Operator Operator Manual Manual: RV Generator Set

Operator Manual
RV Generator Set
HDKCA (Spec F-H)

HDKCB (Spec F-H)
English
Original Instructions 5-2016 A043D713 (Issue 5)
Table of Contents
1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1
1.1 Overview ................................................................................................................................. 1
1.2 Warning, Caution, and Note Styles Used in This Manual ..................................................... 1
1.3 General Safety Precautions.................................................................................................... 1
1.4 Automatic Generator Start Control Hazards ........................................................................... 3
1.5 Electrical Shock and Arc Flash Can Cause Severe Personal Injury or Death ....................... 3
1.6 Generator Voltage Is Deadly .................................................................................................. 4
1.7 Engine Exhaust/Carbon Monoxide Is Deadly ......................................................................... 4
1.8 Diesel Fuel Is Combustible ..................................................................................................... 5
1.9 Battery Gas Is Explosive......................................................................................................... 5
1.10 Moving Parts Can Cause Severe Personal Injury or Death ................................................. 6
1.11 CARB .................................................................................................................................... 6
1.12 Generator Set Warning Labels ............................................................................................. 6
2. INTRODUCTION............................................................................................................................ 9
2.1 About this Manual ................................................................................................................... 9
2.2 Related Literature ................................................................................................................... 9
2.3 Model Identification ............................................................................................................... 10
2.3.1 Nameplate Location ................................................................................................... 11
2.4 How to Obtain Service .......................................................................................................... 11
2.4.1 In North America ........................................................................................................ 12
2.4.2 Outside North America............................................................................................... 12
2.4.3 Information To Have Available................................................................................... 12
3. OVERVIEW .................................................................................................................................. 13
3.1 Electromagnetic Compatibility Compliance........................................................................... 13
3.2 Information for Generator Set Users..................................................................................... 13
3.3 Build Standards..................................................................................................................... 13
3.4 Specifications........................................................................................................................ 15
3.4.1 Diesel Model Specifications ....................................................................................... 15
3.5 List of Acronyms ................................................................................................................... 16
4. OPERATION ................................................................................................................................ 19
4.1 Key Component Locations.................................................................................................... 19
4.2 Control Panel ........................................................................................................................ 21
4.2.1 Generator Set Control Panel...................................................................................... 21
4.2.2 Remote Control Panel................................................................................................ 21
4.3 Starting and Stopping the Generator Set ............................................................................. 23
4.3.1 Pre-start Checks ........................................................................................................ 23
4.3.2 Priming the Fuel System ........................................................................................... 23
4.3.3 Starting the Generator Set ......................................................................................... 24
4.3.4 Stopping the Generator Set ....................................................................................... 24
4.4 Loading the Generator Set ................................................................................................... 24
A043D713 (Issue 5) i Copyright © 2016 Cummins Inc.

Table of Contents 5-2016
4.4.1 Power Versus Altitude................................................................................................ 26

4.5 Exercising the Generator Set................................................................................................ 26
4.6 Resetting Line Circuit Breakers ............................................................................................ 27
4.7 Connecting to Shore Power.................................................................................................. 28
4.8 Operating in Weather Extremes ........................................................................................... 28
4.9 Operating in Dusty Environments ......................................................................................... 29
4.10 Care of New or Rebuilt Engine ........................................................................................... 29
5. MAINTENANCE ........................................................................................................................... 31
5.1 Periodic Maintenance ........................................................................................................... 31
5.1.1 Periodic Maintenance Schedule ................................................................................ 31
5.2 Consumable Parts ................................................................................................................ 32
5.3 General Inspection................................................................................................................ 33
5.4 Maintaining the Battery ......................................................................................................... 33
5.5 Maintaining the Lubrication System...................................................................................... 34
5.5.1 Oil Level ..................................................................................................................... 34
5.5.2 Engine Oil Recommendations ................................................................................... 34
5.5.3 Changing Engine Oil and Oil Filter ............................................................................ 35
5.6 Maintaining the Fuel System ................................................................................................ 37
5.6.1 Fuel System ............................................................................................................... 37
5.6.2 Fuel Recommendations ............................................................................................. 37
5.6.3 Replacing the Fuel Filter ............................................................................................ 38
5.7 Maintaining the Cooling System ........................................................................................... 40
5.7.1 Cooling System .......................................................................................................... 40
5.7.2 Coolant Level ............................................................................................................. 41
5.7.3 Coolant Recommendations........................................................................................ 41
5.7.4 Draining and Cleaning Cooling System ..................................................................... 42
5.7.5 Refilling Cooling System ............................................................................................ 42
5.8 Exhaust System .................................................................................................................... 42
5.9 Mechanical System............................................................................................................... 43
5.10 Replacing the Air Filter Element ......................................................................................... 43
5.11 Cleaning the Spark Arrester ............................................................................................... 44
5.12 Storing the Generator Set................................................................................................... 45
5.13 Returning the Generator Set to Service ............................................................................. 45
6. TROUBLESHOOTING ................................................................................................................. 47
6.1 Overview ............................................................................................................................... 47
6.2 Fault Codes........................................................................................................................... 47
6.2.1 Code 1 - Engine Over Temperature .......................................................................... 48
6.2.2 Code 2 - Low Oil Pressure......................................................................................... 48
6.2.3 Code 3 - Service Check............................................................................................. 48
6.2.4 Code 4 - Over Crank.................................................................................................. 48
6.2.5 Code 12 - Over Voltage ............................................................................................. 49
6.2.6 Code 13 - Under Voltage ........................................................................................... 49
6.2.7 Code 14 - Over Frequency ........................................................................................ 49
6.2.8 Code 15 - Under Frequency ...................................................................................... 49
6.2.9 Code 19 - Governor Actuator..................................................................................... 50
Copyright © 2016 Cummins Inc. ii A043D713 (Issue 5)

