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Cummins Onan Service Manual - SYNERGY Wireline Equipment

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1. CONTROL CARD view A A SCALE 1 2 SIS WA COMPARTMENT COOLING HOT AIR OUT ISOLATED POST FOR 50 HZ 230 VAC AND 50 HZ GROUND WIRE NOT SHOWN FOR CLARITY ES 2X 50 r 251 OIL DRAIN 25 COOLANT DRAIN AX 5 16 18 UNC ENG
2. FIGURE 3 3 SPARK ARRESTOR CLEANOUT PLUG 3 5 DRAINING REPLACING THE FUEL FILTER 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 oth er sources of ignition well away Keep a type ABC fire extinguisher in the vehicle Close any fuel line shutoff valve before discon necting the fuel line from the filter Accidental or remote starting can cause severe personal injury or death Disconnect the nega tive cable at the battery to prevent starting while working on the genset Keep dirt water and other contaminants from entering the fuel sy
3. FIGURE 3 2 REPLACING THE AIR FILTER ELEMENT CLEANING THE SPARK ARRESTOR The spark arrestor cleanout plug is located on the side of the muffler Figure 3 3 Clean out the spark arrestor as follows Refer to Table 3 1 for scheduled cleaning of the de spark arrestor which meets U S Forest Service re 1 Remove the 1 4 NPT cleanout plug from the quirements Cleaning is required for maximum muffler genset performance 2 Start the genset and load it nearly to full power Let the genset run for about five minutes to ex A hot muffler can cause severe pel the soot burns Let the muffler cool down before remov 3 Stop the genset allow the muffler to cool down ing or installing the cleanout plug reinstall the cleanout plug
4. HOSE TO ENGINE Eh EINER FUEL FILTER DRAIN PLUG RETURN FUEL PUMP WATER SEPARATOR FUEL SUPPLY FUEL PUMP FIGURE 3 4 FUEL FILTER MAINTAINING THE ENGINE COOLING SYSTEM Refer to Table 3 1 for scheduled maintenance The engine cooling system is filled at the factory with a 50 50 mixture of ethylene glycol antifreeze and water which is suitable for temperatures down to 34 F 37 C Recommended Coolant See COOLANT page 2 2 RECOMMENDATIONS Pressure Cap Replace the pressure cap Figure 3 5 every two years seals deteriorate and leak Proper cooling system pressure 13 psi is essential for optimal en gine cooling and minimal coolant loss Draining and Cleaning Cooling System Hot coolant spray can cause severe burns Let the engine cool before releasing the pressure cap or removing the drain plug Accidental or remote starting can cause severe personal injury or death Disconnect the nega tive cable at the battery to
5. OIL FILTER OIL DRAIN HOSE OIL DRAIN VALVE OIL PAN PLUG ADDITIONAL LOCATION FOR DRAINING THE ENGINE OIL ON THE BOTTOM OF THE GENERA TOR SET IF THE OIL DRAIN HOSE AND OIL DRAIN VALVE CANNOT BE USED FIGURE 3 1 ENGINE OIL MAINTENANCE 3 3 MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Arcing at battery terminals or in light switches or other equipment and flames or sparks can ignite battery gas causing s
6. 6 EMISSIONS LABEL FIGURE 1 2 EMISSIONS LABEL LOCATION TYPICAL GENSET nection points control panel switches hour meter the coolant and oil fill locations and other operating Figures 1 3 and 1 4 illustrate the location of key op componat locating erating features such as the fuel and battery con P REAR CONTROL PANEL CONNECTIONS COOLANT AIR BLEED VALVE WITH COVER AND GENERATOR SET CONTROL REMOVED FOR CLARITY j SEE DETAIL COMPARTMENT AIR TEMPERATURE SWITCH
7. BATTERY CONNECTIONS COOLANT RECOVERY oL EUER TANK DRAIN CONNECTIONS HOSE FUEL HOT DRAIN FILTER HOT AIR OUT LIFTING EYE COMPARTMENT COOLING FAN COOLING FAN ENGINE COMBUSTION AIR INLET FIGURE 1 4 GENSET COMPONENT LOCATIONS 1 4 2 Operation 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 multi class ABC fire extinguisher handy High quality diesel fuel is necessary for good perfor mance and long engine life The specifications for the type and sulfur con tent ppm weight of the diesel fuel used must comply with all emissions regulations ap plicable in the areas where the genset is to be operated 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 Ce tane Rating of 45 is recommended Where am bient temperatures are below 4 F 20 C the elevati
8. 4 2 liest 5 4 3 Reassembling Mounting System 4 3 5 JBOGIBIESSTIESSOEE 5 5 1 Major Engine Service 5 1 Engine Sensors ss ooo ce dence use P iaa S sa 5 1 Governo Act ator cos MM A UN 5 2 Hligheidle Speed es bcn too 5 Sa 5 2 plug SA cU EU ME 5 3 A a a dnd PRU EUER 5 3 Battery Gharging Altermater eere EET ss 5 3 IS nn RR 5 3 Euel Systemie eee mn n n C 5 3 Exhaust System sn oa 5 5 SAE J1939 CAN GAME E 5 5 6 GENERATOR 5 nay y eee Sameer eee 6 1 Overview a IH 6 1 TESIS TAS AA TRE iun LAS eus 6 1 Replacing the Bearings 4 ihn 6 5 SECTION PAGE CONTROL utili 7 1 Vel VIBW s Sara Ed TS EEN s a 7 1 8 TROUBLESHOOTING NENE O 8 1 Diagnostics Features of the Generator 8 1 Fault Odes ase a 8 1 Mro bleshooting Proced res cc A M n 8 2 SABORES li ten 9 1 MIS EC a o 10 1 SSEBRVIGENSEHEOIEISTESSSESUN 11 1 CONTROL 0 We Q A 1 CONSEBODBOVIRINSUBIARNESS
9. 8 1 FAULT FAULT NAME 91999 941939 SPN 91999 91999 FMI NUMBER SPN DESCRIPTION FMI DESCRIPTION 13 Under voltage 2444 Line to Neutral AC 1 Data Valid Below Normal RMS Voltage Most Severe 14 Over Frequency 2436 AC Frequency 0 Data Valid Above Normal Average Most Severe 15 Under Frequency 2436 AC Frequency 1 Data Valid Below Normal Average Most Severe 19 Actuator Short 51 Throttle position 2 Data Erratic Intermittent or Open Incorrect 22 Actuator overload 51 Throttle position 0 Data Valid Above Normal Most Severe 27 AC Output sense 2444 Line to Neutral AC 4 Voltage Below Normal or lost RMOS Voltage Shorted to Low Source 29 High battery volt 168 Electrical Potential 0 Data Valid Above Normal age Voltage Most Severe 32 Starter Fault 1675 Eng Starter Mode 8 Abnormal Requency or Pulse Width or Period 35 EE Checksum 234 Software Identifi 13 Out of Calibration fault cation 36 Mechanical Fault 190 Engine Speed 11 Root Cause Not Known 43 RAM Failure 234 Software Identifi 13 Out of Calibration cation 45 Speed Sense Lost 190 Engine Speed 2 Data Erratic Intermittent or Incorrect 57 Over Prime 1440 Fuel Flow Rate 1 14 Special Instructions 76 High Ambient 171 Ambient Air Tem 0 Data Valid Above Normal Temperature perature Most Severe TROUBLESHOOTING PROCEDURES Some generator service procedures present hazards that can result in sever
10. J N AIR SUPPORT SUPPORT OUT 1 2 Y YU AIR OUT FIGURE 4 1 AIR OUTLET OPENINGS IN BOTTOM SHADED AREAS REASSEMBLING MOUNTING SYSTEM When reassembling torque the vibration isolator center and mounting screws according to torque specifications page 9 1 4 3 VIBRATION ISOLATORS 4 FIGURE 4 2 MOUNTING SYSTEM 4 4 5 Engine and Accessories MAJOR ENGINE SERVICE Accidental or remote starting can cause severe personal injury or death Before removing an access door or belt guard discon nect the negative cable at the battery to pre vent the engine from starting See the Engine Workshop Manual 981 0551 for major engine service procedures See Specifica tions Section 10 in this manual to identify the en gine model number for the generator set When remounting the engine torque the vibration isolator through bolts to 56 68 Ib ft 76 92 N m TIMING MARKS VIEWING OIL PRESSURE SWITCH ACTUATOR TEMPERATURE COOLANT SENDER GLOW PLUGS BATTERY CHARGING ALTERNATOR FIGURE 5 1 ENGINE COMPONENTS ENGINE SENSORS Engine Oil Pressure Switch Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable at the batt
11. SPARK ARRESTOR PLUG LINE 1 2 n N NH TEN N FIGURE 1 3 GENSET COMPONENT LOCATIONS 1 3 CIRCUIT BREAKER HOUR METER START STOP AIR FILTER COOLANT P OIL FILL 7 OIL DIP l STICK OIL FILTER COOLING VENT AIR IN OPTIONAL BATTERY AND FUEL CON NECTIONS ON THIS END
12. Cooling System Capacity 7 8 quart 7 4 liter DC SYSTEM Nominal Battery Voltage 12 volts Minimum Battery Capacity CCA Cold Cranking Amps 650 amps down to 1740 875 amps down to 101F 2310 1000 amps down to 20 F 2910 Maximum Regulated Charging Current 40 amps WEIGHT 890 lbs 404 kg SIZE L x W x H 48 9 x 23 6 x 29 7 in 1241 x 600 x 708 mm 10 1 MODEL HDKAW SOUND LEVEL 81 9 dB A 10 ft 3m before installation 60 Hertz Models full load 10 2 11 Service Checklist After servicing inspect and test the installation to confirm that the genset will operate as intended Check each of the areas described below before putting the genset into service Mounting Examine all mounting bolts and supporting mem bers to verify that the genset is properly mounted All fasteners should be tightened securely to pre vent them from working loose when subjected to vibration Lubrication If the engine oil was drained refill as required Cooling System If the engine coolant was drained refill as required Wiring Verify that all wiring connections are tight and installed properly Check each of these connec tions Load wires Control wires Ground straps Battery cables Output Check Apply a full load to make sure the genset can pro duce rated output Use a load test panel to apply a progressively
13. 25 C Replace a defective rotor with a new identical part 6 5 DIGITAL OHMMETER MAIN ROTOR LEADS F1 F2 Md FIGURE 6 7 TESTING WINDINGS RESISTANCE REPLACING THE BEARINGS The generator is heavy Use the appropriate tools and procedures to remove it from the generator set Accidentally dropping the genera tor can damage it and cause severe personal in jury and death The hoist straps and chains must have sufficient capacity and be attached properly so that the load cannot shift Before starting disconnect the starting battery cables negative first to make sure the set will not start while working on it Accidental starting of the generator set while working on it can cause severe per sonal injury or death Prevent accidental start ing by disconnecting the starting battery cables negative first Generator Removal Disconnect alternator output leads and exciter F1 and F2 leads Remove the generator from the vehicle Alternator Disassembly Position the alternator with the end bell facing up which facilitates a safer and easier assembly and disassembly Refer to Figure 6 8 for an exploded view of the alternator with parts identification rotor assembly about one inch above the bench with a hoist and rope sling Remove nuts from the rotor through studs Use care to prevent damage to the Remove the end bell by tapping upward around fan blades Broken blades
14. J1 21 K1 WILL STOP BLINKING SEE THE SERVICE MANUAL FOR CAN SHEILD FUEL ACTUATOR 23 85 FURTHER DETAILS FUEL PUMP i REMOTE START FUEL ACTUATOR ENGINE WATER TEMP SENSE LOW ENGINE OIL PRESSURE 2L 711 nel FOR ALL MODELS EXCEPT ISOLATED NEUTRAL CONNECT 271 GENERATOR LEADS T3 AND T2 TO CONTROL BOX GROUND E2 FUEL PUMP EE GLOW PLUS K2 86 STARTER RELAY A FOR ISOLATED NEUTRAL CONNECTIONS CONNECT RING TERMINAL OF LEAD A028J474 FROM CB2 LINE SIDE TO 87 j CONTROL BOX GROUND ENGINE TEMP SENDER 3 27 eH A FOR ISOLATED NEUTRAL INSTALL ISOLATED POST 0332 2370 IA TO STUD ON CONTROL BOX AD26F554 AND TORQUE TO 9 8 12 6Nm CONNECT T2 AND T3 TO ISOLATED POST S2 WITH FASTENER 0821 0008 AND TORQUE TO 9 8 12 8 Nm LOW PLUG HR 1 STARTER SOLENOID BO HZ 120V 240V ISOLATED NEUTRAL SW BAT CB1 MOT CHASSIS GROUND ENGINE Ds DUT BT1 T ST VR GROUND END 177 CHASS S_ GROUND CHASSIS GROUND No A026E150 sh 1 of 1 Rev E Modified 05 10 CONTROL SCH
15. ure 3 5 before the first startup of each day and fill to the COLD mark if necessary with Recommended Coolant COOLANT PRESSURE CAP COOLANT SYSTEM AIR BLEED VALVE COOLANT RECOVERY TANK FIGURE 3 5 ENGINE COOL
16. 23 to 26 inch Ibs 2 6 to 2 9 Nem torque when replacing nuts for F1 and F2 and diodes CR1 through CR6 DIGITAL OHMMETER FIGURE 6 2 TESTING ROTATING RECTIFIERS WHEATSTONE BRIDGE Testing Exciter Stator Test the exciter stator for open or shorted windings and grounds as follows see Figure 6 3 Open or shorted windings Disconnect F1 and F2 exciter field leads from terminal block in generator end bell and measure the resistance between them The re sistance should measure 12 4 ohms 10 at 77 25 C Grounds Connect the ohmmeter between either field lead and exciter stator laminations Set the ohmmeter to the highest resistance range Resistance must read one megohm or greater Note The preferred test is with a megger or insula tion resistance meter that applies 500 VDC or more to the test leads Readings should be 100 000 ohms or greater MEGGER OR INSULATION RESISTANCE METER FIGURE 6 3 TESTING WINDINGS RESISTANCE Testing the Exciter Rotor Test the exciter rotor for open shorted windings or grounds see Figure 6 4 Disconnect the main rotor field leads which connect to the rotating rectifier assemblies at F1 and F2 Disconnect lead wires from diodes CR1 through CR6 Using a Wheatstone bridge or digital ohmme ter measure between exciter lead pairs T1 T2 T2 T3 and T1 T3 Resistance should mea sure 645 milliohms 1096 at 77 25 C EXC
17. 95 F at 2500 ft 1059 F at 2500 ft 20 000 W genset rating 18 400 W RESETTING CIRCUIT BREAKERS If a circuit breaker in the main power distribution panel of the vehicle or on the genset Figure 2 2 trips either a circuit shorted or too many appliances 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 break er 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 dis tribution system has a short or the circuit breaker is faulty Call a qualified electrician If the circuit breaker does not trip reconnect the ap pliances 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 appliance probably has a short Electrical appliances and tools must be used and maintained properly and be properly grounded to cause the line circuit breakers to trip when short cir cuits occur Short circuits in electrical ap pliances and tools can cause fire and electrical shock leading to severe personal injury or death Read and follow the equipment and tool manufacturer s instructions and warnings re garding use maintenance and proper ground ing CONNECTING TO UTILITY POWER A vehic
