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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Engine Emissions Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Typical Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Fuel Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Bio−diesel Fuels B5 − B20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Engine Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Coolant Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Starting Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Stop / Start Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Remote Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Manual Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Manual Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Automatic Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Loading the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Resetting Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Connecting to Utility Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Operating in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Operating in Hot Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Operating at High Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Operating in Dusty Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Breaking In a New Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Exercising the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

i
SECTION PAGE

Storing the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

3. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Changing Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Maintaining the Battery and Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Replacing the Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cleaning the Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Draining/Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Maintaining the Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Adjusting V-Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Replacing the Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
4. PREPARATIONS FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Removing / Installing Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Test Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Reassembling Mounting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
5. ENGINE AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Major Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Governor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
High-idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Battery Charging Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Timing Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
SAE J1939 CAN Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
6. GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Replacing the Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

ii
SECTION PAGE

7. CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
8. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Diagnostics Features of the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
9. BOLT TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
10. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
11. SERVICE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
CONTROL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

CONTROL WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

AC WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

OUTLINE DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

iii
SAFETY PRECAUTIONS

Thoroughly read the OPERATOR’S MANUAL  Engine cooling air must not be used for heating
before operating the genset. Safe operation and the vehicle.
top performance can only be obtained when
equipment is properly operated and main- GENERATOR VOLTAGE IS DEADLY
tained.
 Disable the automatic genset starting feature
The following symbols in this manual alert you to (AGS) of an inverter-charger or other automat-
potential hazards to the operator, service person ic starting device before servicing the genset to
and equipment. avoid electric shock from an unexpected start.
 Generator electrical output connections must
DANGER alerts you to an immediate hazard be made by a trained and experienced electri-
that will result in severe personal injury or cian in accordance with applicable codes.
death.
 The genset must not be connected to shore
WARNING alerts you to a hazard or unsafe power (utility). Back-feed to shore power can
practice that can result in severe personal inju- cause electrocution and damage to equip-
ry or death. ment. An approved switching device must be
used to prevent interconnections.
CAUTION alerts you to a hazard or unsafe  Use caution when working on live electrical
practice that can result in personal injury or equipment. Remove jewelry, make sure cloth-
equipment damage. ing and shoes are dry, stand on a dry wooden
platform or rubber insulating mat and use tools
When equipped with an integral or add−on Auto- with insulated handles.
matic Generator Starting System (AGS) control,
exhaust carbon monoxide (CO), electric shock, and DIESEL FUEL IS COMBUSTIBLE
moving parts hazards are possible due to unex-
pected starting. Turn off AGS whenever performing  Do not smoke or turn electrical switches ON or
maintenance or service, when the vehicle is stored OFF where fuel fumes are present or in areas
between uses, is awaiting service, or is parked in a sharing ventilation with fuel tanks or equip-
garage or other confined area. ment. Keep flames, sparks, pilot lights, arc-
producing equipment and all other sources of
ENGINE EXHAUST IS DEADLY ignition well away.
 Inspect for exhaust leaks at every startup and  Fuel lines must be secured, free of leaks and
after every eight hours of running. separated or shielded from electrical wiring.
 Learn the symptoms of carbon monoxide poi-
soning in the genset Operator’s Manual. MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
 Never sleep in the vehicle while the genset is
running unless the vehicle is equipped with a  Disable the automatic genset starting feature
working carbon monoxide detector. (AGS) of an inverter-charger or other automat-
ic starting device before servicing the genset to
 Do not operate the genset when the vehicle is avoid unexpected starting.
parked in a confined space, such as a garage.
 Do not wear loose clothing or jewelry near
 Disable the AGS feature of an inverter-charger moving parts such as PTO shafts, fans, belts
or other automatic starting device before stor- and pulleys.
ing the vehicle or parking it in a garage or other
confined space.  Keep hands away from moving parts.
 The exhaust system must be installed in accor-  Keep guards in place over fans, belts, pulleys,
dance with the genset Installation Manual. and other moving parts.

iv
 BATTERY GAS IS EXPLOSIVE  Keep the genset and its compartment clean.
Excess oil and oily rags can catch fire. Dirt and
 Wear safety glasses. gear stowed in the compartment can restrict
 Do not smoke. cooling air.
 To reduce arcing when disconnecting or recon-  Make sure all fasteners are secure and
necting battery cables, always disconnect the torqued properly.
negative (−) battery cable first and reconnect  Do not work on the genset when mentally or
it last. physically fatigued or after consuming alcohol
or drugs.
FLAMMABLE VAPOR CAN CAUSE A
 You must be trained and experienced to make
DIESEL ENGINE TO OVERSPEED
adjustments while the genset is running—hot,
moving or electrically live parts can cause se-
Flammable vapor can cause a diesel engine to
vere personal injury or death.
overspeed and become difficult to stop, resulting in
possible fire, explosion, severe personal injury and  Used engine oil has been identified by some
death. Do not operate a diesel-powered genset U. S. state and federal agencies as causing
where a flammable vapor environment can be cancer or reproductive toxicity. Do not ingest,
created by fuel spill, leak, etc. The owners and inhale, or contact used oil or its vapors.
operators of the genset are solely responsible for  Ethylene glycol, used as engine antifreeze, is
operating the genset safely. toxic to humans and animals. Clean up spills
and dispose of used engine coolant in accor-
GENERAL PRECAUTIONS dance with local environmental regulations.
 Keep children away from the genset.  Keep multi-class ABC fire extinguishers readi-
 Do not use evaporative starting fluids. They ly at hand. Class A fires involve ordinary com-
are highly explosive. bustible materials such as wood and cloth.
Class B fires involve combustible and flam-
 To prevent accidental or remote starting while mable liquids and gaseous fuels. Class C fires
working on the genset, disconnect the nega- involve live electrical equipment. See NFPA
tive (−) battery cable at the battery. No. 10 (Portable Fire Extinguishers) or equiva-
 Let the engine cool down before removing the lent—BS EN 3-7:2004.
coolant pressure cap or opening the coolant  Genset installation and operation must comply
drain. Hot coolant under pressure can spray with all applicable local, state and federal
out and cause severe burns. codes and regulations.

Mobile-8

v
THIS PAGE IS INTENDED TO BE BLANK

vi
1. Introduction
ABOUT THIS MANUAL

This is the Service Manual for the generator sets

(gensets) listed on the front cover.

WARNING This genset is not a life support sys-

tem. It can stop without warning. Children, per-
sons with physical or mental limitations, and
pets could suffer personal injury or death. A 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-
sions regulations, including the compliance period or category,
tem must be used if genset operation is critical. appear in this block on the actual nameplate on the genset.]

WARNING 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 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.

1-1
 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. I. EN-
GINES (DIESELS) that was shipped in the same
package as the Operator’s Manual.

EMISSIONS LABEL

FIGURE 1-2. EMISSIONS LABEL LOCATION

1-2
 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-
component locations.
erating features such as the fuel and battery con-

REAR CONTROL PANEL CONNECTIONS

COOLANT AIR BLEED VALVE WITH COVER AND GENERATOR SET
CONTROL REMOVED FOR CLARITY -
SEE DETAIL

COMPARTMENT AIR
TEMPERATURE
SWITCH

SPARK ARRESTOR PLUG

LINE 1

LINE 2

LOAD 1

LOAD 2

GROUND STUD

FIGURE 1-3. GENSET COMPONENT LOCATIONS

1-3
 CIRCUIT BREAKER START/STOP/ AIR FILTER COOLANT FILL
HOUR METER
PRIME

OIL
FILL

OIL DIP-
COOLING/ STICK
VENT AIR
IN OIL FILTER

OPTIONAL
BATTERY
AND FUEL CON-
NECTIONS
ON THIS END

BATTERY
COOLANT CONNECTIONS
RECOVERY OIL FUEL
TANK DRAIN CONNECTIONS
HOSE OIL FUEL HOT
DRAIN FILTER AIR OUT
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 BIO−DIESEL FUELS B5 − B20

B5 bio−diesel fuel that meets industry specifications
WARNING Diesel fuel is combustible and can and quality is suitable for use with this generator set.
cause severe personal injury or death. Do not
smoke near fuel tanks or fuel-burning equip- Bio−Diesel Above B5 and up to B20
ment or in areas sharing ventilation with such Bio−Diesel Blends
equipment. Keep flames, sparks, pilot flames,
electrical arcs and switches and all other The following must be verified before using bio−die-
sources of ignition well away. Keep a multi- sel blends up to B20:
class ABC fire extinguisher handy.  The generator set is at Spec B or higher.
 The vehicle propulsion engine is capable of us-
High quality diesel fuel is necessary for good perfor- ing B20 when sharing the same fuel tank.
mance and long engine life.  The OEM has installed B20 compatible fuel line
from fuel tank to generator set.
 The specifications for the type and sulfur con-
 The OEM has installed a water separator in the
tent (ppm, % weight) of the diesel fuel used
fuel line just before the generator set.
must comply with all emissions regulations ap-
plicable in the areas where the genset is to be Approved Bio−Diesel Fuel:
operated.
 For biodiesel blends above B5 and up to B20,
 Diesel fuels meeting ASTM D975 or EN 590 Cummins Onan requires that the fuel meet the
specifications are recommended. Use Grade specifications outlined in ASTM D7467.
1-D diesel fuel where ambient temperatures  The biodiesel component of this fuel blend
are below 14 F (−10 C). A minimum Fuel Ce- must meet ASTM D6751 or EN14214 and the
tane Rating of 45 is recommended. Where am- petroleum−diesel component must meet
bient temperatures are below −4 F (−20 C), or ASTM D975.
the elevation is above 5000 ft (1500 m), a mini-
mum Cetane Rating of 50 is recommended.  Blended bio−diesels fuels should be bought
pre−blended and not made by customers.
 Current US EPA regulations for Non-Road en-
gines limit diesel fuel sulfur content to a maxi- Bio−Diesel Properties:
mum of 500 ppm (0.05% weight). Therefore,  Bio−diesel has poor oxidation stability which
use Grade 2-D S500 or 2-D S15 diesel fuel. can accelerate fuel oxidation. Fuel oxidation
Where ambient temperatures are below 14 F will reduce generator performance. This effect
(−10 C), use Grade 1-D S500 or 1-D S15 die- is accelerated at increased ambient tempera-
sel fuel. Note that beginning in year 2010, US tures.
EPA regulations for Non-Road engines will limit
 Bio−diesel properties change at low ambient
diesel fuel sulfur content to a maximum of 15
temperatures (below 23F/−5C). Necessary
ppm (0.0015% weight).
precautions must be taken when operating the
generator with bio−diesel blends in low ambi-
 Do not use diesel fuel having a sulfur content
ent temperatures, such as a fuel heater, hose
greater than 10,000 ppm (1.0% weight).
insulation, or additional anti−gel fuel additives.
 Diesel fuel must meet the ASTM D975 stan-  Bio−diesel fuel blends are an excellent medium
dard for lubricity and pass a minimum load level for microbial growth. Microbes cause fuel sys-
of 3100 grams as measured by ASTM D6078, tem corrosion and premature filter plugging.
or maximum scar diameter of 0.45 mm as mea- The effectiveness of all commercially available
sured by ASTM D6079 or ISO 12156−1. conventional anti−microbial additives, when