5-2016 Table of Contents
6.2.10 Code 22 - Governor Actuator Overload ................................................................... 50

6.2.11 Code 27 - Voltage Sense......................................................................................... 50
6.2.12 Code 29 - High Battery Voltage ............................................................................... 50
6.2.13 Code 32 - Low Cranking Speed............................................................................... 50
6.2.14 Code 35 - Control Card Failure................................................................................ 51
6.2.15 Code 36 - Engine Stopped ...................................................................................... 51
6.2.16 Code 38 - Over Current (Field Overload) ................................................................ 51
6.2.17 Code 41 - Generator Rotor ...................................................................................... 51
6.2.18 Code 42 - Processor ................................................................................................ 52
6.2.19 Code 43 - Processor ................................................................................................ 52
6.2.20 Code 45 - Speed Sense .......................................................................................... 52
6.2.21 Code 48 - Generator Field Sense............................................................................ 52
6.2.22 Code 57 - Over Prime.............................................................................................. 52
6.3 Symptom Based.................................................................................................................... 52
6.3.1 Status Indicator Not Working ..................................................................................... 52
6.3.2 Starting Batteries Run Down...................................................................................... 53
6.3.3 Starter Engages-Disengages ..................................................................................... 53
6.3.4 Status Indicator Goes Out While Cranking—No Start ............................................... 53
6.3.5 No Power—Generator Set Running, Status Light On................................................ 53
7. MAINTENANCE RECORD........................................................................................................... 55
A043D713 (Issue 5) iii Copyright © 2016 Cummins Inc.

Table of Contents 5-2016
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Copyright © 2016 Cummins Inc. iv A043D713 (Issue 5)

1 Important Safety Instructions
1.1 Overview
Thoroughly read the Operator Manual before operating the generator set. It contains important instructions
that should be followed during operation and maintenance. Safe operation and top performance can only
be achieved when equipment is properly operated and maintained. The owners and operators of the
generator set are solely responsible for its safe operation.
Generator set operation, maintenance, and installation must comply with all applicable local, state, and
federal codes and regulations. Electricity, fuel, exhaust, moving parts, and batteries present hazards which
can result in severe personal injury or death. Only trained and experienced personnel with knowledge of
fuels, electricity, and machinery hazards should perform generator set installation or adjustment
procedures; or remove, dismantle, or dispose of the generator set.
1.2 Warning, Caution, and Note Styles Used in This

Manual
The following safety styles and symbols found throughout this manual indicate potentially hazardous
conditions to the operator, service personnel, or equipment.
DANGER
Indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION
Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates information considered important, but not hazard-related (e.g., messages relating to
property damage).
1.3 General Safety Precautions

WARNING
Operation of equipment is unsafe when mentally or physically fatigued. Do not operate
equipment in this condition, or after consuming any alcohol or drug.
A043D713 (Issue 5) 1 Copyright © 2016 Cummins Inc.

1. Important Safety Instructions 5-2016
WARNING
Maintaining or installing a generator set can cause severe personal injury. Wear personal
protective equipment such as safety glasses, protective gloves, hard hats, steel-toed boots, and
protective clothing when working on equipment.
WARNING
Running the generator set without the cover or service door can cause severe personal injury or
equipment damage. Do not operate the generator set with the cover or service doors removed.
WARNING
Coolants under pressure can cause severe scalding. Do not open a radiator or heat exchanger
pressure cap while the engine is running. Let the engine cool down before removing the coolant
pressure cap. Turn the cap slowly and do not open it fully until the pressure has been relieved.
WARNING
Hot metal parts can cause severe burns, Avoid contact with the radiator, turbo charger, and
exhaust system.
WARNING
Starting fluids, such as ether, can cause explosion and generator set engine damage. Do not use.
WARNING
Ethylene glycol, used as engine coolant, is toxic to humans and animals. Clean up coolant spills
and dispose of used antifreeze in accordance with local environmental regulations.
WARNING
Used engine oils have been identified by some state and federal agencies to cause cancer or
reproductive toxicity. Do not ingest, breathe the fumes, or contact used oil when checking or
changing engine oil.
CAUTION
To prevent accidental or remote starting while working on the generator set, disconnect the
negative (-) battery cable at the battery using an insulated wrench.
CAUTION
Unsecured or loose fasteners can cause equipment damage. Make sure all fasteners are secure
and properly torqued.
CAUTION
Oily rags and other material can cause fire and restrict cooling. Keep the generator set, drip pan,
and compartment clean.
Copyright © 2016 Cummins Inc. 2 A043D713 (Issue 5)

