15 A 3 Ph FUEL CONSUMPTION No load 0 20 gph 0 74 Iph 0 25 gph 0 95 Iph Half load 0 32 gph 1 23 Iph 0 39 gph 1 47 Iph Full load 0 54 gph 2 04 Iph 0 60 gph 2 27 Iph ENGINE 2 Cylinder In Line Water Cooled Indirect Injection 4 Stroke Cycle Diesel BC RER 2860 2860 2 64 in 67 mm 2 64 in 67 mm 2 68 in 68 mm 2 68 in 68 mm Displacement 29 23 in 479 cc 29 23 in 479 cc Compression Ratio 23 1 23 1 Injection Order 1 2 1 2 Engine Timing 18 25 to 19 75 BTDC 18 25 to 19 75 BTDC Fuel Nozzle Injection Pressure Valve Lash Intake amp
49. properly operated and maintained Only trained and experienced service personnel with knowledge of fuels electricity and machin ery hazards shall remove dismantle and dispose of the generator set See service manual Some generator set installation procedures pres ent hazards that can result in severe personal in jury or death Only trained and experienced per sonnel with knowledge of fuels electricity and machinery hazards should perform generator set installation procedures The following symbols in this manual alert you to po tential hazards to the operator service person and equipment Used to alert you to a lethal hazard against which you must take steps to prevent se vere personal injury or death as when you are in the vicinity of High Voltage equipment Used to alert you to a hazard or un safe practice that can result in severe personal injury or death Used to alert you to a hazard or un safe practice that can result in personal injury or equipment damage Electricity fuel exhaust moving parts and batteries present hazards which can result in severe personal injury or death ENGINE EXHAUST IS DEADLY e Inspect for exhaust leaks at every startup and af ter every eight hours of running e Learn the symptoms of carbon monoxide poi soning in the genset Operator s Manual e Never sleep in the vehicle while the genset is running unless the vehicle is equipped with a working carbon monoxide detector
50. s or sparks can ignite battery gas causing severe personal injury To prevent injury e Ventilate battery area before working on or near battery e Wear safety glasses s Do not smoke e Switch work light ON or OFF away from battery e Stop genset and disconnect charger before disconnecting battery cables e Disconnect negative cable first and reconnect it last 1 Keep the battery case and terminals clean and dry and the terminals tight 2 Remove battery cables with a battery terminal puller 3 Make sure which terminal is positive and which is negative before making battery con nections always removing the negative cable first and reconnecting it last to reduce arc ing REPLACING AIR FILTER ELEMENT Refer to Table 3 for scheduled air filter element re placement In dusty environments the filter element should be inspected and changed more frequently To prevent accidental or remote starting while working on the genset disconnect the negative battery cable at the battery Do not run the genset with the main tenance access covers off Contact with hazard ous moving parts and hot exhaust manifolds can cause severe personal injury Remove the front access door unscrew the 2 wing nuts on the filter housing and pull away the filter hous ing and filter element Figure 9 When installing the new filter element turn the wing nuts hand tight Secure the maintenance access
51. st fault logged will blink even after the condition that caused the shut down has been corrected TABLE 4 TROUBLESHOOTING Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions NO RESPONSE DEAD STATUS INDICATOR LIGHT Poor connections faulty wiring or dead battery Corrective Action 1 Try starting the genset at the operator s console if it does not start at the remote panel 2 Clean and tighten the battery cable connections at the battery and at the genset 3 Recharge or replace the battery Refer to the battery manufacturer s recommendations THE STARTING BATTERIES DO NOT MAINTAIN A CHARGE The battery battery connections or charging system are in marginal condition Corrective Action 1 Clean and tighten the battery cable connections at the battery and at the genset 2 Recharge or replace the battery Refer to the battery manufacturer s recommendations THE STARTER ENGAGES AND DISENGAGES Cranking voltage dips below 6 volts because of low battery charge or poor connections Corrective Action 1 Have the vehicle propulsion engine running while trying to start the genset The battery charging alternator may be able to maintain starting voltage high enough to get the genset started 2 Clean and tighten the