2-1
 used in bio−diesel, is not known. Consult your  Non-Regulated Areas: Use CF, CF−4, CG−4,
fuel and additive supplier for assistance. CH−4 or CI−4 class oil when using high sulfur
fuel—sulfur content between 5000 ppm (0.5%
WARNING It is highly recommended that specific weight) and 10,000 ppm (1.0% weight). The oil
market applications are avoided or excercised with and oil filter must be changed twice as often as
extra care due to some of the properties of bio−die- specified in the PERIODIC MAINTENANCE
sel fuel blends such as cold weather operation, long SCHEDULE (page 3-1).
term storage, material incompatibilities and other
effects on engine operating characteristics. Such Oil Viscosity
applications that should use standard fuels include Look for the SAE (Society of Automotive Engineers)
applications that will experience seasonal usage, viscosity grade. Referring to Figure 2-1, choose the
storage for periods exceeding 90 days, and extreme viscosity grade appropriate for the ambient temper-
temperatures or humidity. atures expected until the next scheduled oil change.
Multi-grade oils such as SAE 15W-40 are recom-
Storage Requirements: mended for year-round use.
 If using bio−diesel for seasonal applications
(stored more than 90 days), the generator must 30
be purged before storage by running the en-
gine on pure diesel fuel meeting ASTM D975 15w40
for a mininmum of 30 minutes. 10w30, 10w40

Warranty Coverage: 5w30

0w40
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 FIGURE 2-1. OIL VISCOSITY VS. TEMPERATURE
the specifications outlined in the applicable Installa-
tion, Operator, and Service Manuals are not consid- COOLANT RECOMMENDATIONS
ered to be defects in material or workmanship and
may affect your generator’s warranty. Use the best quality ethylene glycol antifreeze solu-
tion available. It should be fully formulated with rust
inhibitors and coolant stabilizers and mixed with
ENGINE OIL RECOMMENDATIONS
fresh (distilled) water that is low in minerals and cor-
rosive chemicals. A 50/50 mixture is recommended
Oil Performance Class for all climates and is suitable for temperatures
down to −34 F (−37 C).
Use API (American Petroleum Institute) classified
engine oils according to the following guidelines: CAUTION Do not use any other type of cool-
 Emissions-Regulated Areas: It is mandatory ant in the generator set, or the generator set may
to use CF, CF−4, CG−4, CH−4 or CI−4 class oil be damaged. Use only ethylene glycol.
with low sulfur fuel (sulfur content less than 500 See Section 10. Specifications for coolant capacity.
ppm, 0.05% weight) or ultra low sulfur fuel (sul-
fur content less than 15 ppm, 0.0015% weight). Coolant Recovery Tank Fill Cap − The recovery
tank provides for coolant expansion. Replenish the
 Non-Regulated Areas: CF class oil is recom-
normal loss of coolant by filling here.
mended when using high sulfur fuel—sulfur
content between 500 ppm (0.05% weight) and STARTING BATTERIES
5000 ppm (0.5%weight). If CF−4, CG−4, CH−4
or CI−4 class oil is used, the oil and oil filter The genset requires a 12 volt battery to power its
must be changed twice as often as specified in control and starting circuits. Reliable genset starting
the PERIODIC MAINTENANCE SCHEDULE and starter service life depend upon adequate bat-
(page 3-1). tery system capacity and maintenance.

2-2
See MAINTAINING THE BATTERY AND BATTERY -Engine coolant temperature used to deter
CONNECTIONS (page 3-4) and Section 10. Speci- mine glow plug glow times
fications for minimum required battery ratings.
-Actuator circuit open / shorted
CONTROL OPERATION  Glow plug preheat is activated as needed, de-
pending upon temperature
In order to perform software updates to the control
board, you will need InPower Onan installed on your  Status light flashes during preheat
computer and a service tool harness (338−4840).  Left pump energized
To perform updates.
 Governor actuator to full duty cycle
1. Disconnect the P8 plug to disconnect the oper-
ator panel while performing software updates.  Starter is engaged

2. Connect the service tool harness to the com-  Flash status light to signal engine is cranking
puter and the P8 connector.  Enable field flash
3. Open InPower Onan and connect to the con-  Look for frequency pulses. Command starter to
trol. Perform necessary updates. disengage and turn the starter off at start dis-
connect speed (1100 RPM)
4. Disconnect the service tool harness and recon-
nect the operator panel harnessP8 connector
Run Sequence
.
During a Run sequnce:
STOP / START OPERATION
 The load post load time (automatically shuts
the plugs off when time expires)
Start Control
 The governor actuator regulates engine speed
The starter should only engage when the following  The control begins automatic voltage regula-
conditions have been met: tion
 The stop input to the control is not active. Stop
 The status indicator remains on steady
overrides start.
 The alternator frequency is less than 1 Hz. Stop Sequence
There is also a lock−out timer which prevents
start attempts within 3 seconds after the end of The control software performs the following as part
the previous attempt. of the Stop sequence:
 Disables the voltage regulator
The starter should only disengage when:
 Disables the fuel solenoid and the electronic
 The start button is released, or governor (0% duty cycle)
 Generator speed is greater than the start dis-  Turns off the Run output
connect speed (1100 RPM), or
 Stores usage data
 The stop button is pressed.
Switch Handling
Start Sequence
There is a three−position momentary switch that is
The control software performs, in order, the follow- hard wired to the generator. It configures the state of
ing as part of the start sequence: the generator to Start, Stop / Prime, and Off. The
switch is tied to a momentary power latch that allows
 Control performs a system’s check by looking for the control to enter sleep mode.
at the following:
The control enters sleep mode if there is inactivity
-Control configuration − Identify genset (50 / for 5 minutes. It draws less then 3mA from the bat-
60 Hz) tery. This limit allows the control to remain con-
nected to the battery for a long period of time without
-Battery voltage drawing down the battery.

2-3
 CONTROL PANEL Line Circuit Breaker(s) − The line circuit breakers
protect the AC power leads connected to the gen-
set.
The control panel (Figure 2-2) has the following fea-
tures: Hour Meter − The hour meter records the total run-
ning time of the genset. It cannot be reset.
Control Switch − This switch is used to start and
stop the genset, prime the engine fuel system and REMOTE CONTROL PANEL
restore the fault code (blinking status light).
A remote genset control panel can be installed in-
side the vehicle. Three control panel kits are avail-
Status Lamp − This is a lamp in the control switch able:
that blinks rapidly during preheat and cranking. It
 Remote switch / status lamp
stays on continuously while the genset is running. If
the genset shuts down, it will blink a numerical code  Remote switch / status lamp and hour meter
to indicate the nature of the fault shutdown (see
 Remote switch / status lamp and DC voltmeter
Section 8. Troubleshooting).
The DC voltmeter indicates whether voltage across
(Rapid blinking before cranking starts indicates that the 12 VDC control system and battery is normal. If
the glow plugs are preheating the combustion the indicator consistently stays above or below the
chambers. The genset controller automatically var- normal zone, see MAINTAINING THE BATTERY
ies the time based on engine temperature.) AND BATTERY CONNECTIONS (page 3-4).

CONDUIT
CIRCUIT BREAKER HOUR METER CONTROL SWITCH
CONNECTOR
(START/STOP/PRIME)

FIGURE 2-2. CONTROL PANEL

WARNING EXHAUST GAS is deadly. All en-  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- MANUAL STARTING
TOMS, GET INTO FRESH AIR IMMEDIATELY. If
symptoms persist, seek medical attention. Shut The genset can be started and stopped from the
down the genset and do not operate it until it has genset control panel or from a remote panel.
been inspected and repaired. 1. Perform the PRE-START CHECKS, prime the
fuel system if necessary, and turn off the air
Never sleep in the vehicle while the genset is
conditioners and other large electrical loads.
running unless the vehicle has a working car-
bon monoxide detector. The exhaust system 2. Push and hold Start until the genset starts. The
must be installed in accordance with the genset status lamp will come on when the genset starts
Installation Manual. Make sure there is ample and will stay on while it runs. While starting it will
fresh air when operating the genset in a con- blink rapidly indicating preheating and crank-
fined area. ing. (Depending on how cold it is, preheating
can take up to 15 seconds, extending the time
PRE-START CHECKS that the lamp blinks.)