5-2016 1. Important Safety Instructions
CAUTION
Accumulated grease and oil can cause overheating and engine damage presenting a potential
fire hazard. Keep the generator set clean and repair any oil leaks promptly.
NOTICE
Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible
materials such as wood and cloth. Class B fires involve combustible and flammable liquid fuels
and gaseous fuels. Class C fires involve live electrical equipment. (Refer to NFPA No. 10 in
applicable region.)
1.4 Automatic Generator Start Control Hazards

WARNING
Accidental starting can cause severe personal injury or death. Turn off the AGS whenever
performing maintenance or service, when the vehicle is stored between uses, is awaiting service,
or is parked in a garage or other confined area.
Unexpected starting may occur if the generator set is equipped with an inverter-charger or other Automatic
Generator Start (AGS) control. This may cause exposure to:
• Unexpected generator starting
• Moving parts hazards
• Electric shock
• Exhaust carbon monoxide (CO)
1.5 Electrical Shock and Arc Flash Can Cause Severe

Personal Injury or Death
WARNING
Electrical shocks and arc flashes can cause severe personal injury or death. Adhere to the
following guidelines:
• Only qualified service personnel certified and authorized to work on power circuits should
work on exposed energized power circuits.
• All relevant service material must be available for any electrical work performed by certified
service personnel.
• Exposure to energized power circuits with potentials of 50 VAC or 75 VDC or higher poses a
significant risk of electrical shock and electrical arc flash.
• Refer to standard NFPA 70E, or equivalent safety standards in corresponding regions, for
details of the dangers involved and for safety requirements.

1.6 Generator Voltage Is Deadly

WARNING
Improperly connected generator electrical output connections can cause equipment damage,
severe personal injury, or death. Electrical connections must be made by a trained and
experienced electrician in accordance with applicable codes.
WARNING
Improper installations can cause equipment damage, severe personal injury, or death. All
installations must be conducted by trained and experienced personnel in accordance with the
installation instructions and all applicable codes.
WARNING
Back feed to shore power can cause electrocution and damage to equipment. The generator set
must not be connected to shore power or to any other source of electrical power. An approved
switching device must be used to prevent interconnections.
WARNING
Live electrical equipment can cause electrocution. Use caution when working on live electrical
equipment. Remove jewelry, make sure clothing and shoes are dry, stand on a dry wooden
platform or rubber insulating mat, and use tools with insulated handles.
1.7 Engine Exhaust/Carbon Monoxide Is Deadly

WARNING
Substances in exhaust gases have been identified by some state and federal agencies to cause
cancer or reproductive toxicity. Do not breathe in or come into contact with exhaust gases.
WARNING
Carbon monoxide is a poisonous gas. Inhalation of this gas can cause severe personal injury or
death. Adhere to the following bullet points to make sure carbon monoxide is not being inhaled
by occupants of the vehicle as well as others working on or around the generator set.
• Inspect for exhaust leaks, and test and confirm that all carbon monoxide detectors are
working in accordance with the manufacturer's instructions or owner's manual, prior to
every startup, and after every 8 hours of running.
• Never occupy the vehicle while the generator set is running unless the vehicle is equipped
with a working carbon monoxide detector.
• Never operate the generator set when the vehicle is in a confined space, such as a garage,
basement, or building of any kind.
• Make sure the exhaust system is installed in accordance with the generator set installation
manual.
• Never use engine cooling air for heating a working or living space compartment.
Carbon Monoxide (CO) is odorless, colorless, tasteless, and non-irritating. It cannot be seen or smelled.
Exposure, even to low levels of CO for a prolonged period can lead to asphyxiation (lack of oxygen).