18. A remote genset control panel can be installed in side the vehicle Three control panel kits are avail able Remote switch status lamp Remote switch status lamp and hour meter Remote switch status lamp and DC voltmeter The DC voltmeter indicates whether voltage across the 12 VDC control system and battery is normal If the indicator consistently stays above or below the normal zone see MAINTAINING THE BATTERY AND BATTERY CONNECTIONS page 3 4 CONDUIT CONNECTOB CIRCUIT BREAKER HOUR METER CONTROL SWITCH START STOP PRIME m ES 1 2 N FIGURE 2 2 CONTROL PANEL EXHAUST GAS is deadly All en e Dizziness Headache gine exhaust contains carbon monoxide an Nausea Weakness and Sleepiness odorless colorless poisonous gas that can Vomiting Inability to Think Coherently cause unconsciousness and death Symptoms of carbon monoxide poisoning include 2 4 IF YOU EXPERIENCE ANY OF THESE SYMP TOMS GET INTO FRESH AIR IMMEDIATELY If symptoms persist seek medical attention Shut down the genset and do not operate it until it has been inspected and repaired Never sleep in the vehicle while the genset is running unless the vehicle has a working car bon monoxide detector The exhaust system must be installed in acco
19. diagnosis No troubleshoot actual last fault Update the control calibration using InPower Replace the control board page 7 1 GENERATOR STOPPED WITHOUT FAULT CONDITION CODE NO 36 Possible Cause Fuel supply generator set loads inverter charger governor actuator Logic The generator stopped without a command from the controller Corrective Action Verify that Last Fault is fault code 36 Yes continue diagnosis No troubleshoot actual last fault Check the fuel level and refill as necessary Note The generator fuel pickup is probably higher than the vehicle engine fuel pickup Check for fuel air leaks at all fuel fittings and tighten as necessary Check the engine air filter page 3 4 and remove any blockage Conduct a fuel pump test page 5 3 Replace the fuel filter page 3 6 Check for mechanical damage of engine or alternator Inspect and service the governor actuator as necessary page 5 2 Verify the engine runs rough or smokes Yes conduct cylinder compression tests dry and wet and service a worn engine in accordance with the Engine Workshop Manual Service the internal engine governor mechanism in accordance with the Engine Workshop Manual PROCESSOR FAULT CODE NO 43 Possible Cause Control card Logic Microprocessor RAM error during self test Corrective Action Verify that Last Fault is fault code 43 Yes continue diagnosis No troubleshoot actual last fault
20. filter element if it is dirty page 3 4 5 Open the fuel supply valve if so equipped 6 Inspect the genset See GENERAL INSPEC TION page 3 2 7 Push the genset line circuit breaker ON pagg 2 7 when the genset is ready to power appliances 8 Enable the automatic genset starting feature of an inverter charger or other automatic starting device following the device manufacturer s in structions and safety precautions 3 Periodic Maintenance Periodic maintenance is essential for top perfor mance and long genset life Use Table 3 1 as a guide for normal periodic maintenance In hot and dusty environments some maintenance procedures should be performed more frequently as indicated by the footnotes in the table Maintenance replacement or repair of emission control devices and systems may be performed by any engine repair establishment or individual How ever warranty work must be completed by an au thorized Cummins Onan dealer Accidental or remote starting can cause severe personal injury or death Discon nect the negative cable at the battery to pre vent starting while working on the genset TABLE 3 1 PERIODIC MAINTENANCE SCHEDULE MAINTENANCE TASK General Inspection Check Engine Oil Level 2 Check Engine Coolant Level Check Battery amp Battery Connections Change Engine Oil amp Oil Filter 2 3 8 Clean Spark Arrestor3 Every Day Every Every Every M 250 500 800 Hrs
21. flashes a brief pause and then 1 to 9 flashes The first set of flashes represents the tens digit and the second set of flashes the units digit of the shutdown code number For example Fault Code No 24 appears as flash flash pause flash flash flash flash long pause repeat Four flashes indicate that cranking exceeded a preset time 20 seconds if ambient temperature is above 32 0 C 30 seconds if below without starting Note Fault Codes 33 and 44 have not been assigned so as to avoid the confusion of wrongly interpreting Fault Codes 3 and 4 which are first level faults Restoring Fault Code Flashing The fault code stops flashing after five minutes Press Stop three times within three seconds to restore flashing Note The last fault logged will flash even after the condition that caused the shutdown has been corrected FAULT CODES The generator can generate the fault codes listed in Table 8 1 TABLE 8 1 SUPPORTED FAULT CODES FAULT FAULT NAME J1939 J1939 SPN J1939 J1939 FMI NUMBER SPN DESCRIPTION FMI DESCRIPTION 1 High Engine Cool 110 Eng Coolant Temp 0 Data Valid Above Normal ant Temperature Most Severe 2 Low Oil Pressure 100 Eng Oil Pressure 1 Data Valid Below Normal Most Severe 3 Service Engine Over Crank 1675 Eng Starter Mode 14 Special Instructions 12 Over voltage 2444 Line to Neutral AC 0 Data Valid Above Normal RMS Voltage Most Severe
22. greater load until full load is reached Exhaust System While the genset is running inspect the entire ex haust system Look and listen for leaks at all con nections welds gaskets and joints Also make sure the exhaust pipe is not overheating adjacent materi als or equipment Do not run the genset until all ex haust leaks have been repaired Exhaust gas is deadly The exhaust system must not leak and must discharge all ex haust away from the vehicle Do not run the gen set until the exhaust leaks have been repaired The exhaust tailpipe must be supported by a hanger near the vehicle perimeter and terminate at least 1 inch outside the perimeter and at least 1 foot from doors and windows Fuel System While the genset is running inspect the fuel supply and return lines filter and fittings for leaks Check flexible sections for cuts cracks and abrasions and make sure they are not rubbing against anything that could cause leakage Repair all fuel leaks im mediately Diesel fuel is combustible Leaking fuel could lead to fire and to severe personal in jury or death Repair fuel leaks immediately Control Stop and start the genset several times at the con trol panel on the genset and at the remote control board if provided to verify that they work properly Mechanical Stop the genset and inspect it for leaking gaskets loose fasteners damaged components and inter ference with other equipment Repair as neces
23. must be secured free of leaks and separated or shielded from electrical wiring MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Disable the automatic genset starting feature AGS of an inverter charger or other automat ic starting device before servicing the genset to avoid unexpected starting Do not wear loose clothing or jewelry near moving parts such as PTO shafts fans belts and pulleys Keep hands away from moving parts Keep guards in place over fans belts pulleys and other moving parts BATTERY GAS IS EXPLOSIVE Wear safety glasses Do not smoke 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 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 The owners and operators of the genset are solely responsible for operating the genset safely GENERAL PRECAUTIONS Keep children away from the genset Do not use evaporative starting fluids They are highly explosive To prevent accidental or remote starting while working on the genset disconnect the nega tive battery cable at the battery Let the engi
24. pipe thread sealant can plug the engine fuel system Apply liquid type pipe thread sealant sparingly to the male threads only Do not use Teflon tape Fuel Hose Replace worn or damaged fuel hose with 5 16 in 1 0 SAE J30R9 fuel hose The manufacturer must possess a CARB executive order FUEL PUMP N N FUEL RETURN HOSE FUEL RETURN FUEL SUPPLY FUEL RETURN OPTIONAL FIGURE 5 3 TYPICAL FUEL SYSTEM AN Ax 97 mr FUEL SUPPLY HOSE FUEL FILTER E FUEL SUPPLY V Y HOSE FUEL SUPPLY OPTIONAL EXHAUST SYSTEM Because of the clearance between the muffler and the coolant supply tube on the generator set it may be difficult to remove the muffler When servicing the muffler it is suggested that you follow these steps to avoid damaging the studs on the exhaust manifold 1 Remove the coolant supply tube fastener See Figure 5 4 2 Loosen the screw in the coolant supply tube bracket attached to the tube See Figure 5 4 3 Rotate the tube outward at the pivot point of the fastener on the bracket attached to the coolant tube COOLANT SUPPLY TUBE FASTENER COOLANT SUPPLY TUBE BRACKET FIGURE 5 4 COOLANT SUPPLY TUBE SAE J1939 CAN CONNECTION The generator set controller can communicate over a CAN controlled area network datalink The main use of this datalink is to provide information to an ex isting CAN datalink for example to provide infor mation to a remote operator p
25. two stator through studs in the adapter for aligning the stator assembly over the rotor Install the baffle ring Install the remaining two stator through studs in the adapter Install the stator and end bell Torque the nuts on the through studs to 19 to 21 ft 165 26 to 28 Torque the rotor through stud nut 55 to 60 ft lbs 75 to 81 Nen Install the mounting feet and the control box Connect the alternator output and control leads according to the appropriate wiring diagram Replace the end bell cover Replace the reconnect box cover THIS PAGE LEFT INTENTIONALLY BLANK 6 8 7 Control Accidental or remote starting can cause severe personal injury or death Before removing a housing panel or access door dis connect the negative cable at the battery to prevent the engine from starting OVERVIEW See Figure 7 2 and Figure 7 3 for an illustration of the generator set control components Generator Control General The generator control is an integrated mi crocontroller based engine and generator control It provides all the control monitoring and diagnostic functions required to operate a generator set Connections Fan and compartment air tempera ture switch connections are through connector J2 Other DC control connections to the control are through connector J1 Refer to Table 7 1 below and the appropriate wiring diagrams and wiring harness drawings beginning on Page A 1 TABLE 7 1
26. will throw the fan out the joint and separating it from the stator as sembly Remove four stator through studs with a vise grip Using a safe lifting device stator handling tongs or chain and lift hooks lift stator assem bly from gear case adapter If necessary lift unit off the bench about one inch and tap adapter of balance and reduce the air flow rate If itis necessary to replace a damaged fan sup port the rotor assembly horizontally and re move the fan from the rotor with a gear puller Hold the rotor in a suitable clamp and loosen the nut on the rotor through stud bolt If required remove the bearing with a gear pull er and accessory crutch if available from the housing with a soft faced hammer to free stator rotor through stud from adapter Clamp the alternator rotor in a fixed vertical or horizontal position to remove or install the rotor lock nut The lock nut is torqued to 130 150 ft Ib 176 203 Nen f bearing shaft or oil seal replacement is re quired hold gear case upright and tap drive pin ion and shaft through gear case Do not set stator down on open end top or bottom Stator weight can damage the windings While stator is still on lift tongs or hooks revolve stator to horizontal position and set it on its side Remove the air baffle by loosening four locking With a vise grips remove rotor through stud from the drive pinion shaft Note A rope sling is th
27. 1 If there is no conti nuity check for missing bent or corroded pins and faulty wiring and repair as necessary Disconnect J1 from the control board and check for continuity between J1 34 to L1 and J1 35 to L2 If there is no continuity check for missing bent or corroded pins and faulty wiring and repair as neces sary Measure field quadrature and main winding resistance repair harness and replace rotor or stator as necessary 8 7 Measure field quadrature and main winding resistance to ground repair harness and replace rotor or stator as necessary Measure field quadrature and main winding resistance to each other repair harness and replace rotor or stator as necessary Dealers contact Distributor for technical support Distributors contact factory for technical support UNDERVOLTAGE FAULT CODE NO 13 Possible Cause Generator set loads wire connections generator windings Logic Output voltage dropped below 90 percent of nominal for more than 5 seconds and current is less than 100 percent Corrective Action Verify that Last Fault is fault code 13 Yes continue diagnosis No troubleshoot actual last fault Turn OFF the generator circuit breaker If the generator now runs run with fewer connected loads Measure and verify AC voltage at the customer connection block and at pins J1 34 and J1 35 Measure and verify AC frequency while changing engine rpm to determine if frequency response Verify balanced l