CAUTION Excessive cranking can over-

Before the first start of the day and after every eight heat and damage the starter motor. Do not
hours of operation, inspect the genset as instructed crank for more than 30 seconds at a time.
under GENERAL INSPECTION (page 3-2). Keep a Wait at least 2 minutes before trying again.
log of maintenance and the hours run and perform
any maintenance that may be due. See Returning 3. See Section 8. Troubleshooting if the genset
the Genset to Service (page 2-8) if the vehicle has does not start after several tries.
been in storage. 4. Let the genset warm up for a few minutes until
it is running smoothly before connecting the ve-
Before each start: hicle electrical loads (appliances).
1. Make sure all vehicle carbon monoxide (CO) 5. Check for fuel, oil, coolant and exhaust leaks.
detectors are working. Stop the genset immediately if there is a leak
and have it repaired.
2. Check for fuel, oil and coolant leaks and dam-
age to the exhaust system. MANUAL STOPPING
3. To prevent overheating and to reduce fouling
with dust and debris, make sure the genset’s Run the genset under no load for a few minutes to
normal ground clearance is not reduced by allow the engine to cool down and then push and re-
sloping ground, curbs, logs or other objects. lease Stop.
Repark the vehicle if necessary and/or remove
AUTOMATIC STARTING AND STOPPING
any objects blocking the air inlet or air outlet.
4. Turn off air conditioners and other large ap- The vehicle may be equipped with an inverter-char-
pliances. ger or other automatic genset starting device
(AGS). Always follow the instructions and safety
5. Make sure that nothing is stored in the area precautions provided by the manufacturer of the au-
around the generator set, and make sure that tomatic starting device when enabling automatic
nothing is interfering with generator set opera- genset starting.
tion.
WARNING EXHAUST GAS is deadly. MOV-
PRIMING THE FUEL SYSTEM ING PARTS and ELECTRICITY can cause severe
personal injury or death. To reduce exposure to
The fuel system should be primed after replacing these hazards, always disable automatic genset
the fuel filter or running the genset out of fuel. To starting before:
prime the fuel system, hold the control switch down S Sleeping in vehicle, unless vehicle has a
in its Stop position for at least half a minute. (Shut- working CARBON MONOXIDE detector
down Code No. 57, Overprime, occurs after 3 min-
utes of holding the switch down. See Section 8. S Parking vehicle in garage or confined space
Troubleshooting.) S Parking vehicle for storage

2-5
 S Servicing genset Maximum power decreases as altitude increases
S Servicing batteries because air density decreases. Maximum power
also decreases as ambient temperature increases.
S Servicing electrical appliances For every 1000-foot (305 m) increase in elevation,
S Fueling vehicle expect the power to decrease approximately
3.5 percent. For every 10 F (5.5 C) increase in am-
LOADING THE GENSET bient temperature above 85 F (29.4 C), expect the
power to decrease approximately 1 percent. See
The genset can power AC motors, air conditioners, Table 2-2. It may be necessary to run fewer ap-
AC/DC converters, battery chargers and other ap- pliances at higher altitudes.
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 TABLE 2-1. TYPICAL APPLIANCE LOADS
the sum of the loads exceeds the rated genset pow- Appliance Load (Watts)
er. See Section 8. Troubleshooting.
Air Conditioner 1400−2000
To avoid overloading the genset and causing shut- Battery Charger Up to 3600
downs, compare the sum of the loads of the ap- DC Converter 300−900
pliances that are likely to be used at the same time to Refrigerator 600−1000
the power rating of the genset. Use Table 2-1 or the
Microwave Oven 1000−1500
ratings on the appliances themselves (if so marked)
to obtain the individual appliance loads. It may be Electric Frying Pan or Wok 1000−1500
necessary to run fewer appliances at the same Electric Stove Element 350−1000
time—the sum of the loads must not be greater Electric Water Heater 1000−1500
than genset power rating. Electric Iron 500−1200
The genset may shut down due to overload when a Electric Hair Dryer 800−1500
large motor or air conditioner is started or cycles off Coffee Percolator 550−750
and then on again, even though the sum of the loads Television 200−600
is less than the genset rating. The reason for this is Radio 50−200
that a motor’s startup load is much larger than its
Electric Drill 250−750
running load. It may be necessary to run fewer
appliances when large motors and air condi- Electric Broom 200−500
tioners are cycling on and off. Electric Blanket 50−200

TABLE 2-2. POWER VS. ALTITUDE

Altitude
Maximum Power (60 Hz)
(Elevation above Sea Level)
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
Temperature Maximum Power (60 Hz)
85 F (29.4 C) 20,000 W (genset rating)
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).

2-6
 TABLE 2-4. POWER VS TEMPERATURE AND ALTITUDE
Temperature and Altitude Maximum Power (60 Hz)
85 F at/below 500 ft 20,000 W (genset rating)
95 F at 2500 ft 18,400 W
105 F at 2500 ft 18,200 W

RESETTING CIRCUIT BREAKERS OPERATING IN COLD WEATHER

If a circuit breaker in the main power distribution
Make sure the engine oil viscosity is appropriate for
panel of the vehicle or on the genset (Figure 2-2)
the cold weather temperatures. See ENGINE OIL
trips, either a circuit shorted or too many appliances
RECOMMENDATIONS (page 2-2). Be sure to
were running. Note that the genset will continue to
change the oil if a sudden drop in temperature oc-
run after a circuit breaker trips.
curs.
If a circuit breaker trips, disconnect or turn off as
many loads as possible and reset the circuit break- OPERATING IN HOT WEATHER
er. (Push the circuit breaker to OFF to reset it and
then to ON to reconnect the circuit.) If the circuit Pay particular attention to the following items when
breaker trips right away, either the electrical dis- operating the genset in hot weather:
tribution system has a short or the circuit breaker is
faulty. Call a qualified electrician. 1. Make sure nothing blocks airflow to and from
the genset.
If the circuit breaker does not trip, reconnect the ap-
pliances, one by one, up to a total load that does not 2. Make sure engine oil viscosity is appropriate for
overload the genset or cause the circuit breaker to the ambient temperatures. See ENGINE OIL
trip. If a circuit breaker trips right away when an ap- RECOMMENDATIONS (page 2-2).
pliance is connected, the appliance probably has a
short. 3. Keep the genset clean.
4. Perform maintenance due. See PERIODIC
Electrical appliances and tools must be used and
MAINTENANCE SCHEDULE (page 3-1).
maintained properly and be properly grounded to
cause the line circuit breakers to trip when short cir-
cuits occur. OPERATING AT HIGH ALTITUDE

WARNING Short circuits in electrical ap- For the effect of altitude on maximum power, see
pliances and tools can cause fire and electrical LOADING THE GENSET (page 2-6).
shock leading to severe personal injury or
death. Read and follow the equipment and tool
manufacturer’s instructions and warnings re- OPERATING IN DUSTY ENVIRONMENTS
garding use, maintenance and proper ground-
ing. Pay particular attention to the following items when
operating the genset in dusty environments:
CONNECTING TO UTILITY POWER
1. Do not let dirt and debris accumulate inside the
A vehicle with provisions for connecting to utility genset compartment. Keep the genset clean.
power must have an approved device to keep the
genset and utility from being interconnected. See 2. Perform air cleaner maintenance more often.
the genset Installation Manual for more information. See PERIODIC MAINTENANCE SCHEDULE
(page 3-1).
WARNING Interconnecting the genset and the
3. Change engine oil more often. See PERIODIC
public utility (or any other power source) can MAINTENANCE SCHEDULE (page 3-1).
lead to electrocution of utility line workers,
equipment damage and fire. Use an approved 4. Keep containers of engine oil that have been
switching device to prevent interconnections. opened tightly closed to keep out dust.

2-7
 BREAKING IN A NEW ENGINE WARNING CARBON MONOXIDE is deadly
and can accumulate to dangerous levels in
Proper engine break-in on a new genset or on one garages and other confined spaces. Dis-
with a rebuilt engine is essential for top engine per- able the automatic genset starting feature
formance and acceptable oil consumption. Run the of an inverter-charger or other automatic
genset at approximately 1/2 rated power for the first starting device before storing the vehicle.
2 hours and then at 3/4 rated power for 2 more 2. Push the genset line circuit breaker to OFF
hours. See LOADING THE GENSET (page 2-6). (page 2-7).
3. Disconnect the battery cables (negative [−]
Proper engine oil and oil level are especially critical cable first) from the starting battery and store
during break-in because of the higher engine tem- the battery according to the battery manufac-
peratures that can be expected. Change the oil if not turer’s recommendations. See MAINTAINING
appropriate for the ambient temperatures during THE BATTERY AND BATTERY CONNEC-
break-in. See ENGINE OIL RECOMMENDATIONS TIONS (page 3-4).
(page 2-2). Check oil level twice a day or every
4 hours during the first 24 hours of operation and 4. Change the engine oil and attach a tag indicat-
change the oil and oil filter after the first 50 hours of ing oil viscosity. See ENGINE OIL REC-
operation. OMMENDATIONS (page 2-2).
5. Plug the exhaust tail pipe to keep out dirt, mois-
EXERCISING THE GENSET ture, bugs, etc.
6. Close the fuel supply valve (if so equipped).
Exercise the genset at least 2 hours each month if
use is infrequent. Run the genset at approximately Returning the Genset to Service
1/2 rated power. See LOADING THE GENSET 1. Check the oil tag on the genset and change the
(page 2-6). A single two hour exercise period is oil if the viscosity indicated is not appropriate for
better than several shorter periods. the temperatures expected. See ENGINE OIL
RECOMMENDATIONS (page 2-2).
Exercising a genset drives off moisture, re-lubri- 2. Reconnect the starting battery (negative [−]
cates the engine, replaces stale fuel and removes cable last). See MAINTAINING THE BATTERY
oxides from electrical contacts. The result is better AND BATTERY CONNECTIONS (page 3-4).
starting, more reliable operation and longer engine
life. 3. Remove the plug from the exhaust tailpipe.
4. Replace the air filter element if it is dirty
STORING THE GENSET (page 3-4).
5. Open the fuel supply valve (if so equipped).
Proper storage is essential for preserving top gen- 6. Inspect the genset. See GENERAL INSPEC-
set performance and reliability when the genset TION (page 3-2).
cannot be exercised regularly and will be idle for
more than 120 days. 7. Push the genset line circuit breaker ON
(page 2-7) when the genset is ready to power
appliances.
Storing the Genset
8. Enable the automatic genset starting feature of
1. Disable the automatic genset starting feature of an inverter-charger or other automatic starting
an inverter-charger or other automatic starting device following the device manufacturer’s in-
device. structions and safety precautions.