Mild effects of CO poisoning include:

• headache
• dizziness
• drowsiness
• fatigue
• chest pain
• confusion
More extreme symptoms include:
• vomiting
• seizure
• loss of consciousness
1.8 Diesel Fuel Is Combustible

WARNING
Diesel fuel is highly combustible. Adhere to the following bullets to avoid igniting fuel and fuel
vapors.
• Do not smoke or turn electrical switches on or off where fuel fumes are present or in areas
sharing ventilation with fuel tanks or equipment.
• Keep flame, sparks, pilot lights, arc-producing equipment and all other sources of ignition
well away from fuel lines and sources.
• Fuel lines must be secured, free of leaks, and separated or shielded from electrical wiring.
WARNING
Flammable vapor can cause a diesel engine to over speed and become difficult to stop, resulting
in possible fire or explosion, and severe personnel injury or death. Do not operate a diesel-
powered generator set where a flammable vapor environment can be created by fuel spill, leak,
etc.
1.9 Battery Gas Is Explosive

WARNING
Battery gas is highly explosive and may cause personal injury or death if ignited. Take the proper
precautions to avoid personal injury.
• For personal safety, wear appropriate PPE when working on or around the generator set.
• To make sure battery gas is not ignited, do not smoke around the generator set.
• To reduce arcing when disconnecting or reconnecting battery cables, always disconnect
the negative (–) battery cable first and reconnect it last.

1.10 Moving Parts Can Cause Severe Personal Injury or

Death
WARNING
Moving parts can cause severe personal injury or death, and hot exhaust parts can cause severe
burns. Make sure all protective guards are properly in place before starting the generator set.
WARNING
Hot moving, and electrically live parts can cause severe personal injury or death. Keep children
away from the generator set.
WARNING
Hot, moving, and electrically live parts can cause severe personal injury or death. Only trained
and experienced personnel should make adjustments while the generator set is running.
WARNING
Moving parts can catch on loose items such as clothing or jewelry. Do not wear loose clothing or
jewelry near moving parts such as PTO (power take-off) shafts, fans, belts, and pulleys.
WARNING
Moving parts can entangle appendages such as fingers. Keep the protective guards in place over
fans, belts, pulleys, and other moving parts and keep hands away from all moving parts.
1.11 CARB
CAUTION
Unauthorized modifications or replacement of fuel, exhaust, air intake, or speed control system
components that affect engine emissions are prohibited by law in the state of California.
The California Air Resources Board (CARB) has requirements regarding modification & repair of fuel
system & exhaust components including, but not limited to, adherence to evaporative emissions
requirements in mobile installations. Evaporative generator sets must be used in trailers, fifth wheel
trailers, and other non-motorized vehicles where on-board gasoline fuel storage is self-contained in the
trailer equipment. Completing the installation of the generator set fuel evaporative system provides
compliance with the California code of regulations for small off-road equipment effective January 1, 2008
and Federal Small SI regulation effective January 1, 2011. Any questions regarding the installation or
evaporative emission certification should be directed to Cummins Power Generation for clarification.
1.12 Generator Set Warning Labels

Warning signs are provided on the generator set at or near the point of risk. To avoid injury, always take
the necessary precautions as indicated on the sample signs shown below.

Caution or Warning.
Indicates a risk of personal injury.
Caution or Warning of Temperature Hazard.

Indicates a risk of personal injury from high temperature.
Caution or Warning of High Voltage Hazard.

Indicates a risk of personal injury from electric
shock or electrocution.
Caution or Warning of Engine Coolant Pressure Hazard.

Indicates a risk of personal injury from hot pressurized engine coolant.
Caution or Warning.
Indicates to read Operator Manual for additional information.
Caution or Warning of No Step.

Indicates a risk of personal injury or equipment damage from stepping on
equipment.
Caution or Warning of Combustion or Explosion Hazard.

Indicates a risk of personal injury from explosion.
Caution or Warning of Belt and Rotating Part Hazard.

Indicates a risk of personal injury from entanglement in moving parts.
Caution or Warning of Chemical (ingestion or burn) Hazard.

Indicates a risk of personal injury or asphyxiation from poisonous fumes
or toxic gases.
Caution or Warning of High Voltage or Current Source Hazard.

Indicates a risk of personal injury from electrical shock or electrocution.
Caution or Warning of Fan and Rotating Part Hazard.

Indicates a risk of personal injury from entanglement in moving parts.


2 Introduction
2.1 About this Manual
This is the Operator Manual for the generator set or sets listed on the front cover. Each operator should
study this manual carefully and observe all of its instructions and safety precautions. Keep this manual
readily available for reference.
The information contained within the manual is based on information available at the time of printing. In
line with Cummins Power Generation policy of continuous development and improvement, information
may change at any time without notice. The users should therefore make sure that before commencing
any work, they have the latest information available. The latest version of this manual is available on
QuickServe Online (https://quickserve.cummins.com).
The Operation, Maintenance, and Troubleshooting Chapters of this manual provide instructions necessary
for operating the generator set and maintaining it at top performance. The owner is responsible for
performing maintenance in accordance with the information provided in Chapter 5 on page 31.
This manual also includes generator set specifications and information on how to obtain service,
emissions regulation compliance, and model identification.
See the Parts Manual for part identification numbers and required quantities. Genuine Cummins Onan
replacement parts are recommended for best results.
2.2 Related Literature