28. 7 2 LINE CIRCUIT BREAKER GENERATOR SET CONTROLLER HOUR METER CONTROL SWITCH FIGURE 7 2 CONTROL COMPONENTS FRONT VIEW GENERATOR SET CONTROLLER COMPARTMENT AIR TEMPERATURE SWITCH RELAY K1 RELAY K2 RELAY K3 ENGINE Ss HARNESS FIGURE 7 3 CONTROL COMPONENTS BACK VIEW 8 Troubleshooting DIAGNOSTICS FEATURES OF THE GENERATOR Use the table of symptoms and fault codes to diagnose a shutdown If you are unable to resolve the problem after taking the corrective actions suggested contact an authorized Cummins dealer Operator Panel If a fault shutdown occurs the FAULT status lamp on the Operator panel will come on and the LCD screen will remote panel the description of the Fault the Fault Number and the hour in total generator running time when the Fault occurred Status Indicator Light on Control Switch The generator causes the status indicator light on the Control Switch to flash the first level diagnostic fault code when a fault occurs The status indicator light will repeatedly flash 1 2 3 4 or 9 flashes at a time One flash indicates shut down due to high temperature Two flashes indicate shutdown due to a loss of engine oil pressure Three flashes indicate a service fault Press Stop once to cause the two digit second level shutdown code to flash Pressing Stop again will stop the flashing The two digit code consists of 1 2 3 4 or 7
29. Check the engine air filter page 3 4 and remove any blockage Conduct a fuel pump test page 5 3 Replace the fuel filters page 3 6 Inspect and service the glow plugs as necessary page 5 3 Inspect and service the governor actuator as necessary page 5 2 Check for mechanical damage Service the internal engine governor mechanism in accordance with the Engine Workshop Manual Conduct cylinder compression tests dry and wet and service a worn engine in accordance with the Engine Workshop Manual OVERVOLTAGE FAULT CODE NO 12 Possible Cause Generator set loads wire connections generator windings Logic Output voltage exceeded 115 percent of nominal for more than 3 seconds or spiked to 125 percent for less than a second Corrective Action Verify that Last Fault is fault code 12 Yes continue diagnosis No troubleshoot actual last fault Turn OFF the generator circuit breaker If the generator now runs the problem may be in one of the loads Cycle the loads to determine which one it is and have it repaired Measure and verify AC voltage at the customer connection block and at pins J1 34 and J1 35 Measure and verify AC frequency while changing engine rpm to determine if a frequency response matches engine rpm response Verify balanced loads in 120 240 VAC applications balance loads within 10 percent line to line as re quired Disconnect J3 from P3 and check for continuity between P3 6 to L2 and P3 1 to L
30. Cummins Onan lt Service Manual Generator Set HDKAW Spec A B English Original Instructions 3 2013 A028W414 Issue 8 California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Table of Contents SECTION PAGE SAFETY PRECAUTIONS PETE iv 1 INSI EE 1 1 AUS cT E 1 1 eee 1 1 EmgimesErmmissionms Tm Wh SE 1 2 ens 0 We u 1 3 2 PEFAPISON C RN 2 1 EueliBecommendations En 2 1 Bie diesel Fuels B5 20 amp mnnm 2 1 Engine Oil Recommendations 2 2 Coolant Recommendations 2 2 Starting coc I e n yd ndn 2 2 Control 1 er menu 2 3 Na 2 3 CONTO A RA TIT 2 4 aia Feds _ 2 4 mM 2 5 Priming the Fuel System c n EE 2 5 Manali Starting cacumen n n nn passe M ds 2 5 Matiual Stopplni nn n D E 2 5 Automatic startingeand Stop eer nanan 2 5 Leading thesGerset a 2 6 Resetting Circuit Breakers oec ec EN n U
31. EMATIC A 1 Ol G1 VR KJHGF d B1 SW G1 B Room 0 P DELOD ABCDE 4 B1 BAT VIEW B B P8 B B1 BAT TX 1 52 A TX1 P1 33 TX1 P1 34 52 1 HR 1 E2 2 E2 4 BE GND G doa SS 1 als 2 617 elle 4 5 Ld VIEW C C 338 4461 CONTROL WIRING HARNESS A 2 B1 LOA B2 LOA AC WIRING HARNESS A 3 AC HARNESS NOTES COMPARTMENT COOLING FAN KIT INSTALLED AT TIME OF GENERATOR SET INSTALLATION START STOP PRIME SWITCH OWL AC ALTERNATOR Ol 3X CLEARANCE HOLES FOR 3 16 FASTENER ELAPSED HOUR METER HOT A
32. Hrs Hrs FREQUENCY Every 1500 Hrs Every 3000 Page Hrs EG ER ECO L L L T Replace Fuel Fiter k __ pes ELLE Flush Coolant System Replace Coolant Pressure Cap4 Check V Belt 4 Coolant Hoses 6 Replace as necessary Check Fuel Injector Pressure 7 repes rar L L L CS Perform more often when operating in hot weather Perform at least once a year Perform at least once every two years Perform at least once every five years EPA requirement Perform more often when operating dusty conditions Must be performed by trained and experienced personnel authorized Cummins Onan service representatives Perform every 75 hours when using high sulfur fuel See ENGINE OIL RECOMMENDATIONS page 2 2 Perform every 250 hours when using B20 Bio diesel fuel GENERAL INSPECTION Inspect the genset before the first start of the day and after every eight hours of operation Oil Level Check engine oil level Figure 3 1 Engine Coolant System CAUTION Operating the genset when coolant level is low can cause serious engine damage Check the engine coolant level and look for coolant leaks around the bottom of the genset and on the ground below Minor leaks that can be replenished by daily additions of coolant to the recovery tank should be repaired by a qualified service technician as soon as po
33. INE COOLING HOT AIR OUT GROUND STUD M6 X BONDED NEUTRAL INDICATED LOCATION OF REMOTE HARNESS HARNESS NOT SHOWN FOR CLARITY No A026K862 sh 2 of 2 Rev B Modified 17 09 THIS PAGE IS INTENDED TO BE BLANK 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 02013 Cummins Power Generation Inc All rights reserved
34. ING SYSTEM 3 8 ADJUSTING V BELT TENSION The V belt drives the battery charging alternator and coolant pump Figure 3 6 See Table 3 1 for scheduled inspection or replacement Adjust belt tension as follows 1 Disconnect the negative cable at the battery to prevent the engine from starting Accidental or remote starting can cause severe personal injury or death Disconnect the negative cable at the bat tery to prevent the engine from starting Remove the belt guard Loosen the alternator pivot bolt first and then the adjusting bracket bolt on top Pivot the alternator out to tighten belt tension Hold tension by tightening the tension adjusting bolt and then check tension by applying 20 pounds 10 kg to the middle of the pulley span Belt tension is correct when deflection is 3 8 inch 10 mm Tighten the alternator bolts when tension is correct Tighten the bolts secure the belt guard or en closure and reconnect the battery cables neg ative last 3 9 TENSION ADJUSTING BOLT ALTERNATOR PIVOT BOLT 3 8 INCH 10 MM DEFLECTION 20 LBS 10 KG FIGURE 3 6 ADJUSTING V BELT TENSION REPLACING THE THERMOSTAT See Table 3 1 for scheduled replacement Refer ring to Figure 3 7 replace the thermostat as follows 1 Disconnect the negative cable at the battery to prevent the engine from starting let the en gine cool and remove the front and back access doors if the gene
35. IR OUT m COOLANT FILL ELECTRONIC GOVERNOR LIFTING POIN AC OUT CIRCUIT BREAKER OIL FILTER COOLANT FILL NON METAL CONDUIT AIR FILTER BLEED e 8 180 COMPARTMENT COOLING AIR IN Y 018 0 COOLANT OVERFLOW BOTTLE OPTIONAL BATTERY TERMINAL 54 AND FUEL LOCATIONS SHOWN ENGINE FLEXIBLE OIL DRAIN HOSE COMBUSTION OIL DRAIN HOSE OUTLET BATTERY POSITIVE 5 16 18 UNC BATTERY NEGATIVE 5 16 18 UNC 5331 FUEL FILTER ENGINE AND AC ALTERNATOR EUER IR t str RE COOLING AIR IN FUEL RETURN 1 8 21 NPTF OIL DRAIN VALVE No A026K862 sh 1 of 2 Rev B Modified 17 09 OUTLINE DRAWING A 4 SEE DETAIL 3 8 16 U MOUNT LOCATIO 95 B SPARK ARRESTOR CLEANOUT EXHAUST FLANGE SURFACE CIRCUIT BREAKER CONTROL BOX 2X LOAD SIDE COOLING AIR IN CIRCUIT BREAKER 2X LINE SIDE
36. ITER ROTOR ASSEMBLY e WHEATSTONE BRIDGE TESTING WINDING Test the exciter rotor for grounds With all generator leads disconnected from diodes CR1 through CR6 measure between any diode lead and exciter rotor laminations The reading should be greater than one meg ohm A reading less than one megohm indicates de fective ground insulation Note The preferred test is with a Megger or insula tion resistance meter that applies 500 VDC or more Be sure all exciter leads are disconnected from the diodes Readings should be 100 000 ohms or greater 7 m i MEGGER OR INSULATION RESISTANCE METER EXCITER ROTOR LAMINATION TESTING WINDING FOR GROUNDS CONNECTION DIAGRAM FIGURE 6 4 TESTING THE EXCITER ROTOR Testing the Generator Stator Using the proper test equipment test the stator for grounds opens and shorts in the windings Figure 6 5 Test for grounds Note Some generators have ground connections to the frame Check the wiring diagram All stator leads must be isolated for testing Use a megger or insulation resistance meter which applies 500 VDC or more to the test leads Test each stator winding for a short to the lami nations MEGGER OR INSULATION RESISTANCE METER A reading less than 100 000 ohms indicates questionable stator Thoroughly dry the stator and retest Test the stator for open or shorted windings Use an acc
37. J1 AND J2 CONNECTIONS PN Vo pscmPHON 7 RS 485 B communications Both impar CI Glow plug PN o DESCRIPTION Temperature switch Software Updates To update the control software Compartment Air Temperature Switch 1 Connect the InPower Onan service tool har The compartment air temperature switch Figure ness PN 0338 4840 to remote connector P8 7 3 has normally closed contacts The contacts open when the temperature rises above 180 F 5 F 2 Connect InPower Onan and update the soft The contacts close again when the temperature falls below 165 5 Note sure you use compartment temperature Control Switch switch with a color code Figure 7 1 that is red Unsnap the connector from the back of the switch for access to its terminals Replace the switch if it does not close across terminals 2 and 3 when the switch is held in the Start position close across ter minals 1 and 2 when held in the Stop position or the status indicator light does not light when 12 VDC is connected across terminals 7 and 8 Line Circuit Breaker Disconnect all wiring and check electrical resist COLOR CODE ance across the terminals of each circuit breaker Replace a circuit breaker that does not reset or that does not close or open as the handle is turned ON FIGURE 7 1 COMPARTMENT TEMPERATURE and OFF SWITCH
38. M S 2 7 Powers uec rr E E ME 2 7 Weather maea veu cuente n HUM I EDT 2 7 Operating 2 7 Operating at High Altitude rai UR Le 2 7 Operating in Dusty Environments 2 7 Breaking In New 2 8 Exercising the Genset bee dees 2 8 SECTION PAGE Storing the Genset oe ATA AAA A MAU AA 2 8 3 PERIODIC MAINTENANCE gt AAA O Se ae 3 1 General INSPECTION 3 2 Checking Engine OllBevel m s m 3 2 Changing Engine Oil and Oil Filter 3 3 Maintaining the Battery and Battery Connections 3 4 Replacing the Air Filter 5 3 4 Cleaning the Spark Arrestor 3 5 Draining Replacing the Fuel Filter 3 6 Maintaining the Engine Cooling System 3 7 Ad usungsv Bellsfensian 3999 9 3 9 Thermost t 3 10 FORSSERVICE 4 1 Special 4 1 Safely EIER 4 4 1 Removing Installing Genset
39. Note If a glow plug does not come out after unscrew ing it or the end has broken off it will be necessary to remove the engine head Glow plugs can swell if pre heat voltage is greater than the nominal 12 volts such as when a battery booster is used for starting STARTER Accidental or remote starting can cause severe personal injury or death Before servicing the starter disconnect the negative cable at the battery to prevent the engine from starting The starter motor is bolted to the flywheel housing Figure 5 1 See the Engine Workshop Manual for service or replacement Parts are available for re building the starter Torque the mounting bolts to 31 38 Ib ft 42 51 5 N m BATTERY CHARGING ALTERNATOR See page 3 9 to adjust or replace the alternator V Belt Figure 5 1 See the Engine Workshop Manual for service or replacement TIMING MARKS The flywheel has timing marks to help set the timing of the injection system You can see the timing marks by removing the plug and looking through the hole indicated in Figure 5 1 See the engine work shop manual for the appropriate injection timing set tings FUEL SYSTEM 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 mult
40. TENANCE SCHEDULE page 3 1 3 Change engine oil more often See PERIODIC MAINTENANCE SCHEDULE page 3 1 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 See LOADING THE GENSET page 4 6 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 pagg 2 2 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 See LOADING THE GENSET 6 A single two hour exercise period is better than several shorter periods Exercising a genset drives off moisture re lubri cates 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 essen
41. Update the control calibration using InPower 8 13 Replace the control board page 7 1 SPEED SENSE FAULT CODE NO 45 Possible Cause Fuel supply governor actuator generator windings wire connections Logic Controller unable to sense quadrature frequency Corrective Action Verify that Last Fault is fault code 45 Yes continue diagnosis No troubleshoot actual last fault Measure quadrature winding resistance at stator leads J1 2 and J1 3 and at J1 connector Measure AC frequency while changing engine rpm to determine if frequency response matches en gine rpm response Disconnect J1 from the control board and check for quadrature resistance between J1 2 and J1 3 If there is no continuity check for missing bent or corroded pins and faulty wiring and repair as neces sary Disconnect J3 from P3 and check for continuity between J3 3 to J1 2 and J3 4 to J1 3 If there is no continuity check for missing bent or corroded pins and faulty wiring and repair as necessary Reconnect J1 and 3 connectors and test run genset for fault occurrence repair or replace pins in con nector as necessary Measure field quadrature and main winding resistance repair harness and replace rotor or stator as necessary Measure field quadrature and main winding resistance to ground repair harness and replace rotor or stator as necessary Measure field quadrature and main winding resistance to each other repair har