2-8
3. Periodic Maintenance
Periodic maintenance is essential for top perfor- any engine repair establishment or individual. How-
mance and long genset life. Use Table 3-1 as a ever, warranty work must be completed by an au-
guide for normal periodic maintenance. In hot and thorized Cummins Onan dealer.
dusty environments some maintenance procedures
should be performed more frequently, as indicated
by the footnotes in the table. WARNING Accidental or remote starting can
cause severe personal injury or death. Discon-
Maintenance, replacement or repair of emission nect the negative (−) cable at the battery to pre-
control devices and systems may be performed by vent starting while working on the genset.
TABLE 3-1. PERIODIC MAINTENANCE SCHEDULE
FREQUENCY

MAINTENANCE TASK After Every Every Every Every Every

Every Every
First 50 250 500 800 1500 3000 Page
Day Month
Hrs Hrs Hrs Hrs Hrs Hrs
General Inspection  3-2
Check Engine Oil Level  3-2
Check Engine Coolant Level  3-7
Check Battery & Battery Connections1  3-4
Change Engine Oil & Oil Filter1, 2, 3, 8   3-3
Clean Spark Arrestor3  3-5
Replace Engine Air Filter2, 3  3-4
Replace Fuel Filter3, 9   3-6
Adjust Engine Valve Lash6  −
Flush Coolant System4  3-7
Replace Coolant Pressure Cap4  3-7
Check V-Belt & Coolant Hoses5, 6
 3-9
Replace as necessary

Check Fuel Injector Pressure6, 7  −

Replace Generator Bearing6  −
1. Perform more often when operating in hot weather.
2. Perform more often when operating in dusty conditions.
3. Perform at least once a year.
4. Perform at least once every two years.
5. Perform at least once every five years.
6. Must be performed by trained and experienced personnel (authorized Cummins Onan service representatives).
7. EPA requirement.
8. Perform every 75 hours when using high sulfur fuel. See ENGINE OIL RECOMMENDATIONS (page 2-2).
9. Perform every 250 hours when using B20 Bio−diesel fuel.

3-1
 GENERAL INSPECTION Do not operate power ventilators or exhaust fans
while the vehicle is standing with the genset run-
Inspect the genset before the first start of the day ning. The ventilator or fan can draw exhaust gases
and after every eight hours of operation. into the vehicle.

Oil Level Fuel System

Check engine oil level (Figure 3-1). Check for leaks at hose, tube and pipe fittings in the
fuel supply system while the genset is running and
Engine Coolant System while it is stopped. Check flexible fuel hose sections
for cuts, cracks, and abrasions. Make sure the fuel
CAUTION Operating the genset when coolant line is not rubbing against other parts. Replace worn
level is low can cause serious engine damage. or damaged fuel line parts before leaks occur.

Check the engine coolant level and look for coolant WARNING Diesel fuel leaks can lead to fire. Do
leaks around the bottom of the genset and on the not operate the genset if operation causes fuel
ground below. Minor leaks that can be replenished to leak.
by daily additions of coolant to the recovery tank
should be repaired by a qualified service technician Prime the fuel system if the genset runs out of fuel.
as soon as possible. Larger leaks are cause for
shutting down the genset until it can be repaired. Battery Connections

Exhaust System Check the battery terminals for clean, tight connec-
tions. Loose or corroded connections have high
WARNING EXHAUST GAS IS DEADLY! Do not electrical resistance which makes starting more dif-
operate the genset if there is an exhaust leak or ficult. See MAINTAINING THE BATTERY AND
any danger of exhaust gases entering or being BATTERY CONNECTIONS (page 3-4).
drawn into the vehicle.
Mechanical
Look and listen for exhaust system leaks while the
genset is running. Shut down the genset if a leak is Look for mechanical damage and listen for unusual
found and have it repaired before operating the gen- noises. Check the genset mounting bolts for any
set again. signs of wear.

Look for openings or holes between the genset To prevent overheating and to reduce fouling with
compartment and vehicle cab or living space if the dust and debris, make sure the genset’s normal
genset engine sounds louder than usual. Have all ground clearance is not being reduced by sloping
such openings or holes closed off or sealed to pre- ground, curbs, logs or other objects. Repark the ve-
vent exhaust gases from entering the vehicle. hicle if necessary and/or remove any objects block-
ing the air inlet or air outlet.
Replace dented, bent or severely rusted sections of
the tailpipe and make sure the tailpipe extends at CHECKING ENGINE OIL LEVEL
least 1 inch (25.4 mm) beyond the perimeter of the
vehicle. WARNING State and federal agencies have de-
termined that contact with used engine oil can
WARNING Do not park the vehicle in high grass cause cancer or reproductive toxicity. Avoid
or brush. Contact with the exhaust system can skin contact and breathing of vapors. Use rub-
cause a fire. ber gloves and wash exposed skin.
1. Park the vehicle on level ground, and shut
Park the vehicle so that the genset exhaust gases
down the genset.
can disperse away from the vehicle. Barriers such
as walls, snow banks, high grass and brush and oth- 2. Pull out the oil dip stick, wipe it clean, reinsert
er vehicles can cause exhaust gases to accumulate it and pull it out again to check the oil level (Fig-
in and around the vehicle. ure 3-1).

3-2
 3. Add or drain 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
drain valve or reinsert the oil drain plug (Fig-
CAUTION Too much oil can cause high oil
ure 3-1).
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-
CHANGING ENGINE OIL AND OIL FILTER ter and apply a thin film of clean oil to the gas-
ket. Spin the new filter on until the gasket just
Refer to Table 3-1 for scheduled engine oil change.
touches the block. Turn it an additional 1/2 to
Change oil more often in hot and dusty environ-
3/4 turn. Do not overtighten.
ments.
1. Run the genset until warm and shut it off. 5. Refill with 10 quarts (9.5 liters) of oil, check oil
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

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 viced if DC system voltage is consistently low or
BATTERY CONNECTIONS high. Always:
1. Keep the battery case and terminals clean and
dry and the terminals tight.
WARNING Arcing at battery terminals or in
2. Remove battery cables with a battery terminal
light switches or other equipment, and flames or
puller.
sparks, can ignite battery gas causing severe
personal injury—Ventilate battery area before 3. Make sure which terminal is positive (+) and
working on or near battery—Wear safety which is negative (−) before making battery
glasses—Do not smoke—Switch work light ON connections, always removing the negative (−)
or OFF away from battery—Stop genset and dis- cable first and reconnecting it last to reduce
connect charger before disconnecting battery arcing.
cables—Disconnect negative (−) cable first and
reconnect last. REPLACING THE AIR FILTER ELEMENT
Refer to Table 3-1 for scheduled air filter replace-
Refer to Table 3-1 for scheduled battery mainte- ment. Replace it more often in dusty environments.
nance, and follow the battery manufacturer’s in- The air filter is located on the side of the engine as
structions. Have the battery charging system ser- shown in Figure 3-2.

AIR FILTER

FIGURE 3-2. REPLACING THE AIR FILTER ELEMENT

3-4
 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
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-
WARNING 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.

FIGURE 3-3. SPARK ARRESTOR CLEANOUT PLUG

3-5
DRAINING/REPLACING THE FUEL FILTER Replacing the Fuel Filter
See Table 3-1 for scheduled fuel filter replacement.
WARNING Diesel fuel is combustible and can Replace the fuel filter if the engine lacks power.
cause severe personal injury or death. Do not 1. Disconnect the negative (−) cable at the battery
smoke near diesel fuel tanks or equipment. to prevent the engine from starting, and close
Keep flames, sparks, pilot lights, electrical any fuel supply and return valves.
switches, arc-producing equipment and all oth-
er sources of ignition well away. Keep a type WARNING Accidental or remote starting can
ABC fire extinguisher in the vehicle. cause severe personal injury or death. Discon-
nect the negative (−) cable at the battery to pre-
Close any fuel line shutoff valve before discon- vent the engine from starting.
necting the fuel line from the filter. 2. Spin off the old filter with a filter wrench, and
dispose of it in accordance with local environ-
Accidental or remote starting can cause severe mental regulations.
personal injury or death. Disconnect the nega-
tive (−) cable at the battery to prevent starting 3. Clean the contact surface on the filter base, lu-
while working on the genset. bricate the new filter gasket, and spin the new
filter on hand tight.
4. Prime the engine for at least 30 seconds to fill
Keep dirt, water and other contaminants from entering the new filter (page 2-5). Run the generator set
the fuel system and corroding or clogging fuel injection and check for leaks. Tighten the filter by hand,
components. if necessary.

RETURN HOSE

HOSE TO
ENGINE

FUEL HOSE FROM

FILTER RETURN FUEL PUMP
FUEL FILTER DRAIN PLUG
(WATER-SEPARATOR) FUEL SUPPLY/
FUEL PUMP

FIGURE 3-4. FUEL FILTER

3-6
 MAINTAINING THE ENGINE COOLING cap, turn it the rest of the way and withdraw it. Then
SYSTEM remove the coolant drain plug (Figure 3-5) and
drain the coolant into a suitable container.
Refer to Table 3-1 for scheduled maintenance. The
engine cooling system is filled at the factory with a WARNING Ethylene glycol antifreeze is con-
50/50 mixture of ethylene glycol antifreeze and sidered toxic. Dispose of it according to local
water, which is suitable for temperatures down to regulations for hazardous substances.
−34 F (−37 C).
Flush and clean the cooling system before refilling.
Recommended Coolant Radiator cleaning chemicals are available at local
auto parts stores. Follow the instructions for clean-
See COOLANT RECOMMENDATIONS ing and flushing that come with the cleaning solu-
(page 2-2). tion.