Before any attempt is made to operate the generator set, the operator should take time to read all of the
manuals supplied with the generator set, and to familiarize themselves with the warnings and operating
procedures.
CAUTION
A generator set must be operated and maintained properly if you are to expect safe and reliable
operation. The Operator manual includes a maintenance schedule and a troubleshooting guide.
The Health and Safety manual must be read in conjunction with this manual for the safe
operation of the generator set:
• Health and Safety Manual (0908-0110)

The relevant manuals appropriate to your generator set are also available, the documents below are in
English:
• Operator Manual for RV Generator Set HDKCA and HDKCB (Spec F-H) (A043D713)
• Installation Manual for RV Generator Set HDKCA and HDKCB (Spec F-H) (A043D717)
• Parts Manual for RV Generator Set HDKCA and HDKCB (Spec F-H) (A043T420)
• Standard Repair Times - BJ Family (900-0621)
• Warranty Manual (1117-0005)
• Global Commercial Warranty Statement (A028U870)

2. Introduction 5-2016
2.3 Model Identification

Each generator set is provided with a nameplate that contains the model and serial numbers. This
information is needed when contacting Cummins Onan for parts, service, and product information.
Every character of the model number is significant. The last character of the model number is the
specification letter which is important for obtaining the correct parts.
Record the generator set model and serial numbers in the figure below to have them available if needed.

5-2016 2. Introduction
2.3.1 Nameplate Location
FIGURE 1. NAMEPLATE LOCATION
2.4 How to Obtain Service

For generator set parts, service, and literature, contact the nearest authorized Cummins Onan distributor.
You may go to the Internet site www.power.cummins.com for information on contacting our distributors
worldwide.

2. Introduction 5-2016
2.4.1 In North America

Call +1 800 8886626 for the nearest Cummins Onan distributor in the United States or Canada. Press 1
(option 1) to be automatically connected.
If you are unable to contact a distributor using the automated service, consult the Yellow Pages. Typically,
our distributors are listed under: generators - electric.
2.4.2 Outside North America

If you are outside North America, refer to www.cumminspower.com and select Distributor Locator, or
send an email to [email protected].
2.4.3 Information To Have Available

• model number
• serial number
• date of purchase
• nature of the problem (see Chapter 6 on page 47)

3 Overview
3.1 Electromagnetic Compatibility Compliance
Generator sets emit and receive electromagnetic (radio frequency) energy. If the generator set affects
operation of nearby devices, or nearby devices affect generator set operation, increase the distance
between them.
When used in countries where compliance to the EMC directive is required: This generator set has been
evaluated for use in the residential, commercial, and light industrial environments.
3.2 Information for Generator Set Users

This generator set meets the requirements of California Air Resources Board (CARB) as stated on the
nameplate.
As a user of this generator set, please be aware that unauthorized modifications or replacement of fuel,
exhaust, air intake, or speed control system components that affect engine emissions are prohibited.
Unauthorized modification, removal, or replacement of the generator set label is prohibited.
Carefully review Operator (Owner), Installation, and other manuals and information you receive with the
generator set. If unsure that the installation, use, maintenance, or service of the generator set is
authorized, seek assistance from an approved Cummins Onan dealer.
Generator set users may use the following table as an aid in locating information related to the CARB
requirements for emissions control.
TABLE 1. EMISSIONS CONTROL INFORMATION
The emissions control warranty statement is located in the same

Generator Set Warranty Information packet of information as this manual when the generator set is shipped
from the factory.
Engine Valve Lash See Section 3.4 on page 15.
The engine is certified to operate on diesel fuel.
Engine Fuel Requirements
See Section 5.6 on page 37 for fuel recommendations.
Engine Lubricating Oil Requirements See Section 5.5 on page 34 for engine oil recommendations.
High idle speed. This is a service procedure requiring trained
Engine Adjustments
personnel and proper tools. See the Service Manual.
The engine emissions control system consists of engine design and
Engine Emission Control System
precision manufacture (IFI).
3.3 Build Standards

The generator set and its control system have been designed, constructed and tested generally in
accordance with the following Standards where applicable.