42. VERNOR OVERLOAD FAULT CODE NO 22 Possible Cause Generator set loads inverter charger wire connections fuel supply governor actuator Logic The actuator was at full duty cycle for 10 seconds Corrective Action Verify that Last Fault is fault code 22 Yes continue diagnosis No troubleshoot actual last fault Reduce the number of appliances running at the same time Check for fuel air leaks at all fuel fittings and tighten as necessary Replace the engine air filter page 3 4 Replace the fuel filters page 3 6 Conduct a fuel pump test page 5 3 Inspect and service the governor actuator and leads as necessary page 5 2 Service the internal engine governor mechanism in accordance with the Engine Workshop Manual Conduct cylinder compression tests dry and wet and service a worn engine in accordance with the Engine Workshop Manual AC VOLTAGE SENSE FAULT CODE NO 27 Possible Cause Generator set loads inverter charger generator windings wire connections Logic The voltage sense signal was less than 5 VAC and frequency greater than 40 Hz Corrective Action Verify that Last Fault is fault code 27 Yes continue diagnosis No troubleshoot actual last fault Measure and verify AC voltage at the customer connection block and at pins J1 34 and J1 35 Disconnect J3 from P3 and check for continuity between P3 6 to L2 and P3 1 to L1 If there is no conti nuity check for missing bent or corroded pins an
43. ad signals on a high resolution oscillo scope The bad signal is caused by termination 5 6 problems no termination wrong termination or bad termination FIGURE 5 7 CAN DATALINK GOOD SIGNAL FIGURE 5 8 CAN DATALINK BAD SIGNAL SAE J1939 Broadcasts The source address of the generator controller is 234 Instruments will not display any messages from the generator controller if the instruments do not recognize this address The controller supports the SAE J1939 broadcasts identified in Table 5 4 broadcast data and in Table 8 1 fault codes Use the PCan tool to monitor these broadcasts The controller does not receive SAE J1939 messages TABLE 5 4 SAE J1939 BROADCASTS Description __ PON Claim Address 60928 Engine temperature 65262 coolant temperature AC output frequency in 65030 2436 place of engine speed AC output voltage 65030 Battery voltage 65271 5 7 Software part number 65242 software version Genset faults Full list of fault codes identified in Section 8 These messages are only broadcasted on request The genset has a low oil pressure switch not a sender so it cannot provide oil pressure in SAE J1939 broadcasts It does broadcast fault code 2 Low Oil Pressure Fault instead THIS PAGE LEFT INTENTIONALLY BLANK 5 8 6 Generator OVERVIEW The Cummins Onan YD series AC generators are two bearing 1800 rpm 60 Hertz units A centrifugal blower on the front end
44. ain oil as necessary See ENGINE OIL your generator set Finally drain all the oil from RECOMMENDATIONS page 2 2 Keep the the engine into a suitable container Reinstall oil level between the FULL and ADD marks the oil drain hose securely and close the oil Too much oil can cause high oil md the ON Oral plug NENG consumption Too little oil can cause severe engine damage Keep the oil level between 3 Spin off the oil filter canister and clean the filter the FULL and ADD marks mounting surface on the engine block Remove 4 Reinsert the dipstick and secure the oil fill cap the old gasket if it remains 4 Make sure the gasket is in place on the new fil ter and apply a thin film of clean oil to the gas ket Spin the new filter on until the gasket just touches the block Turn it an additional 1 2 to 3 4 turn Do not overtighten CHANGING ENGINE OIL AND OIL FILTER Refer to Table 3 1 for scheduled engine oil change Change oil more often in hot and dusty environ ments 1 Run the genset until warm and shut it off 5 Refill with 10 quarts 9 5 liters of oil check oil re level Figure 3 1 2 Remove the oil fill cap and disconnect the oil drain hose Then open the oil drain valve or re 6 Dispose of the used oil and oil filter according move the plug from the oil pan according to to local environmental regulations OIL FILL DIP STICK
45. anel CAN communications is based on the SAE J1939 communication protocol The CAN datalink is based on a main trunk no more than 40 meters long and 30 devices that is terminated by 120 ohm resistors on each end Stubs no longer than 1 meter extend from the main trunk to each module in the bus The connection between the generator set control ler and the CAN datalink is shown in Figure 5 5 GENERATOR SET CONTROLLER FIGURE 5 5 CAN DATALINK Pin Connections The SAE J1939 pin connections for the generator controller are identified in Table 5 2 TABLE 5 2 SAE J1939 PIN CONNECTIONS Beso CANA CANB CAN In order to connect to the CAN datalink a terminat ing resistor of 120 ohms is required at each end of the CAN datalink This is not included on the control board or in the remote harness CAN Datalink Signals The CAN datalink carries a series of 1 s and O s in each message Figure 5 6 and Table 5 3 show how the generator set controller distinguishes between 1 s and O s FIGURE 5 6 CAN DATALINK VOLTAGE DIFFEREN TIALS TABLE 5 3 CAN DATALINK VOLTAGE DIFFERENTIALS SIGNAL _____ 31989 Low Voltage Differential The CAN datalink transmits O s and 1 s at 250 KBaud or 250 kilobits per second Hence it is pos sible for the voltages on J1939 High and J1939 Low to change 250 000 times per second Figure 5 7 and Figure 5 8 show some examples of good and b
46. ar loose or damp clothing that might get caught in equipment or conduct electricity Reduce the hazard A safe orderly workshop area and well maintained equipment reduce the hazard potential Keep guards and shields in place on machinery and maintain equipment in good working condition Store flammable liq uids in approved containers away from fire flame spark pilot light switches arc produc ing equipment and other ignition sources Keep the workshop clean and well lit and provide ad equate ventilation Develop safe work habits Unsafe actions cause accidents with tools and machines Be familiar with the equipment and know how to use it safely Use the correct tool for the job and check its condition before starting Comply with the warnings in this manual and take special precautions when working around electrical equipment Do not work alone if possible and do not take any risks 4 1 Be prepared for an accident Keep fire extin guishers and safety equipment nearby Agen cies such as the Red Cross and public safety departments offer courses in first aid CPR and fire control Take advantage of this information to be ready to respond to an accident Learn to be safety conscious and make safety proce dures part of the work routine TABLE 4 1 HAZARDS AND THEIR SOURCES Leaking or spilled fuel Hydrogen gas from battery Oily rags improperly stored Flammable liquids improperly stored Fire and Explosio
47. are prohibited by law in the State of California NAMEPLATE Be ready to provide the genset model and serial numbers on the nameplate when contacting Cum mins Onan for parts service or information Fig ure 1 1 illustrates the nameplate and its location The gray boxes illustrate where to look for the model FIGURE 1 1 TYPICAL NAMEPLATE and serial numbers ENGINE EMISSIONS COMPLIANCE The label that states compliance with applicable en gine emissions regulations is located on the side wall of the base pan as shown circled in Figure 1 2 Refer also to the FEDERAL EMISSION DESIGN AND DEFECT LIMITED WARRANTY FOR C l EN GINES DIESELS that was shipped in the same package as the Operator s Manual 1 2
48. ations that should use standard fuels include applications that will experience seasonal usage storage for periods exceeding 90 days and extreme temperatures or humidity Storage Requirements f using bio diesel for seasonal applications stored more than 90 days the generator must be purged before storage by running the en gine on pure diesel fuel meeting ASTM D975 for a mininmum of 30 minutes Warranty Coverage Cummins Onan Warranty covers failures that are a direct result of defects in material or factory work manship Generator damage service issues and or performance issues determined by Cummins Onan to be caused by bio diesel fuel blends not meeting the specifications outlined in the applicable Installa tion Operator and Service Manuals are not consid ered to be defects in material or workmanship and may affect your generator s warranty ENGINE OIL RECOMMENDATIONS Cil Performance Class Use API American Petroleum Institute classified engine oils according to the following guidelines 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 sul fur content less than 15 ppm 0 0015 weight Non Regulated Areas CF class oil is recom mended when using high sulfur fuel sulfur content between 500 ppm 0 05 weight and 5000 ppm 0 5 weight If CF 4 CG 4 CH 4 or CI 4 class o
49. breaker tripping under load can cause frequency to overshoot 8 8 Check for fuel air leaks at all fuel fittings and tighten as necessary Air bubbles can disrupt frequency Measure AC frequency while changing engine rpm to determine if frequency response matches en gine rpm response Disconnect J1 from the control board and check for quadrature resistance between J1 2 and J1 3 If there is no continuity check for missing bent or corroded pins and faulty wiring and repair as neces sary Disconnect J3 from P3 and check for continuity between J3 3 to J1 2 and J3 4 to J1 3 If there is no continuity check for missing bent or corroded pins and faulty wiring and repair as necessary Reconnect J1 and J3 connectors and test run genset for fault occurrence repair or replace pins in con nector as necessary Check all grounds and neutral leads for looseness at battery amp genset tighten or replace terminals and leads as necessary Check governor actuator and fuel rack for debris damage and looseness readjust and repair as nec essary Measure field quadrature and main winding resistance repair harness and replace rotor or stator as necessary Measure field quadrature and main winding resistance to ground repair harness and replace rotor or stator as necessary Measure field quadrature and main winding resistance to each other repair harness and replace rotor or stator as necessary Dealers contact Distributor for tec
50. cidental or remote starting can cause severe personal injury or death Disable the automatic starting feature of an inverter charger or other automatic starting device and disconnect the negative cable at the battery to prevent starting while working on the genset Sparks and high current could cause fire and other damage to the battery battery cables and vehicle if the loose ends of cables connected to the battery touch Al ways disconnect the negative battery cable from the battery before disconnecting the battery cables from the genset Disconnect the remote control wiring harness connector at the genset Disconnect the AC output leads at the genset terminals Disconnect the exhaust tailpipe from the muf fler flange Disconnect the supply and return fuel lines from the genset 4 2 Diesel fuel is combustible and can cause severe personal injury or death Do not smoke if you are near fuel tanks or fuel burning equipment or are in an area sharing ventilation with such equipment Keep flames sparks pilot lights electrical arcs and arc producing equipment and all other sources of ignition well away Removal from Vehicle Make sure that the genset is firmly supported before loosening any mounting bolts There are four bolt holes in the skid base for securing the genset to the floor or supporting frame The lifting eye is accessi ble near the top of the genset Gensets are heavy and can cause severe p
51. ctive Action Check the engine oil level and add oil as necessary page 3 2 Drain excess oil if the 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 Tighten the terminal on pressure switch S2 if loose page 5 1 Disconnect P1 from the control board and check for continuity between J1 6 and S2 If there is no conti nuity check for missing bent or corroded pins and faulty wiring and repair as necessary Connect manual pressure gauge in place of oil pressure switch and verify oil pressure is 7 psi or great er Check for a faulty switch or engine oil lubrication system and service accordingly page 5 1 SERVICE CHECK CODE NO 3 Possible Cause Any two digit fault code Logic Single digit fault to indicate shutdown due to a two digit fault Corrective Action Check the second level fault code by momentarily pressing Stop Troubleshoot the two digit fault code giv en 8 6 OVERCRANK FAULT CODE NO 4 Possible Cause Faulty switch fuel supply wire connections starter Logic First level fault code cranked for 35 sec without the generator starting with the oil pressure switch closed Corrective Action Check the fuel level and refill as necessary Note The generator fuel pickup is probably higher than the vehicle engine fuel pickup Check for fuel air leaks at all fuel fittings and tighten as necessary