Pressure Cap Refilling Cooling System

Install the coolant drain plug in the radiator using
Replace the pressure cap (Figure 3-5) every two pipe thread sealant. Tighten it just enough so that it
years (seals deteriorate and leak). Proper cooling does not leak when the genset is running and has
system pressure (13 psi) is essential for optimal en- warmed up.
gine cooling and minimal coolant loss.
Open the air bleed valve located in the engine ther-
Draining and Cleaning Cooling System mostat housing. Fill the system using a funnel to
prevent coolant from entering the overflow bottle
WARNING Hot coolant spray can cause severe hose. Once coolant begins to bleed out of the air
burns. Let the engine cool before releasing the bleed valve, close the air bleed valve and add cool-
pressure cap or removing the drain plug. ant until it reaches the fill opening. Also, fill the re-
covery tank to the COLD mark, then install the pres-
Accidental or remote starting can cause severe sure cap. Add more coolant if necessary after the
personal injury or death. Disconnect the nega- generator set has run for a few minutes.
tive (−) cable at the battery to prevent starting
while working on the genset. Coolant Level Check
Let the engine cool before removing the pressure Check coolant level in the recovery tank (Fig-
cap. Relieve any remaining pressure by turning the ure 3-5) before the first startup of each day and fill to
pressure cap slowly, without pushing down. When the COLD mark if necessary with Recommended
the pressure has been relieved, push down on the Coolant.

3-7
 COOLANT PRESSURE CAP

COOLANT SYSTEM
AIR BLEED VALVE

COOLANT DRAIN PLUG COOLANT RECOVERY TANK

FIGURE 3-5. ENGINE COOLING SYSTEM

3-8
 ADJUSTING V-BELT TENSION
TENSION
The V-belt drives the battery charging alternator and ADJUSTING
coolant pump (Figure 3-6). See Table 3-1 for BOLT
scheduled inspection or replacement. Adjust belt
tension as follows:
1. Disconnect the negative (−) cable at the battery
to prevent the engine from starting.
ALTERNATOR
WARNING Accidental or remote starting PIVOT BOLT
can cause severe personal injury or death.
Disconnect the negative (−) cable at the bat-
tery to prevent the engine from starting.
2. Remove the belt guard.
3. Loosen the alternator pivot bolt first and then
the adjusting bracket bolt on top.
4. 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)
3/8 inch (10 mm). Tighten the alternator bolts DEFLECTION @
when tension is correct. 20 LBS (10 KG)

5. Tighten the bolts, secure the belt guard or en-

closure and reconnect the battery cables, neg-
ative (−) last. FIGURE 3-6. ADJUSTING V-BELT TENSION

3-9
 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 generator set has an enclosure.

WARNING ACCIDENTAL OR REMOTE

STARTING can cause severe personal inju-
ry or death. Disconnect the negative (−) THERMOSTAT
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
FIGURE 3-7. TYPICAL THERMOSTAT
thermostat and gasket. Apply Three Bond 1215
liquid sealant or equivalent to the top side of the
gasket.
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  Be prepared for an accident: Keep fire extin-
guishers and safety equipment nearby. Agen-
The following tools are necessary for servicing the cies such as the Red Cross and public safety
genset: departments offer courses in first aid, CPR and
fire control. Take advantage of this information
 Torque wrench: 0−75 lbs-ft (0−100 N-m)
to be ready to respond to an accident. Learn to
 Tachometer be safety-conscious and make safety proce-
 Digital multi-meter: AC and DC Voltage, Ohms dures part of the work routine.

 Load test panel and leads (load bank) TABLE 4-1. HAZARDS AND THEIR SOURCES

SAFETY  Leaking or spilled fuel

Fire and
 Hydrogen gas from battery
Hazards and Their Sources Explosion  Oily rags improperly stored
 Flammable liquids improperly
stored
There are hazards in servicing gensets. Study Safe-
ty Precautions and become familiar with the haz-  Hot exhaust pipes and ex-
ards listed in Table 4-1. Note the following safe- haust components
guards and ways of avoiding hazards: Burns
 Hot engine and generator sur-
faces
 Use personal protection: Wear appropriate  Electrical shorts
protective safety equipment, such as safety  Hot engine coolant
shoes and safety glasses. Poisonous  Operating genset where ex-
Do not wear rings or jewelry and do not wear Gas haust gases can accumulate
loose or damp clothing that might get caught  Improper generator connec-
in equipment or conduct electricity. tions
Electrical  Faulty wiring
 Reduce the hazard: A safe, orderly workshop Shock (AC)  Working in damp conditions
area and well-maintained equipment reduce  Jewelry touching electrical
the hazard potential. Keep guards and shields components
in place on machinery and maintain equipment Rotating  Fan or belt guards not in place
in good working condition. Store flammable liq- Machinery
uids in approved containers; away from fire,
flame, spark, pilot light, switches, arc-produc- Slippery  Leaking or spilled oil
Surfaces
ing equipment and other ignition sources. Keep
the workshop clean and well-lit and provide ad- Heavy  Removing genset from vehicle
equate ventilation. Objects  Removing heavy components
 Develop safe work habits: Unsafe actions Testing the Genset Inside a Building
cause accidents with tools and machines. Be
familiar with the equipment and know how to Make sure there is ample fresh air when operating
use it safely. Use the correct tool for the job and the genset inside a building to prevent carbon mon-
check its condition before starting. Comply with oxide asphyxiation.
the warnings in this manual and take special
precautions when working around electrical WARNING EXHAUST GAS IS DEADLY! Engine
equipment. Do not work alone if possible, and exhaust must be vented outside if the genset is
do not take any risks. operated inside a building.

4-1
 REMOVING / INSTALLING GENSET WARNING Diesel fuel is combustible and
can cause severe personal injury or death.
See Section 8. Troubleshooting to determine the Do not smoke if you are near fuel tanks or
probable cause of the problem before removing the fuel-burning equipment or are in an area
genset for service. The genset is normally mounted sharing ventilation with such equipment.
in a special compartment on the floor of the vehicle Keep flames, sparks, pilot lights, electrical
or on a supporting frame. Contact the vehicle arcs and arc-producing equipment and all
manufacturer or installer if the best way to remove other sources of ignition well away.
the genset is not obvious.

Disconnections Removal from Vehicle

1. Disable the automatic genset starting feature of
Make sure that the genset is firmly supported before
an inverter-charger or other automatic starting
loosening any mounting bolts. There are four bolt
device and disconnect the negative (−) battery
holes in the skid-base for securing the genset to the
cable from the battery to keep the genset from
floor or supporting frame. The lifting eye is accessi-
starting while working on it. Then disconnect
ble near the top of the genset.
the battery cables from the genset.

WARNING Accidental or remote starting WARNING Gensets are heavy and can cause
can cause severe personal injury or death. severe personal injury if dropped during remov-
Disable the automatic starting feature of an al. Use adequate lifting devices. Keep hands
inverter-charger or other automatic starting and feet clear while lifting.
device and disconnect the negative (−)
cable at the battery to prevent starting while Installation in Vehicle
working on the genset.
Generally, installation is the reverse of removal and
Sparks and high current could cause fire disconnection. Before installing the genset, repair
and other damage to the battery, battery any damage to and seal all holes in the vapor-tight,
cables and vehicle if the loose ends of fire-resistive barrier between the genset and coach
cables connected to the battery touch. Al- interior. Make sure all mounting screws, and brack-
ways disconnect the negative (−) battery ets are secure and that all battery, AC output, con-
cable from the battery before disconnecting trol, exhaust and fuel connections are proper and in
the battery cables from the genset. good repair. Perform the service checklist before
2. Disconnect the remote control wiring harness placing the genset in service (Section 11. Service
connector at the genset. Checklist).
3. Disconnect the AC output leads at the genset
terminals. Use four Grade 5 screws (3/8-16 UNC) to secure
the genset to the floor or frame. The screws must
4. Disconnect the exhaust tailpipe from the muf- protrude at least 1/2 inch (10 mm) but not more than
fler flange. 1 inch (25 mm) into the base, as measured from the
5. Disconnect the supply and return fuel lines from bottom surface of the base. Torque the screws to
the genset. 35 lb-ft (41 N-m).

4-2
 TEST STAND WARNING 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 CAUTION 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.

ÅÅÅÅ ÅÅÅÅ
ÅÅÅÅ ÅÅÅÅ
ÉÉÉÉÉÉÉÉÉÅÅÅÅ
ÉÉÉÉÉÉÉÉÉÅÅÅÅ
ÅÅÅÅ
ÅÅÅÅ
ÉÉÉÉÉÉÉÉÉÅÅÅÅ ÅÅÅÅ
ÉÉÉÉÉÉÉÉÉÅÅÅÅ
ÉÉÉÉÉÉÉÉÉÅÅÅÅ
ÅÅÅÅ
ÅÅÅÅ
ÉÉÉÉÉÉÉÉÉÅÅÅÅ ÅÅÅÅ
ÉÉÉÉÉÉÉÉÉÅÅÅÅ
AIR SUPPORT
ÅÅÅÅÉÉÉÉÉÉ
SUPPORT

ÉÉÉÉÉÉÉÉÉÅÅÅÅ ÅÅÅÅÉÉÉÉÉÉ
OUT 1 2

ÉÉÉÉÉÉÉÉÉÅÅÅÅ ÅÅÅÅÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÅÅÅÅ ÅÅÅÅÉÉÉÉÉÉ AIR

ÉÉÉÉÉÉÉÉÉÅÅÅÅ ÅÅÅÅÉÉÉÉÉÉ OUT

ÉÉÉÉÉÉÉÉÉÅÅÅÅ
ÅÅÅÅ ÅÅÅÅÉÉÉÉÉÉ
ÅÅÅÅÉÉÉÉÉÉ
ÅÅÅÅ ÅÅÅÅ
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 See the Engine Workshop Manual 981-0551 for
major engine service procedures. See Specifica-
WARNING Accidental or remote starting can tions (Section 10) in this manual to identify the en-
cause severe personal injury or death. Before gine model number for the generator set.
removing an access door or belt guard, discon-
nect the negative (−) cable at the battery to pre- When remounting the engine torque the vibration
vent the engine from starting. isolator through bolts to 56−68 lb-ft (76−92 N-m).