3. Overview 5-2016
Standard Title
BS EN 1037:1995+a1:2008 Safety of machinery - Prevention of unexpected start up.
BS EN ISO 14121-1:2007 Safety of machinery. Risk assessment principles.
BS EN ISO 13857:2008 Safety of machinery. Safety distances to prevent hazard zones being
reached by upper and lower limbs.
BS EN 349:1993+A1:2008 Safety of machinery - Minimum gaps to avoid crushing parts on the human
body.
BS EN 547-1:1996+A1:2008 Safety of machinery - Human body dimensions - Part 1: Principles for
determining the dimensions required for openings for whole body access
into machinery.
BS EN 547-2:1996+A1:2008 Safety of machinery - Human body dimensions - Part 2: Principles for
determining the dimensions required for access openings.
BS EN 547-3:1996+A1:2008 Safety of machinery - Human body dimensions - Part 3: Anthropomorphic
data.
BS EN 60204-1:2006+A1:2009 Safety of machinery. Electrical equipment of machines. General
requirements.
BS EN 614-1:2006+A1:2009 Safety of machinery. Ergonomic design principles. Terminology and
general principles.
BS EN 953:1997+A1:2009 Safety of machinery - Guards - General requirements for the design and
construction of fixed and movable guards.
BS EN ISO 12100-1:2003+A1:2009 Safety of machinery. Basic concepts, general principles for design. Basic
terminology, methodology
BS EN ISO 12100-2:2003+A1:2009 Safety of machinery. Basic concepts, general principles for design.
Technical principles
BS EN ISO 13732-1:2008 Ergonomics of the thermal environment. Methods for the assessment of
human responses to contact with surfaces. Hot surfaces
BS EN ISO 13849-1:2008 Safety of machinery - Safety-related parts of control systems
BS EN ISO 13850:2006 Safety of machinery - Emergency stop. Principles for design.
BS EN 61310-1:2008 Safety of machinery - Indication, marking and actuation - Part 1:
Requirements for visual, auditory and tactile signals.
BS EN 61310-2:2008 Safety of machinery - Indication, marking and actuation - Part 2:
Requirements for marking.
BS EN 61000-6-1:2007 Electromagnetic compatibility (EMC). Generic standards. Immunity
standard for residential, commercial and light-industrial environments.
BS EN 61000-6-3:2007 Electromagnetic compatibility (EMC). Generic standards. Emission
standard for residential, commercial and light-industrial environments.
BS EN 1299:1997+A1:2008 Mechanical vibration and shock - Vibration isolation of machines -
Information for the application of source isolation
BS EN 1679-1:1998 Reciprocating internal combustion engines - Safety - Part 1: Compression
ignition engines
BS EN 12601:2001 Reciprocating internal combustion engine driven generating sets - Safety

5-2016 3. Overview
3.4 Specifications
3.4.1 Diesel Model Specifications
TABLE 2. DIESEL MODEL SPECIFICATIONS
HDKCA HDKCB
GENERATOR SET CONTROL: Integrated Microprocessor-Based Engine and Generator Control
GENERATOR: Single-Bearing, 4-Pole Rotating Field, 1800 RPM
Power (@1.0 power factor) 10,000 Watts1 12,500 Watts1,2
Frequency 60 Hz 60 Hz
Voltage 120/240 Volts 120/240 Volts
Number of Phases 1 1
Current 41.7 Amps 52.0 Amps
Line Circuit Breaker 2-pole, 45 Amp 2-pole, 50 Amp
FUEL CONSUMPTION:
No Load 1.2 l/h (0.33 gph) 1.4 l/h (0.38 gph)
Half Load 2.0 l/h (0.54 gph) 2.7 l/h (0.71 gph)
Full Load 3.0 l/h (0.78 gph) 4.8 l/h (1.28 gph)
ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection (IDI), 4-Stroke Cycle Diesel
Bore 83 mm (3.27 in) 83 mm (3.27 in)
Stroke 92.4 mm (3.64 in) 92.4 mm (3.64 in)
Displacement 1499 cm3 (91.44 in3) 1499 cm3 (91.44 in3)
Compression Ratio 23.0:1 23.0:1
Fuel Injection Timing (BTDC) 14.25° 14.25°
Firing Order 1-3-2 1-3-2
Fuel Nozzle Injection Pressure 13.731 MPa (1991 psi) 13.731 MPa (1991 psi)
Cylinder Compression Test 2.55 MPa (370 psi) minimum 2.55 MPa (370 psi) minimum
0.18 to 0.22 mm (0.0071 to 0.18 to 0.22 mm (0.0071 to
Valve Lash: Intake and Exhaust (cold)
0.0087 in) 0.0087 in)
Oil Capacity 5.6 liters (5.9 qt) 5.6 liters (5.9 qt)
Cooling System Capacity 6.2 liters (6.6 qt) 6.2 liters (6.6 qt)
DC SYSTEM:
Nominal Battery Voltage 12 Volts 12 Volts
475 Amps down to –17 °C (0 °F) 475 Amps down to –17 °C (0 °F)
Minimum Battery Capacity CCA (Cold
Cranking Amps) 650 Amps down to –29 °C (–20 650 Amps down to –29 °C (–20
°F) °F)
Battery Recharging Installer must provide Installer must provide