52. d 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 runs out of fuel Battery Connections Check the battery terminals for clean tight connec tions Loose or corroded connections have high electrical resistance which makes starting more dif ficult See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS pagg 3 4 Mechanical Look for mechanical damage and listen for unusual noises Check the genset mounting bolts for any signs of wear To prevent overheating and to reduce fouling with dust and debris make sure the genset s normal ground clearance is not being reduced by sloping ground curbs logs or other objects Repark the ve hicle if necessary and or remove any objects block ing the air inlet or air outlet CHECKING ENGINE OIL LEVEL 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 rub ber gloves and wash exposed skin 1 Park the vehicle on level ground and shut down the genset 2 Pull out the oil dip stick wipe it clean reinsert it and pull it out again to check the oil level Fig ure 3 1 3 Add or dr
53. d faulty wiring and repair as necessary Disconnect J1 from the control board and check for continuity between J1 34 to L1 and J1 35 to L2 If there is no continuity check for missing bent or corroded pins and faulty wiring and repair as neces sary 8 11 HIGH BATTERY VOLTAGE FAULT CODE NO 29 Possible Cause Incorrect battery configuration wire damage faulty charger Logic Battery system voltage was greater than 19 2 volts for 1 second Corrective Action Verify that Last Fault is fault code 29 Yes continue diagnosis No troubleshoot actual last fault Check battery bank connections and reconnect if necessary so that the 12 volt batteries are con nected in parallel 12 volt rather than in series 24 volt Select a lower battery booster charge rate on vehicle s inverter charger if applicable Check all ground leads for looseness at battery 4 genset tighten or replace terminals and leads as necessary Connect the generator to a separate known good battery and while running the genset verify the out put voltage of the DC charge alternator If the voltage goes above the threshold replace the DC alter nator STARTING FAULT CODE NO 32 Possible Cause Fuel system starter governor actuator exhaust system generator windings battery condition wire con nections Logic Cranking speed less than 2 5 Hz for more than 3 seconds Corrective Action Verify that Last Fault is fault code 32 Yes c
54. d stay in while power is applied The coil in the actuator has a resistance of 5 3 0 3 ohms Reinstall the actuator with a new flange gasket Torque the two mounting screws to 7 9 lb ft 9 5 12 2 N m HIGH IDLE SPEED Reset high idle speed if the stop screw seals have been broken or internal governor parts have been replaced or are worn To reset high idle speed 1 Remove the governor actuator to allow opera tion at full fuel rack but leave it connected to keep Fault No 19 from preventing a start Plug the opening to keep oil from splashing out 2 Disconnect the fuel pump and power it directly witha 12 Volt battery to keep the engine run ning when Fault No 12 or 14 occurs These adjusting screws are in close proximity to rotating belts and pulleys that can cause severe personal injury Be very careful not to get your hands near the pulleys and belts while making the adjust ments 3 Disconnect all loads from the generator set to protect them from overfrequency and start the generator set Adjust the stop screws to obtain 67 3 68 3 Hz 2019 2049 rpm TO STOP THE ENGINE disconnect the fuel pump from the battery HIGH IDLE SPEED STOP SCREWS GOVERNOR ACTUATOR FIGURE 5 2 COOLANT SUPPLY TUBE 4 Seal the adjusting threads with paint 5 Re install all of the components that were re moved or disconnected GLOW PLUGS Refer to the Engine Workshop Manual when replac ing the glow plugs Figure 5 1
55. e most suitable device for han Remove the snap ring from the bearing on the dling rotors drive pinion shaft Remove the rotor and fan by using a soft faced Press the bearing from the drive pinion shaft if hammer to tap on the adapter while holding the bearing replacement is required 6 6 END BELL STATOR N EXCITER I STATOR END BELL RETAINER BRUSHLESS EXCITER ROTOR BEARING RECTIFIER ASSEMBLY GENERATOR FAN FIGURE 6 8 ALTERNATOR PARTS IDENTIFICATION Torque the shaft nut against the exciter rotor to 130 to 150 ft Ibs 176 to 203 Nen Alternator Assembly Assemble alternator components in reverse order from disassembly using the following additional in structions Use care to prevent damage to the fan blades Broken blades will throw the fan out of balance and reduce the air flow rate Clean and inspect mating surfaces Coat mating area between alternator bearing and end bell bearing hole with a thin film of Mo lykote or equivalent lubricant Install rotor through stud in drive pinion shaft if it was removed Install the rotor and fan assembly on the adapt er Guide the key slot in the fan onto the key in the drive pinion shaft A raised line on the fan body casting indicates the location of the key slot in side The drive shaft and key can be seen through the air outlet in the adapter If they were removed install the exciter rotor and shaft bearing 6 7 Install
56. e personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform generator service Refer to the following lists of faults and their possible causes and corrective actions to diagnose and repair a fault Dealers contact an authorized Cummins Distributor if you are unable to resolve the problem after taking the corrective actions suggested Distributors contact the factory if you are unable to resolve the problem Most shutdowns can be prevented by maintaining engine oil and coolant levels keeping battery connections clean and tight keeping the air inlet and outlet openings clear watching the fuel gauge and by not overload ing the generator 8 2 THE STARTER ENGAGES AND DISENGAGES Possible Cause Battery voltage battery condition wire connections Logic Cranking voltage dips below 6 volts Corrective Action Clean and tighten the battery cable connections at the battery and at the generator Recharge or replace the batteries Refer to the battery manufacturer s recommendations Clean and tighten the starter cable connections inside the generator THE STARTING BATTERIES DO NOT MAINTAIN A CHARGE Possible Cause Battery charge system battery condition parasitic load Logic Low or no battery voltage Corrective Action Clean and tighten the battery cable connections at the battery and at the generator Recharge or replace the batt
57. empt The starter should only disengage when The start button is released or Generator speed is greater than the start dis connect speed 1100 RPM or The stop button is pressed Start Sequence The control software performs in order the follow ing as part of the start sequence Control performs a system s check by looking at the following Control configuration Identify genset 50 60 Hz Battery voltage 2 3 Engine coolant temperature used to deter mine glow plug glow times Actuator circuit open shorted Glow plug preheat is activated as needed de pending upon temperature Status light flashes during preheat Left pump energized Governor actuator to full duty cycle e Starter is engaged Flash status light to signal engine is cranking Enable field flash Look for frequency pulses Command starter to disengage and turn the starter off at start dis connect speed 1100 RPM Run Sequence During a Run sequnce The load post load time automatically shuts the plugs off when time expires The governor actuator regulates engine speed The control begins automatic voltage regula tion The status indicator remains on steady Stop Sequence The control software performs the following as part of the Stop sequence Disables the voltage regulator Disables the fuel solenoid and the electronic governor 096 duty cycle Turns off the Run output e Stores
58. en the vehicle is parked in a confined space such as a garage Disable the AGS feature of an inverter charger or other automatic starting device before stor ing the vehicle or parking it in a garage or other confined space The exhaust system must be installed in accor dance with the genset Installation Manual Engine cooling air must not be used for heating the vehicle GENERATOR VOLTAGE IS DEADLY Disable the automatic genset starting feature AGS of an inverter charger or other automat ic starting device before servicing the genset to avoid electric shock from an unexpected start Generator electrical output connections must be made by a trained and experienced electri cian in accordance with applicable codes The genset must not be connected to shore power utility Back feed to shore power can cause electrocution and damage to equip ment An approved switching device must be used to prevent interconnections Use caution when working on live electrical equipment Remove jewelry make sure cloth ing and shoes are dry stand on a dry wooden platform or rubber insulating mat and use tools with insulated handles DIESEL FUEL IS COMBUSTIBLE Do not smoke or turn electrical switches ON or OFF where fuel fumes are present or in areas sharing ventilation with fuel tanks or equip ment Keep flames sparks pilot lights arc producing equipment and all other sources of ignition well away Fuel lines
59. enset enclosure for clear intake and exhaust air openings Verify the temperature at the back side of the alternator within the genset Verify the temperature sensor resistance between J2 4 and ground Replace as necessary Measure the temperature sensor wiring between J2 4 and temperature sensor for continuity Repair or replace as necessary Dealers contact Distributor for technical support Distributors contact factory for technical support 8 15 THIS PAGE LEFT INTENTIONALLY BLANK 8 16 9 Bolt Torques Cooling Fan Guard Screws 20 25 in Ib 2 3 2 8 Cooling Fan Plate Screws 20 25 in Ib 2 3 2 8 Cooling Fan Screws ZA UL 9 5 12 2 7 Compartment Cooling Fan Hose Clamp Screws Scroll Housing Screws Coolant Hose Screws Water Tube Bracket Screws Radiator Duct Bracket Screws 6 7 y 7 ENS Skid Mounting Scerws Engine Adapter Screws Lifting Bracket Screw Lifting Bracket Flange Screw Water Sender Terminal Nut on Water Sender Starter Mounting Screws Engine Mount Alternator side Screw Engine Mount Fan Belt side Screw Governor Actuator Mounting Screws Air Filter Bracket Engine Mounting Screws Air Filter Mounting Screws Intake Resonator Clamp Screws Air Hose Clamp Screws Fuel Hose Loop Clamp Screw Fuel Filter Bracket Engine Mounting Screws Fuel Filter Bracket Fuel Filter Mounting Screws Fuel Filter Bracket Side Mounting Screws Fuel Hose Fitting Nut Generator Mounting Screws Silencer Underneath Moun
60. eries Refer to the battery manufacturer s recommendations Locate the DC parasitic load and repair as necessary THERE IS NO POWER WHEN THE GENERATOR IS RUNNING Possible Cause Circuit Breaker Logic Generator is running with no AC output Corrective Action Resetor turn ON the line circuit breaker on the generator Reset or turn ON any other circuit breaker in the power supply system f there is no voltage test circuit breaker CB1 and replace if necessary page 7 2 Check for and tighten the top starter motor mounting bolt to secure generator lead T2 to GND Check the connection of generator lead T1 to CB1 1 and repair as necessary 8 3 THE GENERATOR WILL NOT STOP RUNNING RUN LIGHT OFF Possible Cause Governor Actuator Logic The governor mechanism is stuck or binding Corrective Action Close the fuel supply valve if provided or squeeze off the fuel supply line Inspect and service the governor actuator as necessary page 5 2 Service the internal engine governor mechanism in accordance with the Engine Workshop Manual 8 4 THE GENERATOR WILL NOT STOP RUNNING RUN LIGHT ON Possible Cause Faulty wiring control switch or remote panel Logic Control does not sense ground for stop command Corrective Action Try stopping with the control switch inside the generator page 2 4 Disconnect the remote control harness at the generator page 2 4 Close the fuel supply valve if pro
61. ersonal injury if dropped during remov al Use adequate lifting devices Keep hands and feet clear while lifting Installation in Vehicle Generally installation is the reverse of removal and disconnection Before installing the genset repair any damage to and seal all holes in the vapor tight fire resistive barrier between the genset and coach interior Make sure all mounting screws and brack ets are secure and that all battery AC output con trol exhaust and fuel connections are proper and in good repair Perform the service checklist before placing the genset in service Section 11 Service Checklist Use four Grade 5 screws 3 8 16 UNC to secure the genset to the floor or frame The screws must protrude at least 1 2 inch 10 mm but not more than 1 inch 25 mm into the base as measured from the bottom surface of the base Torque the screws to 35 Ib ft 41 N m TEST STAND EXHAUST GAS IS DEADLY Engine exhaust must be vented outside if the genset is When testing and servicing the genset on a work operated inside a building bench or test stand make sure the openings in the skid base shown in Figure 4 1 Air Out areas are free and clear Also make sure there is ample fresh Restricting the air inlet and outlet air when operating the genset Support the genera openings could lead to damage to the genset tor set at the indicated locations due to overheating 4 b
62. ery to prevent the engine from starting The oil pressure sender is threaded into the side of the block or a manifold Figure 5 1 Use thread sealant and engage at least two full threads when installing Engine Coolant Temperature Sender The engine coolant temperature sender is located at the top of the engine block Figure 5 1 Use thread sealant and engage at least two full threads when installing In isolated ground applications the sender has two terminals The sensor resistance varies by temperature as in dicated in Table 5 1 TABLE 5 1 COOLANT TEMPERATURE SENSOR RESISTANCE BY TEMPERATURE ao as 5 o GOVERNOR ACTUATOR Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable at the battery to prevent the engine from starting The generator set controller modulates the pulse width of the current it sends to governor actuator A12 Figure 5 1 which positions the engine fuel rack accordingly If troubleshooting indicates that the actuator might be malfunctioning disconnect its two leads and re move the actuator Replace the actuator if the plunger does not move smoothly when pushed in or the internal spring does not return it smoothly If the plunger moves smoothly without binding apply bat tery voltage 12 volts and observe the plunger Re place the actuator if the plunger does not pull in all the way an