52. tributor nearest to you If you are unable to contact a distributor using the au tomated service consult the Yellow Pages Typically our distributors are listed under GENERATORS ELECTRIC ENGINES GASOLINE OR DIESEL or 40 RECREATIONAL VEHICLES EQUIPMENT PARTS AND SERVICE If you have difficulty in arranging service or resolving a problem please contact the Service Manager at the nearest Cummins Onan distributor for assistance Outside North America If you are outside North America call Cummins Onan at 1 763 574 5000 from 7 30 AM to 4 00 PM Cen tral Standard Time Monday through Friday or fax 1 763 528 7229 Information to Have Ready Before calling for service have the following infor mation available 1 The complete genset model number and serial number See Model Identification Page 4 2 The date of purchase 3 The nature of the problem See Troubleshooting Page 30 This page is intentionally blank 41 7 Maintenance Record Record all periodic and unscheduled maintenance and service See Periodic Maintenance Page 20 HOUR METER MAINTENANCE OR SERVICE PERFORMED ae Record the name address and phone number of your authorized Cummins Onan service center 42 This page is intentionally blank 43 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 c
53. tricity and machinery hazards should perform genset service See Safety Precautions UNDERVOLTAGE FAULT CODE NO 13 The controller is not able to regulate to rated voltage Corrective Action Turn OFF the line circuit breaker on the operator s console If the genset now runs run it with fewer connected loads OVERFREQUENCY FAULT CODE NO 14 The controller is not able to regulate to rated frequency Corrective Action 1 Check for a tripped genset circuit breaker reset it if necessary and run with fewer connected loads A breaker tripping under load can cause frequency to overshoot 2 Check for fuel air leaks at all fuel fittings and tighten as necessary Prime the engine fuel system by holding the control switch at Stop for one minute Air bubbles can disrupt frequency UNDERFREQUENCY FAULT CODE NO 15 The controller is not able to regulate to rated frequency Corrective Action Turn OFF the line circuit breaker If the genset now runs run it with fewer connected loads especially those with high motor starting loads such as air conditioners Check the fuel level and refill as necessary Note The genset fuel pickup is probably higher than the vehicle engine fuel pickup Check for fuel air leaks at all fuel fittings and tighten as necessary Prime the engine fuel system by holding the control switch at Stop for one minute Air bubbles can disrupt frequency Check the engine air filter Page 24 and remo
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55. ve battery cable at the battery e Keep the genset and its compartment clean Ex cess oil and oily rags can catch fire Dirt and gear stowed in the compartment can restrict cooling air e Make sure all fasteners are secure and torqued properly e Do not work on the genset when mentally or physically fatigued or after consuming alcohol or drugs e Used engine oil has been identified by some U S state and federal agencies as causing can cer or reproductive toxicity Do not ingest inhale or contact used oil or its vapors Ethylene glycol used as engine antifreeze is toxic to humans and animals Clean up spills and dispose of used engine coolant in accordance with local environmental regulations Keep multi purpose fire extinguishers handy Multi purpose fire extinguishes are used for fires that involve ordinary combustible materials such as wood and cloth combustible and flammable liquid fuel and gaseous fuels live electrical equipment North America or US ref NFPA No 10 Genset installation and operation must comply with all applicable local state and federal codes and regulations Generator sets with a sound shield shall not be run with the service doors remove missing Engine components can be hot and cause se vere burns Hot coolant under pressure can spray and cause severe burns Use personal protective equipment when per forming periodic maintenance operations such as gloves safety glasses etc
56. ve any blockage Check for mechanical damage Replace the fuel filter Page 26 GOVERNOR ACTUATOR FAULT CODE NO 19 The controller sensed that the actuator circuit is either open or shorted Corrective Action See an authorized Cummins Onan dealer 33 TABLE 4 TROUBLESHOOTING CONT Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions GOVERNOR OVERLOAD FAULT CODE NO 22 The duration of operation at or near full duty cycle was beyond the design limit Corrective Action Reduce the number of appliances running at the same time especially those with high motor starting loads such as air conditioners Check for fuel air leaks at all fuel fittings and tighten as necessary Prime the engine fuel system by holding the control switch at Stop for one minute Replace the engine air filter Page 24 Replace the fuel filter Page 26 TEMPERATURE SENDER FAULT CODE NO 24 The controller sensed that the sender circuit is either open or shorted Corrective Action See an authorized Cummins Onan dealer AC VOLTAGE SENSE FAULT CODE NO 27 The controller was unable to sense output voltage Corrective Action See an authorized Cummins Onan dealer HIGH BATTERY VOLTAGE FAULT CODE NO 29 The controller s
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