3. Overview 5-2016
HDKCA HDKCB
INSTALLATION:
Weight 348 kg (767 lbs) 357 kg (787 lbs)
1051 x 622 x 685 mm 1051 x 622 x 685 mm
Size (L x W x H)
(41.4 x 24.5 x 27 in) (41.4 x 24.5 x 27 in)
70 dB(A) @ 3 m (10 ft) and 54 70 dB(A) @ 3 m (10 ft) and 54
Sound dB(A) @ 15 m (50 ft)—in "free dB(A) @ 15 m (50 ft)—in "free
field site" @ half load field site" @ half load
1. Maximum power capability decreases 3.5% for each 305 m (1000 ft) above 152.4 m (500 ft) and 1% for each 5.5
°C (10 °F) increase in ambient temperature above 25 °C (77 °F).
2. Ratings are at intermittent power output. Continuous power is 95% of rated power.
3.5 List of Acronyms

TABLE 3. ACRONYM DEFINITIONS
Acronym Definition
AC Alternating Current
AGS Automatic Generator Start
ANSI American National Standards Institute
API American Petroleum Institute
ASTM American Society for Testing and Materials (now known as ASTM International)
BS Build Standard
BTDC Before Top Dead Center
CARB California Air Resources Board
CCA Cold Cranking Amp
CO Carbon Monoxide
CPG Cummins Power Generation
CSA Canadian Standards Association
DC Direct Current
EEPROM Electronically Erasable Programmable Read Only Memory
EMC Electromagnetic Compatibility
EPA Environmental Protection Agency
GFCI Grounded Fault Circuit Interrupters
hp High Pressure
I.D. Inside Diameter
ISO International Organization for Standardization

5-2016 3. Overview
Acronym Definition
LED Light-emitting Diode
NFPA National Fire Protection Agency
NPT National Pipe Thread
OEM Original Equipment Manufacturer
PPE Personal Protective Equipment
PTO Power Take-Off
RAM Random Access Memory
ROM Read Only Memory
RV Recreational Vehicle
RVIA RV Industry Association
SAE Society of Automotive Engineers
US, U.S. United States
WC Water Column
TABLE 4. ACRONYMS FOR UNITS OF MEASUREMENT
Acronym Definition
Amp Ampere
C Celsius
cm centimeter
dB(A) Decibel A-Weighted
F Fahrenheit
ft Feet, foot
ft-lbs Foot-pounds
gph Gallons per hour
H Height
Hz Hertz
in Inch
kg kilogram
kW kilowatt
l/h Liters per hour
L Length
lb Pound
lbs/h Pounds per hour
m Meter

3. Overview 5-2016
Acronym Definition
mm millimeter
MPa megapascal
Nm Newton meter
psi Pound per square inch
qt Quart
RPM Revolutions per Minute
VAC Volts Alternating Current
VDC Volts Direct Current
W Watts, Width

4 Operation
4.1 Key Component Locations
The figure below illustrates the components of a typical generator set. There may be some variation
depending on the generator set model.

4. Operation 5-2016
No. Description No. Description

1 Control Panel 6 Oil Dipstick
2 Coolant Recovery Tank Fluid Level 7 Fuel Filter
3 Coolant Recovery Tank Fill Cap 8 Air Filter
4 Oil Fill Cap 9 Muffler (inside)
5 Oil Filter
FIGURE 2. KEY COMPONENT LOCATIONS

5-2016 4. Operation
4.2 Control Panel

4.2.1 Generator Set Control Panel
No. Name Description

1 Line Circuit Breaker Protects the AC power leads connected to the generator set from overloads
and equipment short circuits.
2 Hour Meter Records the total running time of the generator set. Cannot be reset.
3 Control Switch Used to start and stop the generator set, and to prime the engine fuel system.
4 Status Indicator LED in the control switch that blinks rapidly during preheat and cranking.
Stays on continuously after generator set is running. If the generator set shuts
down abnormally, the indicator blinks a numerical code to indicate the cause
of the shutdown (see Chapter 6 on page 47).
FIGURE 3. GENERATOR SET CONTROL PANEL
4.2.2 Remote Control Panel

A remote control panel may be installed inside the vehicle. Cummins Onan offers 3 remote control panel
kits.
• Control switch with status indicator.
• Control switch with status indicator and an hour meter.
• Control switch with status indicator and a DC voltmeter.

4. Operation 5-2016
No. Name Description

1 Control Switch Used to start and stop the generator set, and to prime the engine fuel system.
Hold the switch in its Start position to crank and start the generator set. Press
the switch to the Stop position to stop the generator set. Hold the switch in its
Stop position to prime the fuel system.
2 Status Indicator LED in the control switch that blinks rapidly during preheat and cranking.
Stays on continuously after generator set is running. If the generator set shuts
down abnormally, the indicator flashes a numerical code to indicate the cause
of the shutdown (see Chapter 6 on page 47).
3 Hour Meter Records the total running time of the generator set. Cannot be reset.
4 DC Voltmeter Displays voltage of the generator set. If the voltage across the 12 VDC control
system consistently stays above or below 12 VDC, see Section 5.4 on page
33.
FIGURE 4. REMOTE CONTROL PANELS