63. evere personal injury Ventilate battery area before working on or near battery Wear safety glasses Do not smoke Switch work light ON or OFF away from battery Stop genset and dis connect charger before disconnecting battery cables Disconnect negative cable first and reconnect last Refer to Table 3 1 for scheduled battery mainte nance and follow the battery manufacturer s in structions Have the battery charging system ser viced if DC system voltage is consistently low or high Always 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 connections always removing the negative cable first and reconnecting it last to reduce arcing REPLACING THE AIR FILTER ELEMENT Refer to Table 3 1 for scheduled air filter replace ment Replace it more often in dusty environments The air filter is located on the side of the engine as shown in Figure 3 2 AIR FILTER
64. genset rating The reason for this is that a motor s startup load is much larger than its running load t may be necessary to run fewer appliances when large motors and air condi tioners are cycling on and off Maximum power decreases as altitude increases because air density decreases Maximum power also decreases as ambient temperature increases For every 1000 foot 305 m increase in elevation expect the power to decrease approximately 3 5 percent For every 10 5 5 C increase in am bient temperature above 85 F 29 4 C expect the power to decrease approximately 1 percent See Table 2 2 It may be necessary to run fewer ap pliances at higher altitudes TABLE 2 1 TYPICAL APPLIANCE LOADS 50 200 TABLE 2 2 POWER VS ALTITUDE Altitude i Elevation above Sea Level eben tud at below 500 ft 152 m 20 000 W genset rating at 2500 ft 762 m 18 600 W at 5500 ft 1676 m 16 500 W above 5500 ft 1676 m 16 500 W minus 700 W every 1000 ft 305 m TABLE 2 3 POWER VS TEMPERATURE 85 F 29 450 20 000 W genset rating 29 4 C 95 F 35 C 19 800 W 105 F 40 6 C 19 600 W 122 F 50 C or greater 19 260 W minus 200 W every 10 F 5 5 C Appliance load and genset power are measured in terms of watts W or kilowatts KW where 1 kilowatt KW 1000 watts W TABLE 2 4 POWER VS TEMPERATURE AND ALTITUDE Temperature and Altitude Maximum Power 60 Hz 85 F at below 500 ft
65. hnical support Distributors contact factory for technical support 8 9 UNDERFREQUENCY FAULT CODE NO 15 Possible Cause Generator set loads engine governor fuel supply generator windings wire connections Logic Frequency dropped below 54 Hz for more than 8 seconds Corrective Action Verify that Last Fault is fault code 15 Yes continue diagnosis No troubleshoot actual last fault Turn OFF the generator circuit breaker If the generator now runs run with fewer connected loads Check the fuel level and refill as necessary Note The generator fuel pickup is probably higher than the vehicle engine fuel pickup Check for fuel air leaks at all fuel fittings and tighten as necessary Air bubbles can disrupt frequency Check the engine air filter page 3 4 and remove any blockage Replace the fuel filters page 3 6 Conduct a fuel pump test page 5 3 Disconnect J1 from the control board and check for quadrature resistance between J1 2 and J1 3 If there is no continuity check for missing bent or corroded pins and faulty wiring and repair as neces sary Disconnect J3 from P3 and check for continuity between J3 3 to J1 2 and J3 4 to J1 3 If there is no continuity check for missing bent or corroded pins and faulty wiring and repair as necessary Reconnect J1 and J3 connectors and test run genset for fault occurrence repair or replace pins in con nector as necessary Check all grounds and neutral leads fo
66. i class ABC fire extinguisher handy Figure 5 3 illustrates how the fuel system is as sembled for delivering fuel to and from the fuel injec 5 3 tion system See the engine Workshop Manual for fuel injection system service Fuel Filter See DRAINING CHANGING FUEL FILTER page 3 6 regarding fuel filter maintenance Fuel Pump Test Accidental or remote starting can cause severe personal injury or death Before removing an access door or belt guard discon nect the negative cable at the battery to pre vent the engine from starting First service all of the fuel filters in the system and repair any restrictions to fuel flow If fuel delivery still appears to be weak test for pump delivery as fol lows 1 Disconnect the fuel return hose from the line to the supply tank and point the end into a contain er of known volume such as a 1 or 2 liter quart bottle Prime the generator set by pushing the Start Stop switch to STOP Prime and holding it there for the duration of the test It should not take longer than 1 5 minutes to fill a 1 liter con tainer 2 3 liter per minute 3 Replace the pump if flow is less than specified Fuel Fittings The generator set has a bulkhead fitting on the re turn end For this fitting use iquid type pipe thread sealant Listed as suitable for diesel fuel Apply the sealant sparingly to the male threads only Excess liquid type pipe thread sealant or pieces of Teflon type
67. ic starting device when enabling automatic genset starting EXHAUST GAS is deadly MOV ING PARTS and ELECTRICITY can cause severe personal injury or death To reduce exposure to these hazards always disable automatic genset starting before Sleeping in vehicle unless vehicle has a working CARBON MONOXIDE detector Parking vehicle in garage or confined space Parking vehicle for storage Servicing genset Servicing batteries Servicing electrical appliances Fueling vehicle LOADING THE GENSET The genset can power AC motors air conditioners AC DC converters battery chargers and other ap pliances How much appliance load can be pow ered depends upon the genset power rating The genset will shut down or its circuit breakers will trip if the sum of the loads exceeds the rated genset pow er See Section 8 Troubleshooting 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 2 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 the sum of the loads must not be greater than genset power rating 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 the
68. il is used the oil and oil filter must be changed twice as often as specified in the PERIODIC MAINTENANCE SCHEDULE page 3 1 2 2 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 0 596 weight and 10 000 ppm 1 096 weight The oil and oil filter must be changed twice as often as specified in the PERIODIC MAINTENANCE SCHEDULE page 3 1 Cil Viscosity Look for the SAE Society of Automotive Engineers viscosity grade Referring to Figure 2 1 choose the viscosity grade appropriate for the ambient temper atures expected until the next scheduled oil change Multi grade oils such as SAE 15W 40 are recom mended for year round use 15w40 1 10w30 10w40 32 OF 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 0 OC 29 23 18 12 4 10 16 21 27 32 38 43 48 OOOO FIGURE 2 1 OIL VISCOSITY VS TEMPERATURE COOLANT RECOMMENDATIONS Use the best quality ethylene glycol antifreeze solu tion available It should be fully formulated with rust inhibitors and coolant stabilizers and mixed with fresh distilled water that is low in minerals and cor rosive chemicals A 50 50 mixture is recommended for all climates and is suitable for temperatures down to 34 F 37 C Do not use any other type of cool ant in the generator set or the generator set may be damaged Use onl
69. le with provisions for connecting to utility power must have an approved device to keep the genset and utility from being interconnected 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 device to prevent interconnections 18 200 W OPERATING IN COLD WEATHER Make sure the engine oil viscosity is appropriate for the cold weather temperatures See ENGINE OIL RECOMMENDATIONS page 2 2 Be sure to change the oil if a sudden drop in temperature oc curs 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 pagq 3 2 3 Keep the genset clean 4 Perform maintenance due See PERIODIC MAINTENANCE SCHEDULE page 3 1 OPERATING AT HIGH ALTITUDE For the effect of altitude on maximum power see LOADING THE GENSET page 3 6 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 MAIN
70. leshooting 2 5 MANUAL STARTING The genset can be started and stopped from the genset control panel or from a remote panel 1 Perform the PRE START CHECKS prime the fuel system if necessary and turn off the air conditioners and other large electrical loads Push and hold Start until the genset starts The status lamp will come on when the genset starts and will stay on while it runs While starting it will blink rapidly indicating preheating and crank ing Depending on how cold it is preheating can take up to 15 seconds extending the time that the lamp blinks Excessive cranking can over heat and damage the starter motor Do not crank for more than 30 seconds at a time Wait at least 2 minutes before trying again See Section 8 Troubleshooting if the genset does not start after several tries Let the genset warm up for a few minutes until it is running smoothly before connecting the ve hicle electrical loads appliances Check for fuel oil coolant and exhaust leaks Stop the genset immediately if there is a leak and have it repaired MANUAL STOPPING Run the genset under no load for a few minutes to allow the engine to cool down and then push and re lease 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 au tomat
71. n Hot exhaust pipes and ex haust components Hot engine and generator sur faces Electrical shorts Hot engine coolant Poisonous Operating genset where ex Gas haust gases can accumulate Improper generator connec tions Faulty wiring Working in damp conditions Jewelry touching electrical components Rotating Fan or belt guards not in place Machinery Slippery Leaking or spilled oil Surfaces Heavy Removing genset from vehicle Objects Removing heavy components Testing the Genset Inside a Building Electrical Shock AC Make sure there is ample fresh air when operating the genset inside a building to prevent carbon mon oxide asphyxiation EXHAUST GAS IS DEADLY Engine exhaust must be vented outside if the genset is operated inside a building REMOVING INSTALLING GENSET See Section 8 Troubleshooting to determine the probable cause of the problem before removing the genset for service The genset is normally mounted in a special compartment on the floor of the vehicle or on a supporting frame Contact the vehicle manufacturer or installer if the best way to remove the genset is not obvious Disconnections 1 Disable the automatic genset starting feature of an inverter charger or other automatic starting device and disconnect the negative battery cable from the battery to keep the genset from starting while working on it Then disconnect the battery cables from the genset Ac
72. nds above B5 and up to B20 Cummins Onan requires that the fuel meet the specifications outlined in ASTM D7467 The biodiesel component of this fuel blend must meet ASTM D6751 or EN14214 and the petroleum diesel component must meet ASTM D975 Blended bio diesels fuels should be bought pre blended and not made by customers Bio Diesel Properties Bio diesel has poor oxidation stability which can accelerate fuel oxidation Fuel oxidation will reduce generator performance This effect is accelerated at increased ambient tempera tures Bio diesel properties change at low ambient temperatures below 23 F 5 C Necessary precautions must be taken when operating the generator with bio diesel blends in low ambi ent temperatures such as a fuel heater hose insulation or additional anti gel fuel additives Bio diesel fuel blends are an excellent medium for microbial growth Microbes cause fuel sys tem corrosion and premature filter plugging The effectiveness of all commercially available conventional anti microbial additives when used in bio diesel is not known Consult your fuel and additive supplier for assistance It is highly recommended that specific market applications are avoided or excercised with extra care due to some of the properties of bio die sel fuel blends such as cold weather operation long term storage material incompatibilities and other effects on engine operating characteristics Such applic
73. ne cool down before removing the coolant pressure cap or opening the coolant drain Hot coolant under pressure can spray out and cause severe burns Mobile 8 Keep the genset and its compartment clean Excess oil and oily rags can catch fire Dirt and gear stowed in the compartment can restrict cooling air Make sure all fasteners are secure and torqued properly Do not work on the genset when mentally or physically fatigued or after consuming alcohol or drugs You must be trained and experienced to make adjustments while the genset is running hot moving or electrically live parts can cause se vere personal injury or death Used engine oil has been identified by some U S state and federal agencies as causing cancer or reproductive toxicity Do not ingest inhale or contact used oil or its vapors Ethylene glycol used as engine antifreeze is toxic to humans and animals Clean up spills and dispose of used engine coolant in accor dance with local environmental regulations Keep multi class ABC fire extinguishers readi ly at hand Class A fires involve ordinary com bustible materials such as wood and cloth Class B fires involve combustible and flam mable liquids and gaseous fuels Class C fires involve live electrical equipment See NFPA No 10 Portable Fire Extinguishers or equiva lent BS EN 3 7 2004 Genset installation and operation must comply with all applicable local state and federal codes and regula