COOLANT
TEMPERATURE
SENDER

GLOW PLUGS BATTERY

CHARGING
ALTERNATOR

TIMING
MARKS
(VIEWING)

STARTER

OIL PRESSURE
SWITCH

ACTUATOR

FIGURE 5-1. ENGINE COMPONENTS

ENGINE SENSORS the negative (−) cable at the battery to prevent
the engine from starting.
Engine Oil Pressure Switch
The oil pressure sender is threaded into the side of
WARNING Accidental or remote starting can the block or a manifold (Figure 5-1). Use thread
cause severe personal injury or death. Before sealant and engage at least two full threads when
removing a panel or access door, disconnect installing.

5-1
Engine Coolant Temperature Sender HIGH-IDLE SPEED

The engine coolant temperature sender is located Reset high-idle speed if the stop screw seals have
at the top of the engine block (Figure 5-1). Use been broken or internal governor parts have been
thread sealant and engage at least two full threads replaced or are worn. To reset high-idle speed:
when installing. In isolated-ground applications, the 1. Remove the governor actuator to allow opera-
sender has two terminals. tion at full fuel rack, but leave it connected to
keep Fault No. 19 from preventing a start. Plug
The sensor resistance varies by temperature, as in- the opening to keep oil from splashing out.
dicated in Table 5-1.
2. Disconnect the fuel pump, and power it directly
TABLE 5-1. COOLANT TEMPERATURE SENSOR witha 12-Volt battery to keep the engine run-
RESISTANCE BY TEMPERATURE ning when Fault No. 12 or 14 occurs.

Temperature Resistance WARNING These adjusting screws are in

5C 5F Ohms close proximity to rotating belts and pulleys
that can cause severe personal injury. Be
38 100 450+45
very careful not to get your hands near the
66 150 158.2+15.8 pulleys and belts while making the adjust-
93 200 64.3+6.4 ments.
104 219 46.6+2.3 3. Disconnect all loads from the generator set to
121 250 29.3+2.9 protect them from overfrequency, and start the
149 300 15.0+2.2 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
GOVERNOR ACTUATOR the battery.
WARNING Accidental or remote starting can
cause severe personal injury or death. Before
removing a panel or access door, disconnect HIGH-IDLE
the negative (−) cable at the battery to prevent SPEED STOP
SCREWS
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-
GOVERNOR
place the actuator if the plunger does not pull in all ACTUATOR
the way and stay in while power is applied.

The coil in the actuator has a resistance of 5.3+0.3

ohms. FIGURE 5-2. COOLANT SUPPLY TUBE
4. Seal the adjusting threads with paint.
Reinstall the actuator with a new flange gasket.
Torque the two mounting screws to 7−9 lb-ft 5. Re-install all of the components that were re-
(9.5−12.2 N-m). moved or disconnected.

5-2
 GLOW PLUGS tion system. See the engine Workshop Manual for
fuel injection system service.
Refer to the Engine Workshop Manual when replac-
ing the glow plugs (Figure 5-1). Fuel Filter
Note: If a glow plug does not come out after unscrew-
See DRAINING / CHANGING FUEL FILTER
ing it or the end has broken off, it will be necessary to
remove the engine head. Glow plugs can swell if pre- (page 3-6) regarding fuel filter maintenance.
heat voltage is greater than the nominal 12 volts,
such as when a battery booster is used for starting. Fuel Pump Test

STARTER WARNING Accidental or remote starting can

cause severe personal injury or death. Before
WARNING Accidental or remote starting can removing an access door or belt guard, discon-
cause severe personal injury or death. Before nect the negative (−) cable at the battery to pre-
servicing the starter, disconnect the negative vent the engine from starting.
(−) cable at the battery to prevent 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
The starter motor is bolted to the flywheel housing appears to be weak, test for pump delivery as fol-
(Figure 5-1). See the Engine Workshop Manual for lows:
service or replacement. Parts are available for re-
building the starter. Torque the mounting bolts to 1. Disconnect the fuel return hose from the line to
31−38 lb-ft (42−51.5 N-m). the supply tank and point the end into a contain-
er of known volume, such as a 1 or 2 liter (quart)
BATTERY CHARGING ALTERNATOR bottle.
2. Prime the generator set by pushing the Start/
See page 3-9 to adjust or replace the alternator V- Stop switch to STOP(Prime) and holding it
Belt (Figure 5-1). See the Engine Workshop Manual there for the duration of the test. It should not
for service or replacement. take longer than 1.5 minutes to fill a 1 liter con-
tainer (2/3 liter per minute).
TIMING MARKS
3. Replace the pump if flow is less than specified.
The flywheel has timing marks to help set the timing
of the injection system. You can see the timing Fuel Fittings
marks by removing the plug and looking through the
hole indicated in Figure 5-1. See the engine work-
The generator set has a bulkhead fitting on the re-
shop manual for the appropriate injection timing set-
turn end. For this fitting, use liquid-type pipe thread
tings.
sealant Listed as suitable for diesel fuel. Apply the
sealant sparingly to the male threads only.
FUEL SYSTEM
CAUTION Excess liquid-type pipe thread
WARNING Diesel fuel is combustible and can
sealant or pieces of Teflon-type pipe thread
cause severe personal injury or death. Do not
sealant can plug the engine fuel system. Apply
smoke near fuel tanks or fuel-burning equip-
liquid-type pipe thread sealant sparingly to the
ment or in areas sharing ventilation with such
male threads only. Do not use Teflon tape.
equipment. Keep flames, sparks, pilot flames,
electrical arcs and switches and all other
sources of ignition well away. Keep a multi- Fuel Hose
class ABC fire extinguisher handy.
Replace worn or damaged fuel hose with 5/16 in.
Figure 5-3 illustrates how the fuel system is as- I.D. SAE J30R9 fuel hose. The manufacturer must
sembled for delivering fuel to and from the fuel injec- possess a CARB executive order.

5-3
 FUEL SUPPLY
FUEL HOSE
PUMP

FUEL RETURN
HOSE

FUEL
FILTER

FUEL SUPPLY
HOSE

FUEL RETURN
FUEL SUPPLY FUEL SUPPLY (OPTIONAL)
FUEL RETURN (OPTIONAL)

FIGURE 5-3. TYPICAL FUEL SYSTEM

5-4
 EXHAUST SYSTEM SAE J1939 CAN CONNECTION
Because of the clearance between the muffler and The generator set controller can communicate over
the coolant supply tube on the generator set, it may a CAN (controlled area network) datalink. The main
be difficult to remove the muffler. When servicing the use of this datalink is to provide information to an ex-
muffler, it is suggested that you follow these steps to isting CAN datalink, for example, to provide infor-
avoid damaging the studs on the exhaust manifold. mation to a remote operator panel.
1. Remove the coolant supply tube fastener. See
Figure 5-4. CAN communications is based on the SAE J1939
2. Loosen the screw in the coolant supply tube communication protocol. The CAN datalink is based
bracket attached to the tube. See Figure 5-4. on a main trunk (no more than 40 meters long and
3. Rotate the tube outward at the pivot point of the 30 devices) that is terminated by 120-ohm resistors
fastener on the bracket attached to the coolant on each end. Stubs (no longer than 1 meter) extend
tube. 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.

COOLANT SUPPLY
TUBE FASTENER

COOLANT SUPPLY
TUBE BRACKET

FIGURE 5-4. COOLANT SUPPLY TUBE

GENERATOR
SET
CONTROLLER

FIGURE 5-5. CAN DATALINK

Pin Connections TABLE 5-2. SAE J1939 PIN CONNECTIONS

Description Pin
The SAE J1939 pin connections for the generator
controller are identified in Table 5-2. CAN A P8-D
CAN B P8-G
CAN Shield P8-H

5-5
In order to connect to the CAN datalink, a terminat- problems (no termination, wrong termination, or
ing resistor of 120 ohms is required at each end of bad termination).
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 0’s in

each message. Figure 5-6 and Table 5-3 show how
the generator set controller distinguishes between
1’s and 0’s.

A FIGURE 5-7. CAN DATALINK: GOOD SIGNAL

0 1
t

FIGURE 5-6. CAN DATALINK VOLTAGE DIFFEREN-

TIALS

TABLE 5-3. CAN DATALINK VOLTAGE

DIFFERENTIALS
SIGNAL 0 1
J1939 High (+) 2.5 V 3.5 V FIGURE 5-8. CAN DATALINK: BAD SIGNAL
J1939 Low (−) 2.5 V 1.5 V
Voltage Differential 0V 2V SAE J1939 Broadcasts

The source address of the generator controller is

The CAN datalink transmits 0’s and 1’s at 250 234. Instruments will not display any messages
KBaud, or 250 kilobits per second. Hence, it is pos- from the generator controller if the instruments do
sible for the voltages on J1939 High (+) and J1939 not recognize this address.
Low (−) to change 250,000 times per second.
The controller supports the SAE J1939 broadcasts
identified in Table 5-4 (broadcast data) and in Table
Figure 5-7 and Figure 5-8 show some examples of 8-1 (fault codes). Use the PCan tool to monitor
good and bad signals on a high-resolution oscillo- these broadcasts. The controller does not receive
scope. The bad signal is caused by termination SAE J1939 messages.

5-6
 TABLE 5-4. SAE J1939 BROADCASTS Genset hours* 65253 247
Software part number, 65242
Description PGN SPN software version*
Claim Address* 60928 DM2* 65227
DM1 65226 Genset faults Full list of fault codes
Engine temperature 65262 110 identified in Section 8
(coolant temperature) * These messages are only broadcasted on request.
AC output frequency (in 65030 2436
place of engine speed) The genset has a low oil pressure switch, not a
sender, so it cannot provide oil pressure in SAE
AC output voltage 65030 2444
J1939 broadcasts. It does broadcast fault code 2
Battery voltage 65271 168 (Low Oil Pressure Fault) instead.