74. ness and replace rotor or stator as necessary Dealers contact Distributor for technical support Distributors contact factory for technical support OVER PRIME CODE NO 57 Possible Cause Wire harness faulty switch auto gen start wiring harness Logic Generator is off but priming circuit continuously active for 3 minutes or more Corrective Action Verify that Last Fault is fault code 57 Yes continue diagnosis No troubleshoot actual last fault Disconnect P1 from the control board and P8 from the remote panel and check for a constant ground signal between P1 32 and P8 E If there is a constant ground signal bent or corroded pins and faulty wiring and repair as necessary If there is no continuity test and replace remote panel switch page 2 4 as necessary Disconnect P1 from the control board and P9 from control switch S1 on the generator control panel and check for a constant ground signal between P1 32 and P9 1 If there is a constant ground signal bent or corroded pins and faulty wiring and repair as necessary If there is no continuity test and replace switch S1 page 7 2 as necessary 8 14 ALTERNATOR OVER TEMP CODE NO 76 Possible Cause DC fan blower fan temperature sender wiring harness Logic Temperature at generator alternator is greater than 180 degrees F Corrective Action Verify that Last Fault is fault code 76 Yes continue diagnosis No troubleshoot actual last fault Verify the g
75. oads in 120 240 VAC applications balance loads within 10 percent line to line as re quired Disconnect J3 from P3 and check for continuity between P3 6 to L2 and P3 1 to L1 If there is no conti nuity check for missing bent or corroded pins and faulty wiring and repair as necessary Disconnect J1 from the control board and check for continuity between J1 34 to L1 and J1 35 to L2 If there is no continuity check for missing bent or corroded pins and faulty wiring and repair as neces sary Measure field quadrature and main winding resistance repair harness and replace rotor or stator as necessary Measure field quadrature and main winding resistance to ground repair harness and replace rotor or stator as necessary Measure field quadrature and main winding resistance to each other repair harness and replace rotor or stator as necessary Dealers contact Distributor for technical support Distributors contact factory for technical support OVERFREQUENCY FAULT CODE NO 14 Possible Cause Generator set loads inverter charger engine governor fuel supply generator windings wire connections Logic Frequency exceeded 66 Hz for more than 6 seconds or spiked to 70 Hz for less than a second Corrective Action Verify that Last Fault is fault code 14 Yes continue diagnosis No troubleshoot actual last fault Check for a tripped generator circuit breaker reset if necessary and run with fewer connected loads A
76. of the rotor shaft circulates the generator cooling air which is drawn in through the cooling air inlet over the rotor MOUNTING FOOT and discharged through the outlet slots at the blow er end See Figure 6 1 The end bell and stator housing are attached by four through studs which pass through the stator as sembly The brushless exciter stator mounts in the end bell while the exciter rotor and its rotating rectifi er assemblies mount on the rotor shaft COOLING AIR OUTLET COOLING AIR INLET END OF GENERATOR FIGURE 6 1 GENERATOR TESTS Testing Rotating Rectifiers Two different rectifier assemblies make up the rotat ing rectifier bridge assembly see Figure 6 2 Test each diode on the rectifier assemblies with an ohm meter using negative and positive polarities Connect one test lead to the F1 stud connect the other lead to diodes CR1 CR2 and CR3 6 1 sequentially and record the resistance value of each rectifier Connect one test lead to the F2 stud connect the other lead to diodes CR4 CR5 and CR6 sequentially and measure the resistance value of each rectifier Reverse the ohmmeter leads from the preced ing steps and repeat the resistance measure ments F1 stud to CR1 through and F2 to CR4 through 6 All resistance values should read high for one test and low for the other test If any reading is high or low for both tests the rectifier assembly is defective Note Use
77. on is above 5000 ft 1500 m a mini mum Cetane Rating of 50 is recommended Current US EPA regulations for Non Road en gines limit diesel fuel sulfur content to a maxi mum of 500 ppm 0 0596 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 515 die sel 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 001596 weight Do not use diesel fuel having a sulfur content greater than 10 000 ppm 1 096 weight Diesel fuel must meet the ASTM D975 stan dard for lubricity and pass a minimum load level of 3100 grams as measured by ASTM D6078 or maximum scar diameter of 0 45 mm as mea sured by ASTM D6079 or ISO 12156 1 2 1 BIO DIESEL FUELS B5 B20 B5 bio diesel fuel that meets industry specifications and quality is suitable for use with this generator set Bio Diesel Above B5 and up to B20 Bio Diesel Blends The following must be verified before using bio die sel blends up to B20 The generator set is at Spec B or higher The vehicle propulsion engine is capable of us ing B20 when sharing the same fuel tank The OEM has installed B20 compatible fuel line from fuel tank to generator set The OEM has installed a water separator in the fuel line just before the generator set Approved Bio Diesel Fuel For biodiesel ble
78. ontinue diagnosis No troubleshoot actual last fault Verify engine oil is of proper viscosity for the ambient temperatures High oil viscosity can slow down cranking speed Clean and tighten the battery cable connections at the battery and at the generator Recharge or replace the batteries Refer to the battery manufacturer s recommendations Verify the starter and starter wiring to verify the starter is functional when generator is trying to start Disconnect genset control J1 connector verify J1 2 and J1 3 pins are fully inserted and inspect pin condition per PSB 676 insert repair or replace pins as necessary Disconnect J3 from P3 and check for continuity between P3 3 to Q1 and P3 4 to Q2 If there is no conti nuity check for missing bent or corroded pins and faulty wiring and repair as necessary Disconnect J1 from the control board and check for continuity between J1 2 to Q1 and J1 3 to Q2 If there is no continuity check for missing bent or corroded pins and faulty wiring and repair as neces sary Test the generator field stator and quadrature windings for opens and shorts page 6 1 Replace a stator or rotor that has faulty windings Service the generator engine starter in accordance with the Engine Workshop Manual 8 12 CONTROL CARD FAULT CODE NO 35 Possible Cause Control card Logic Microprocessor EEPROM error during self test Corrective Action Verify that Last Fault is fault code 35 Yes continue
79. prevent starting while working on the genset Let the engine cool before removing the pressure cap Relieve any remaining pressure by turning the pressure cap slowly without pushing down When the pressure has been relieved push down on the 3 7 cap turn it the rest of the way and withdraw it Then remove the coolant drain plug Figurer3 5 and drain the coolant into a suitable container Ethylene glycol antifreeze is con sidered toxic Dispose of it according to local regulations for hazardous substances Flush and clean the cooling system before refilling Radiator cleaning chemicals are available at local auto parts stores Follow the instructions for clean ing and flushing that come with the cleaning solu tion Refilling Cooling System Install the coolant drain plug in the radiator using pipe thread sealant Tighten it just enough so that it does not leak when the genset is running and has warmed up Open the air bleed valve located in the engine ther mostat housing Fill the system using a funnel to prevent coolant from entering the overflow bottle hose Once coolant begins to bleed out of the air bleed valve close the air bleed valve and add cool ant until it reaches the fill opening Also fill the re covery tank to the COLD mark then install the pres sure cap Add more coolant if necessary after the generator set has run for a few minutes Coolant Level Check Check coolant level in the recovery tank Fig
80. r looseness at battery amp genset tighten or replace terminals and leads as necessary Check governor actuator and fuel rack for debris damage and looseness readjust and repair as nec essary Measure field quadrature and main winding resistance repair harness and replace rotor or stator as necessary Measure field quadrature and main winding resistance to ground repair harness and replace rotor or stator as necessary Measure field quadrature and main winding resistance to each other repair harness and replace rotor or stator as necessary Service the internal engine governor mechanism in accordance with the Engine Workshop Manual Conduct cylinder compression tests dry and wet and service a worn engine in accordance with the Engine Workshop Manual GOVERNOR ACTUATOR FAULT CODE NO 19 Possible Cause Wire connections governor Logic The controller sensed that the actuator circuit is either open or shorted 8 10 Corrective Action Verify that Last Fault is fault code 19 Yes continue diagnosis No troubleshoot actual last fault Verify the actuator leads are securely connected at the governor actuator Disconnect J1 from the control board and check for continuity between J1 23 and E1 1 and between Ground and E1 2 If there is no continuity check for missing bent or corroded pins and faulty wiring and repair as necessary Inspect and service the governor actuator as necessary page 5 2 GO
81. rator set has an enclosure ACCIDENTAL OR REMOTE STARTING can cause severe personal inju ry or death Disconnect the negative cable from the battery to prevent the engine from starting HOT COOLANT is under pressure and can cause severe burns when loosening the pressure cap Let the engine cool before loosening the pressure cap 2 Remove the coolant pressure cap 3 Remove the two thermostat housing bolts and pull off the housing thermostat and gasket The hose does not need to come off 4 Clean off the gasket area and install the new thermostat and gasket Apply Three Bond 1215 liquid sealant or equivalent to the top side of the gasket FIGURE 3 7 TYPICAL THERMOSTAT 5 Replenish any lost coolant secure the pres sure cap and reconnect the battery cables negative last 3 10 4 Preparations for Service SPECIAL TOOLS The following tools are necessary for servicing the genset Torque wrench 0 75 Ibs ft 0 100 N m Tachometer Digital multi meter AC and DC Voltage Ohms Load test panel and leads load bank SAFETY Hazards and Their Sources There are hazards in servicing gensets Study Safe ty Precautions and become familiar with the haz ards listed in Table 4 1 Note the following safe guards and ways of avoiding hazards Use personal protection Wear appropriate protective safety equipment such as safety shoes and safety glasses Do not wear rings or jewelry and do not we
82. rdance with the genset Installation Manual Make sure there is ample fresh air when operating the genset in a con fined area PRE START CHECKS Before the first start of the day and after every eight hours of operation inspect the genset as instructed under GENERAL INSPECTION page 3 2 Keep a log of maintenance and the hours run and perform any maintenance that may be due See Returning the Genset to Service page 8 8 if the vehicle has been in storage Before each start 1 Make sure all vehicle carbon monoxide CO detectors are working Check for fuel oil and coolant leaks and dam age to the exhaust system To prevent overheating and to reduce fouling with dust and debris make sure the genset s normal ground clearance is not reduced by sloping ground curbs logs or other objects Repark the vehicle if necessary and or remove any objects blocking the air inlet or air outlet Turn off air conditioners and other large ap pliances Make sure that nothing is stored in the area around the generator set and make sure that nothing is interfering with generator set opera tion 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 half a minute Shut down Code No 57 Overprime occurs after 3 min utes of holding the switch down See Section 8 Troub
83. s v A 2 AIV INCITA RANES A 3 nn A 4 loo NER DD D DM A 5 SAFETY PRECAUTIONS Thoroughly read the OPERATOR S MANUAL before operating the genset Safe operation and top performance can only be obtained when equipment is properly operated and main tained The following symbols in this manual alert you to potential hazards to the operator service person and equipment alerts you to an immediate hazard that will result in severe personal injury or death alerts you to a hazard or unsafe practice that can result in severe personal inju ry or death alerts you to a hazard or unsafe practice that can result in personal injury or equipment damage When equipped with an integral or add on Auto matic Generator Starting System AGS control exhaust carbon monoxide CO electric shock and moving parts hazards are possible due to unex pected starting Turn off AGS whenever performing maintenance or service when the vehicle is stored between uses is awaiting service or is parked in a garage or other confined area ENGINE EXHAUST IS DEADLY Inspect for exhaust leaks at every startup and after every eight hours of running Learn the symptoms of carbon monoxide poi soning in the genset Operator s Manual Never sleep in the vehicle while the genset is running unless the vehicle is equipped with a working carbon monoxide detector Do not operate the genset wh