5-7
THIS PAGE LEFT INTENTIONALLY BLANK

5-8
6. Generator

OVERVIEW and discharged through the outlet slots at the blow-

er end. See Figure 6-1.
The Cummins Onan YD series AC generators are
two-bearing, 1800-rpm, 60-Hertz units. The end bell and stator housing are attached by four
through-studs which pass through the stator as-
A centrifugal blower on the front end of the rotor sembly. The brushless exciter stator mounts in the
shaft circulates the generator cooling air which is end bell while the exciter rotor and its rotating rectifi-
drawn in through the cooling air inlet, over the rotor, er assemblies mount on the rotor shaft.

COOLING
AIR OUTLET

MOUNTING COOLING AIR INLET

FOOT (END OF
GENERATOR)

FIGURE 6-1. GENERATOR

TESTS sequentially, and record the resistance value of
each rectifier.
Testing Rotating Rectifiers  Connect one test lead to the F2− stud, connect
the other lead to diodes CR4, CR5, and CR6
Two different rectifier assemblies make up the rotat- sequentially, and measure the resistance value
ing rectifier bridge assembly (see Figure 6-2). Test of each rectifier.
each diode on the rectifier assemblies with an ohm
 Reverse the ohmmeter leads from the preced-
meter using negative and positive polarities:
ing steps, and repeat the resistance measure-
 Connect one test lead to the F1+ stud, connect ments: F1+ stud to CR1 through 3, and F2− to
the other lead to diodes CR1, CR2, and CR3 CR4 through 6.

6-1
  All resistance values should read high for one Testing Exciter Stator
test and low for the other test. If any reading is
high or low for both tests, the rectifier assembly
is defective. Test the exciter stator for open or shorted windings,
and grounds, as follows (see Figure 6-3).
Note: Use 23 to 26 inch-lbs (2.6 to 2.9 Nwm) torque
when replacing nuts for F1+ and F2−, and diodes CR1
through CR6. Open or shorted windings:

 Disconnect F1+ and F2− exciter field leads

from terminal block in generator end bell, and
DIGITAL measure the resistance between them. The re-
OHMMETER 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.

FIGURE 6-2. TESTING ROTATING RECTIFIERS

WHEATSTONE MEGGER OR INSULATION

BRIDGE RESISTANCE METER

FIGURE 6-3. TESTING WINDINGS RESISTANCE

6-2
Testing the Exciter Rotor Test the exciter rotor for grounds.
 With all generator leads disconnected from
Test the exciter rotor for open, shorted windings, or
diodes CR1 through CR6, measure between
grounds (see Figure 6-4):
any diode lead and exciter rotor laminations.
 Disconnect the main rotor field leads which
connect to the rotating rectifier assemblies at  The reading should be greater than one meg-
F1+ and F2−. ohm.

 Disconnect lead wires from diodes CR1  A reading less than one megohm indicates de-
through CR6. fective ground insulation.

 Using a Wheatstone bridge or digital ohmme- Note: The preferred test is with a Megger or insula-
ter, measure between exciter lead pairs T1−T2, tion resistance meter that applies 500 VDC or more.
T2−T3, and T1−T3. Resistance should mea- Be sure all exciter leads are disconnected from the
sure 645 milliohms  10% at 77 (25 C). diodes. Readings should be 100,000 ohms or greater.

EXCITER ROTOR
ASSEMBLY

EXCITER ROTOR
LAMINATION

MEGGER OR INSULATION
RESISTANCE METER
WHEATSTONE
BRIDGE TESTING WINDING FOR GROUNDS

TESTING WINDING

CONNECTION DIAGRAM

ES−1794s

FIGURE 6-4. TESTING THE EXCITER ROTOR

6-3
Testing the Generator Stator  A reading less than 100,000 ohms indicates a
questionable stator.
Using the proper test equipment, test the stator for  Thoroughly dry the stator and retest.
grounds, opens, and shorts in the windings (Figure
6-5). Test the stator for open or shorted windings:
 Use an accurate instrument for this test such as
Test for grounds: a Kelvin bridge or digital ohmmeter.
Note: Some generators have ground connections to  For single-phase stators, measure between
the frame. Check the wiring diagram. All stator leads T1−T2 and T3−T4.
must be isolated for testing.  Resistance values at 77 (25 C) are listed in
 Use a megger or insulation resistance meter Table 6-1 (lead length between 0 and 15 feet).
which applies 500 VDC or more to the test  If any windings are shorted, open, or grounded,
leads. replace the stator assembly.
 Test each stator winding for a short to the lami-  Before replacing the assembly, check the leads
nations. for broken wires or insulation.

MEGGER OR WHEATSTONE
INSULATION BRIDGE
RESISTANCE
METER

FIGURE 6-5. TESTING THE GENERATOR STATOR

TABLE 6-1. STATOR RESISTANCE VALUES Test for grounds:
Single Phase kW Rating Resistance (ohms +  Remove rotor leads F1+ and F2− from the ro-
5%) tating rectifier assemblies.
20 .075 + .083
 Connect test leads between F1+ and the rotor
shaft. Meter should read 100,000 ohms or
greater.
Testing the Generator Rotor
 If the measurement value is less than 100,000
For these measurements, use a megger or insula- ohms, the rotor is questionable.
tion resistance meter which applies 500 VDC or
more to the test leads.  Thoroughly dry the rotor and retest.

6-4
  Replace a grounded rotor with a new identical
part.

DIGITAL
OHMMETER

MAIN ROTOR
LEADS F1+, F2−

MEGGER OR
INSULATION
RESISTANCE
METER

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.
WARNING 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
FIGURE 6-6. TESTING WINDINGS RESISTANCE properly so that the load cannot shift.
Before starting, disconnect the starting battery
cables (negative [−] first) to make sure the set will
Test for open or shorted windings: not start while working on it.

 Remove rotor leads F1+ and F2− from the ro- WARNING Accidental starting of the generator
set while working on it can cause severe per-
tating rectifier assemblies.
sonal injury or death. Prevent accidental start-
ing by disconnecting the starting battery cables
 Using an ohmmeter, measure the resistance (negative [−] first).
between F1+ and F2− (see Figure 6-7).
Generator Removal
 Refer to the Rotor Resistance Values Table for  Disconnect alternator output leads and exciter
F1 and F2 leads.
the appropriate resistance values at 77F
 Remove the generator from the vehicle.
(25C).
Alternator Disassembly
 Replace a defective rotor with a new, identical Position the alternator with the end bell facing up
part. which facilitates a safer and easier assembly and

6-5
disassembly. Refer to Figure 6-8 for an exploded rotor assembly about one inch above the bench
view of the alternator with parts identification. with a hoist and rope sling.
 Remove nuts from the rotor through studs. CAUTION Use care to prevent damage to the
 Remove the end bell by tapping upward around fan blades. Broken blades will throw the fan out
the joint and separating it from the stator as- of balance and reduce the air flow rate.
sembly.  If it is necessary to replace a damaged fan, sup-
 Remove four stator through-studs with a vise port the rotor assembly horizontally and re-
grip. move the fan from the rotor with a gear puller.
 Using a safe lifting device, stator handling  Hold the rotor in a suitable clamp and loosen
tongs, or chain and lift hooks, lift stator assem- the nut on the rotor through-stud bolt.
bly from gear case adapter. If necessary, lift unit  If required, remove the bearing with a gear pull-
off the bench about one inch and tap adapter 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
CAUTION Do not set stator down on open horizontal position to remove or install the rotor
end, top or bottom. Stator weight can damage lock nut. The lock nut is torqued to 130−150 ft.
the windings. lb. (176−203 NSm).
 If bearing, shaft, or oil seal replacement is re-
 While stator is still on lift tongs or hooks, revolve
quired, hold gear case upright and tap drive pin-
stator to horizontal position and set it on its side.
ion and shaft through gear case.
 Remove the air baffle by loosening four locking  With a vise grips, remove rotor through-stud
screws.
from the drive pinion shaft.
Note: A rope sling is the 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

BRUSHLESS
EXCITER
ROTOR

ROTOR

EXCITER
STATOR

END BELL
RETAINER

BEARING

RECTIFIER
ASSEMBLY
GENERATOR
FAN

FIGURE 6-8. ALTERNATOR PARTS IDENTIFICATION

Alternator Assembly  Torque the shaft nut against the exciter rotor to
130 to 150 ft. lbs. (176 to 203 NSm).
Assemble alternator components in reverse order CAUTION Use care to prevent damage to the
from disassembly using the following additional in- fan blades. Broken blades will throw the fan out
structions.
of balance and reduce the air flow rate.
 Clean and inspect mating surfaces.  Install two stator through-studs in the adapter
for aligning the stator assembly over the rotor.
 Coat mating area between alternator bearing
and end bell bearing hole with a thin film of Mo-  Install the baffle ring.
lykote or equivalent lubricant.  Install the remaining two stator through-studs
 Install rotor through-stud in drive pinion shaft, in the adapter.
if it was removed.  Install the stator and end bell. Torque the nuts
on the through-studs to 19 to 21 ft. lbs. (26 to 28
 Install the rotor and fan assembly on the adapt- NSm).
er.
 Torque the rotor through-stud nut to 55 to 60 ft.
 Guide the key slot in the fan onto the key in the lbs (75 to 81 NSm).
drive pinion shaft. A raised line on the fan body
 Install the mounting feet and the control box.
casting indicates the location of the key slot in-
side. The drive shaft and key can be seen  Connect the alternator output and control leads
through the air outlet in the adapter. according to the appropriate wiring diagram.

 If they were removed, install the exciter rotor  Replace the end bell cover.
and shaft bearing.  Replace the reconnect box cover.

6-7
THIS PAGE LEFT INTENTIONALLY BLANK

6-8
7. Control

WARNING Accidental or remote starting can the generator set control components.
cause severe personal injury or death. Before Generator Control
removing a housing panel or access door, dis-
connect the negative (−) cable at the battery to General: The generator control is an integrated mi-
prevent the engine from starting. crocontroller-based engine and generator control. It
provides all the control, monitoring and diagnostic
OVERVIEW functions required to operate a generator set.
Connections: Fan and compartment air tempera-
See Figure 7-2 and Figure 7-3 for an illustration of
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. J1 AND J2 CONNECTIONS
PIN I/O DESCRIPTION
J1-1 Output Field−
J1-2 Input Quad1
J1-3 Input Quad2
J1-4 N/A Not used
J1-5 Input Genset start
J1-6 Input Low oil pressure
J1-7 Output Status light
J1-8 Input B+
J1-9 Input B+
J1-10 N/A Not used
J1-11 Output Starter solenoid; B+ output
J1-12 N/A Not used
J1-13 Output Field+
J1-14 N/A Not used
J1-15 N/A Not used
J1-16 N/A Not used
J1-17 N/A Not used
J1-18 N/A Not used
J1-19 Both RS-485 A; communications
J1-20 Both CAN A
J1-21 Both CAN B
J1-22 Both CAN GND
J1-23 Output Fuel actuator; pulse-width modulated
J1-24 Output Fuel pump; B+ output
J1-25 Output Hour meter; B+ output
J1-26 Both RS-485 B; communications
J1-27 Input B−
J1-28 Output Glow plug
J1-29 N/A Not used

7-1
 PIN I/O DESCRIPTION
J1-30 N/A Not used
J1-31 N/A Not used
J1-32 Input Genset stop
J1-33 Input Must be closed
J1-34 Input Generator Voltage Sense S1
J1-35 Input Generator Voltage Sense S2
J2-3 Output Fan output
J2-4 Input 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
ware. falls below 165F+5F.
Note: Make sure you use a 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

7-2
 LINE CIRCUIT
BREAKER
GENERATOR SET
CONTROLLER

HOUR METER

CONTROL SWITCH

FIGURE 7-2. CONTROL COMPONENTS (FRONT VIEW)

7-3
 GENERATOR SET
CONTROLLER

COMPARTMENT
AIR TEMPERATURE
SWITCH

RELAY K1
RELAY K2
RELAY K3

ENGINE
HARNESS

FIGURE 7-3. CONTROL COMPONENTS (BACK VIEW)

7-4
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 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 F[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 −− −− −− −−
4 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

8-1
 FAULT FAULT NAME J1939 J1939 SPN J1939 J1939 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

WARNING Some generator service procedures present hazards that can result in severe 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 batteries. 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:
 Reset or turn ON the line circuit breaker on the generator.
 Reset or turn ON any other circuit breaker in the power supply system.
 If 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 provided, 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 readjust 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.
Corrective 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.
 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 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.

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 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 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 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 & 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 technical 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 for looseness at battery & 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).

GOVERNOR 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 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.

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 & 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, continue 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 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.
 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 J3 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 harness 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 genset 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

lb-ft N-m
Cooling Fan Guard Screws 20−25 in-lb 2.3−2.8
Cooling Fan Plate Screws 20−25 in-lb 2.3−2.8
Cooling Fan Hub Screw 36−44 49−60
Cooling Fan Screws 7−9 9.5−12.2
Compartment Cooling Fan Hose Clamp Screws 20−25 in-lb 2.3−2.8
Scroll Housing Screws 4.4−5.2 6−7
Coolant Hose Screws 15−19 20−25.7
Water Tube Bracket Screws 27.3−33 37−44.7
Radiator Duct Bracket Screws 15−19 20−25.7
Alternator End Bell Screws 4.4−5.2 6−7
Skid Mounting Scerws 7−9 9.5−12.2
Flywheel Scerws 56−68 76−92
Engine Adapter Screws 27−33 37−44.7
Lifting Bracket Screw 56−68 76−92
Lifting Bracket Flange Screw 15−19 20−25.7
Water Sender 8−12 11−16
Terminal Nut on Water Sender 6−8 in-lb 0.7−0.9
Starter Mounting Screws 31−38 42−51.5
Engine Mount Alternator-side Screw 56−68 76−92
Engine Mount Fan-Belt-side Screw 27−33 37−44.7
Engine Oil Drain Valve 31−38 42−51.5
Governor Actuator Mounting Screws 7.2−9.3 9.8−12.6
Air Filter Bracket Engine Mounting Screws 15−19 20−25.7
Air Filter Mounting Screws 8−12 11−16
Intake Resonator Clamp Screws 25−30 in-lb 2.8−3.4
Air Hose Clamp Screws 25−30 in-lb 2.8−3.4
Fuel Hose Loop Clamp Screw 7.2−9.3 9.8−12.6
Fuel Filter Bracket Engine Mounting Screws 56−68 76−92
Fuel Filter Bracket Fuel Filter Mounting Screws 15−19 20−25.7
Fuel Filter Bracket Side Mounting Screws 7.2−9.3 9.8−12.6
Fuel Pump Nuts 7.2−9.3 9.8−12.6
Fuel Hose Fitting Nut 22.1−29.5 30−40
Generator Mounting Screws 27−33 37−44.7
Silencer Underneath Mounting Screw 56−68 76−92
Silencer Top Mounting Nuts 15−19 20−25.7
Heat Shield Screws and Nuts 15−19 20−25.7
Vibration Isolator Center Mounting Screws 56−68 76−92
Vibration Isolator Side Mounting Screws 15−19 20−25.7

9-1
 lb-ft N-m
Control Cover Screws 7.2−9.3 9.8−12.6
Control Box Generator Lead Screws 7.2−9.3 9.8−12.6
Control Box Circuit Breaker Mounting Screws 1.2−1.5 1.6−2.0
Control Box Saddle Screws 17.7−19.2 24−26
Ground Strap Screws and Nuts 17.7−19.2 24−26
Starter Battery Screws 7.2−9.3 9.8−12.6
Battery Harness Skid Mounting Screws 7.2−9.3 9.8−12.6
Control Card Bottom Mounting Screws 7.2−9.3 9.8−12.6
Control Box Relay Mounting Screws 4.4−5.2 6−7
Control Card Side Mounting Screws (to Back of Control Box) 4.4−5.2 6−7
Control Saddle Alternator Mounting Screws 17.7−19.2 24−26
Temperature Switch 2−3 2.7−4.1
Fan Belt Guard Brackets Engine Mounting Screws 17.7−21.4 24−29
Fan Belt Guard Mounting Screws 3.0−3.6 4.2−4.8

9-2
10. Specifications

CAUTION 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 1
Current 83.3 amps per leg
Line Circuit Breaker 2-pole, 85 amp
FUEL CONSUMPTION:
No-load 0.54 gph (2.04 lph)
Half-load 1.12 gph (4.24 lph)
Full-load 1.95 gph (7.39 lph)
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 in3 (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 & Exhaust (cold) 0.0071 to 0.0087 in (0.18 to 0.22 mm)
Oil Capacity (with filter) 10 quart (9.5 liter)
Cooling System Capacity 7.8 quart (7.4 liter)
DC SYSTEM:
Nominal Battery Voltage 12 volts
650 amps down to 0 F (−17 C)
Minimum Battery Capacity
875 amps down to −10 F (−23 C)
CCA (Cold Cranking Amps)
1000+ amps down to −20 F (−29 C)
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 the exhaust pipe is not overheating adjacent materi-
confirm that the genset will operate as intended. als or equipment. Do not run the genset until all ex-
Check each of the areas described below before haust leaks have been repaired.
putting the genset into service.
WARNING Exhaust gas is deadly. The exhaust
Mounting system must not leak and must discharge all ex-
haust away from the vehicle. Do not run the gen-
Examine all mounting bolts and supporting mem- set until the exhaust leaks have been repaired.
bers to verify that the genset is properly mounted.
All fasteners should be tightened securely to pre- The exhaust tailpipe must be supported by a
vent them from working loose when subjected to hanger near the vehicle perimeter and terminate
vibration. at least 1 inch outside the perimeter and at least
1 foot from doors and windows.
Lubrication
Fuel System
If the engine oil was drained, refill as required.
While the genset is running, inspect the fuel supply
Cooling System and return lines, filter and fittings for leaks. Check
flexible sections for cuts, cracks and abrasions and
If the engine coolant was drained, refill as required. make sure they are not rubbing against anything
that could cause leakage. Repair all fuel leaks im-
Wiring mediately.
Verify that all wiring connections are tight and WARNING Diesel fuel is combustible. Leaking
installed properly. Check each of these connec- fuel could lead to fire and to severe personal in-
tions: jury or death. Repair fuel leaks immediately.
 Load wires
Control
 Control wires
 Ground straps Stop and start the genset several times at the con-
 Battery cables trol panel on the genset and at the remote control
board (if provided) to verify that they work properly.
Output Check
Mechanical
Apply a full load to make sure the genset can pro-
duce rated output. Use a load test panel to apply a Stop the genset and inspect it for leaking gaskets,
progressively greater load until full load is reached. loose fasteners, damaged components and inter-
ference with other equipment. Repair as necessary.
Exhaust System Inspect the generator compartment and verify that
there are no breaks or openings in the vapor-proof
While the genset is running inspect the entire ex- wall that separates the compartment from the ve-
haust system. Look and listen for leaks at all con- hicle interior. Seal openings as necessary. Make
nections, welds, gaskets and joints. Also make sure sure that all soundproofing material is in place.

11-1
THIS PAGE LEFT INTENTIONALLY BLANK

11-2
 No. A026E150 sh 1 of 1
Rev. E
Modified 05/10

CONTROL SCHEMATIC

A-1
 338-4461

CONTROL WIRING HARNESS

A-2
 AC HARNESS

AC WIRING HARNESS

A-3
 No. A026K862 sh 1 of 2
Rev. B
Modified 17/09

OUTLINE DRAWING

A-4
 No. A026K862 sh 2 of 2
Rev. B
Modified 17/09

A-5
THIS PAGE IS INTENDED TO BE BLANK

A-6
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
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are trademarks of Cummins Inc.
E2013 Cummins Power Generation, Inc. All rights reserved.