84. sary Inspect the generator compartment and verify that there are no breaks or openings in the vapor proof wall that separates the compartment from the ve hicle interior Seal openings as necessary Make sure that all soundproofing material is in place THIS PAGE LEFT INTENTIONALLY BLANK 11 2 LOCAL START STOP SWITCH GENSET 51 51 3 START P9 3LOCAL START STATUS ES gale STOP Pg 1 LOCAL STOP T S1 2 GND P9 2LOCAL GROUND 51 8 LED P9 8LOCAL STATUS 51 7 LED 9 7 REMOTE PANEL OPTIONAL CONTROL BOARD GENERATOR Fs 31 13 REMOTE J1 5 pium METER REMOTE eos ie 12 02 J1 3 T3 r F J1 1 T4 NOTES BATT VOLT LOCAL RUN J1 METER STATUS INDICATOR j 4 7 1 ALL COMPONENTS SHOWN IN DE ENERGIZED STATE 2 TO ADJUST OUTPUT VOLTAGE WITHIN 1 MINUTE OF START DISCONNECT PRESS AND RELEASE THE START SWITCH 8 TIMES WITHIN en Sm 10 SECONDS THE STATUS LIGHT WILL BEGIN BLINKING PRESS amp RELEASE THE START BUTTON QUICKLY 0 5 SEC REMOTE RUN j4 TO ADJUST THE VOLTAGE UP 0 5V PRESS amp RELEASE THE START BUTTON LONGER gt 1 SEC AIR TEMP SWITCH TO ADJUST THE VOLTAGE DOWN O 5V NORMALLY CLOSED ALLOW GENSET TO RUN FOR 20 SEC TO SAVE SETTINGS CAN A jJ1 2 L amp RETURN TO NORMAL OPERATION THE STATUS LIGHT CAN B
85. ssible 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 Do not park the vehicle in high grass or brush Contact with the exhaust system can cause fire Park the vehicle so that the genset exhaust gases can disperse away from the vehicle Barriers such as walls snow banks high grass and brush and oth er vehicles can cause exhaust gases to accumulate in and around the vehicle 3 2 Do not operate power ventilators or exhaust fans while the vehicle is standing with the genset run ning 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 an
86. stem and corroding or clogging fuel injection components Replacing the Fuel Filter See Table 3 1 for scheduled fuel filter replacement Replace the fuel filter if the engine lacks power 1 Disconnect the negative cable at the battery to prevent the engine from starting and close any fuel supply and return valves Accidental or remote starting can cause severe personal injury or death Discon nect the negative cable at the battery to pre vent the engine from starting 2 Spin off the old filter with a filter wrench and dispose of it in accordance with local environ mental regulations 3 Clean the contact surface on the filter base lu bricate the new filter gasket and spin the new filter on hand tight 4 Prime the engine for at least 30 seconds to fill the new filter page 2 5 Run the generator set and check for leaks Tighten the filter by hand if necessary RETURN HOSE
87. tial for preserving top gen set performance and reliability when the genset cannot be exercised regularly and will be idle for more than 120 days Storing the Genset 1 Disable the automatic genset starting feature of an inverter charger or other automatic starting device 2 8 CARBON MONOXIDE is deadly and can accumulate to dangerous levels in garages and other confined spaces Dis able the automatic genset starting feature of an inverter charger or other automatic starting device before storing the vehicle 2 Push the genset line circuit breaker to OFF page 4 7 3 Disconnect the battery cables negative cable first from the starting battery and store the battery according to the battery manufac turer s recommendations See MAINTAINING THE BATTERY AND BATTERY CONNEC TIONS page 3 4 Change the engine oil and attach a tag indicat ing oil viscosity See ENGINE OIL REC OMMENDATIONS pagq 4 2 Plug the exhaust tail pipe to keep out dirt mois ture bugs etc 6 Close the fuel supply valve if so equipped 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 pagq 3 2 2 Reconnect the starting battery negative cable last See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS page 3 4 3 Remove the plug from the exhaust tailpipe Replace the air
88. ting Screw Silencer Top Mounting Nuts Heat Shield Screws and Nuts Vibration Isolator Center Mounting Screws Vibration Isolator Side Mounting Screws 9 Alternator End Bell Screws 4 4 5 2 9 Engine Oil Drain Valve 31 38 42 51 5 EE EE gt 10 Specifications Do not convert the generator set from 60 Hz to 50 Hz Attempting to do so will damage the equipment MODEL HDKAW GENERATOR SET CONTROL Integrated Microprocessor Based Engine and Generator Controller GENERATOR Single Bearing 4 Pole Rotating Field Power 1 0 power factor 20 000 W Voltage 120 240 Frequency 60 Hz Number of Phases 4 Current 83 3 amps per leg Line Circuit Breaker 2 pole 85 amp FUEL CONSUMPTION No load Half load Full load 0 54 gph 2 04 Iph 1 12 gph 4 24 Iph 1 95 gph 7 39 Iph ENGINE 4 Cylinder In Line Water Cooled Indirect Injection IDI 4 Stroke Cycle Diesel Model V2403 Bore 3 43 in 87 mm Stroke 4 03 in 102 4 mm Displacement 148 53 in 2 434 cc Compression Ratio 24 3 1 Fuel Injection Timing BTDC 13 5 15 Firing Order Clockwise Rotation 1 3 4 2 Fuel Nozzle Injection Pressure 1991 psi 13 73 MPa Cylinder Compression Test 370 psi 2 55 MPa minimum Valve Lash Intake amp Exhaust cold 0 0071 to 0 0087 in 0 18 to 0 22 mm Oil Capacity with filter 10 quart 9 5 liter
89. tions THIS PAGE IS INTENDED TO BE BLANK vi 1 Introduction ABOUT THIS MANUAL IMPORTANT ENGINE INFORMATION CUMMINS POWER GENERATION 1400 73rd Ave NE _Minneapris MN 55432 This is the Service Manual for the generator sets 27 gensets listed on the front cover RPM Hz Bat Ph This genset is not a life support sys tem It can stop without warning Children per Wiring Diagram sons with physical or mental limitations and insulation NEMA Css D Ambient 40 pets could suffer personal injury or death A per The engine family designation engine displacement statement sonal attendant redundant power or alarm sys of compliance with the applicable EPA and or California emis 5 A m sions regulations including the compliance period or category tem must be used if genset opera tion is critical appear in this block on the actual nameplate on the genset sezass Improper service or replacement of parts can lead to severe personal injury or death and to damage to equipment and property Ser vice personnel must be qualified to perform electrical and mechanical service Unauthorized modifications or replacement of fuel exhaust air intake or speed control system components that affect engine emissions
90. urate instrument for this test such as a Kelvin bridge or digital ohmmeter For single phase stators measure between T1 T2 and T3 T4 Resistance values at 77 25 C are listed in Table 6 1 lead length between 0 and 15 feet f any windings are shorted open or grounded replace the stator assembly Before replacing the assembly check the leads for broken wires or insulation WHEATSTONE BRIDGE FIGURE 6 5 TESTING THE GENERATOR STATOR TABLE 6 1 STATOR RESISTANCE VALUES 5 O75 083 Testing the Generator Rotor For these measurements use a megger or insula tion resistance meter which applies 500 VDC or more to the test leads Test for grounds Remove rotor leads F1 and F2 from the tating rectifier assemblies Connect test leads between F1 and the rotor shaft Meter should read 100 000 ohms or greater f the measurement value is less than 100 000 ohms the rotor is questionable Thoroughly dry the rotor and retest Replace a grounded rotor with a new identical part MEGGER OR INSULATION RESISTANCE METER FIGURE 6 6 TESTING WINDINGS RESISTANCE Test for open or shorted windings Remove rotor leads F1 and F2 from the ro tating rectifier assemblies Using an ohmmeter measure the resistance between F1 and F2 see Figure 6 7 Refer to the Rotor Resistance Values Table for the appropriate resistance values at 77 F
91. usage data Switch Handling There is a three position momentary switch that is hard wired to the generator It configures the state of the generator to Start Stop Prime and Off The Switch is tied to a momentary power latch that allows for the control to enter sleep mode The control enters sleep mode if there is inactivity for 5 minutes It draws less then 3mA from the bat tery This limit allows the control to remain con nected to the battery for a long period of time without drawing down the battery CONTROL PANEL The control panel Figure 2 2 has the following fea tures Control Switch This switch is used to start and stop the genset prime the engine fuel system and restore the fault code blinking status light Status Lamp This is a lamp in the control switch that blinks rapidly during preheat and cranking It stays on continuously while the genset is running If the genset shuts down it will blink a numerical code to indicate the nature of the fault shutdown see Section 8 Troubleshooting Rapid blinking before cranking starts indicates that the glow plugs are preheating the combustion chambers The genset controller automatically var ies the time based on engine temperature Line Circuit Breaker s The line circuit breakers protect the AC power leads connected to the gen set Hour Meter The hour meter records the total run ning time of the genset It cannot be reset REMOTE CONTROL PANEL
92. ust if necessary Service the engine in accordance with the Engine Workshop Manual HIGH TEMPERATURE FAULT CODE NO 1 Possible Cause Blower fan thermostat temperature sender air trapped in cooling system cooling system failing water pump 8 5 Logic First level fault code engine coolant temperature exceeded 230 F 110 C for 2 3 seconds while running or 1minute upon startup Corrective Action Check the engine coolant level and add coolant as necessary page 3 7 Check for and remove any objects blocking the air inlet or outlet openings of the generator Purge the coolant system of air page 3 7 Flush the coolant system to remove coolant passage fouling page 3 7 Tighten the terminal on temperature sensor E3 if loose page 5 2 Disconnect P1 from the control board and check for continuity between J1 31 and E3 If there is no continuity check for missing bent or corroded pins and faulty wiring and repair as necessary Test coolant sender E3 and replace if necessary page 5 2 Replace the engine thermostat which might not be opening fully in accordance with the Engine Work shop Manual LOW OIL PRESSURE FAULT CODE NO 2 Possible Cause Low High oil level faulty switch faulty oil pressure relief valve faulty oil pump Logic First level fault code the low oil pressure cutoff switch opened for 3 seconds or more after oil pressure has closed the switch for 3 seconds or longer Corre
93. vided or squeeze off the fuel supply line Disconnect P1 from the control board and P8 from the remote panel and check for continuity between P1 32 and P8 E If there is no continuity check for missing bent or corroded pins and faulty wiring and repair as necessary Disconnect P1 from the control board and P9 from control switch S1 on the generator control panel and check for continuity between P1 32 and P9 1 If there is no continuity check for missing bent or corroded pins and faulty wiring and repair as necessary If there is continuity test and replace switch S1 page 7 2 as necessary THE GENERATOR RUNS BUT THERE IS PERSISTENT AUDIBLE ENGINE SURGING Possible Cause Fuel leaks restrictions or air bubbles failed rotating rectifier cycling loads misadjusted or faulty governor Logic Generator control adjusting to monitored input variables Corrective Action Verify the condition under no load and full load condition utilizing a consistent non cycling load such as a load bank Check all fuel fittings for fuel and air leaks and tighten as necessary Replace the fuel filters page 3 6 Conduct a fuel pump test page 5 3 Test and service the rotating rectifier as necessary page 6 1 Remove the governor actuator test it for proper operation and replace if necessary page 5 2 Service the internal engine governor mechanism in accordance with the Engine Workshop Manual Check high idle speed and readj
94. y ethylene glycol See Section 10 Specifications for coolant capacity Coolant Recovery Tank Fill Cap The recovery tank provides for coolant expansion Replenish the normal loss of coolant by filling here STARTING BATTERIES The genset requires a 12 volt battery to power its control and starting circuits Reliable genset starting and starter service life depend upon adequate bat tery system capacity and maintenance See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS page 3 4 and Section 10 Speci fications for minimum required battery ratings CONTROL OPERATION In order to perform software updates to the control board you will need InPower Onan installed on your computer and a service tool harness 338 4840 To perform updates 1 Disconnect the P8 plug to disconnect the oper ator panel while performing software updates 2 Connect the service tool harness to the com puter and the P8 connector 3 Open InPower Onan and connect to the con trol Perform necessary updates 4 Disconnect the service tool harness and recon nect the operator panel harnessP8 connector STOP START OPERATION Start Control The starter should only engage when the following conditions have been met The stop input to the control is not active Stop overrides start The alternator frequency is less than 1 Hz There is also a lock out timer which prevents start attempts within 3 seconds after the end of the previous att

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