5-2016 4. Operation
4.3 Starting and Stopping the Generator Set

4.3.1 Pre-start Checks
WARNING
EXHAUST GAS IS DEADLY!
Exhaust gases contain carbon monoxide, an odorless, colorless gas. Carbon monoxide is
poisonous and can cause unconsciousness and death. Symptoms of carbon monoxide
poisoning include:
• Dizziness
• Muscular twitching
• Weakness and sleepiness
• Throbbing in temples
• Headache
• Inability to think clearly
• Nausea
• Vomiting
IF YOU OR ANYONE ELSE EXPERIENCES ANY OF THESE SYMPTOMS, GET OUT INTO THE
FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the generator
set and do not operate it until it has been inspected and repaired.
Never occupy the vehicle with the generator set running unless the vehicle is equipped with a
working carbon monoxide detector. However, primary protection against inhaling carbon
monoxide is proper installation of the exhaust system, and daily (every 8 hours) inspection for
visible and audible exhaust system leaks.
Perform pre-start checks before the first start of the day and after every 8 hours of operation. See
Chapter 5 if the vehicle has been in storage.
1. Make sure all vehicle CO detectors are working properly.
2. Remove access cover.
3. Inspect the generator set as instructed in Chapter 5.
4. Perform any maintenance due (Section 5.1 on page 31).
5. Keep a maintenance log (Chapter 7 on page 55).
6. Check for signs of fuel and exhaust leaks and for damage to the exhaust system.
7. Replace access cover.
8. Turn off the air conditioner and other large appliances.
4.3.2 Priming the Fuel System

The fuel system should be primed after the fuel filter is replaced or after the generator set runs out of fuel.
Position the control switch to STOP/PRIME for 30 seconds. The status indicator stays on while the pump
is on.

4. Operation 5-2016
4.3.3 Starting the Generator Set

1. Visually inspect for fuel and exhaust leaks. Do not start the generator set until any fuel or exhaust
leak is repaired.
2. Position and hold the control switch to START until the generator set starts. The status indicator on
the switch flashes while cranking. It will stay on continuously when the generator set is running.
3. If the generator set fails to start, cranking will stop in approximately 30 seconds. The status indicator
will blink, indicating an over crank fault. Wait 5 seconds for the control to reset before trying again.
After 5 tries, let the starter motor cool down for 30 seconds before trying again. See Chapter 6 on
page 47 if the generator set does not start after several tries.
CAUTION
The starter motor can be damaged by overheating. Allow it to cool down for 30 seconds
after every fifth crank.
4. For top performance and engine life, especially in colder weather, let the engine warm up for 2
minutes before connecting appliances.
5. See Chapter 6 on page 47 if the generator set shuts down and the status indicator blinks, indicating
a fault.
4.3.4 Stopping the Generator Set

1. Turn off the air conditioner and other large appliances.
2. Run generator set for 2 minutes to allow for cool down.
3. Press the control switch in its STOP position.
4.4 Loading the Generator Set

The power rating (kW) on the generator set nameplate determines how much electrical load (motors, fans,
heaters, air conditioners, and other appliances) the generator set can power. If the sum of the loads
exceeds the generator set power rating, the generator set will shut down or its line circuit breakers will trip.
NOTICE
It may be necessary to run fewer appliances at the same time—the sum of the loads must not be
greater than the generator set power rating.
To avoid shutdowns due to generator set overload, use the electrical ratings on the nameplates of
equipment (if available) to compare the sum of the electrical loads that are likely to be used at the same
time to the generator set power rating. Refer to the table below for typical appliance ratings.
Appliance load and generator set power are measured in terms of Watts (W) or kilowatts (kW), where 1
kilowatt (kW) = 1000 Watts (W).
• If the equipment is marked in Amps and Volts only, multiply the Amps times the Volts to obtain the
load in Watts.
• Divide Watts by 1000 to obtain load in terms of kilowatts.
It is possible that the generator set circuit breaker may trip even though the sum of the steady state loads
is less than the generator set power rating. When a large motor or air conditioner is started last or cycles
off and on, the startup load is larger than its normal running load, causing the load to temporarily exceed
the generator set power rating.

5-2016 4. Operation
Typical "invisible" charging loads:

• During startup, air conditioners need "reserve" power and can draw 3–4 times the typical 1400–2400
Watts needed to run. Too much baseload can prevent air conditioners from starting.
• Battery chargers are activated automatically and can draw a large load (up to 3000 Watts). Manage
electrical loads by adjusting battery charge rates to best suit your needs. Consult your
inverter/charger manual or manufacturer.
TABLE 5. TYPICAL APPLIANCE LOADS
Appliance Average Required Wattage Amps

Air Compressor (1hp) 900-1800 7.5-15
Air Conditioner 1200-2400 10-20
Battery Charger1 Up to 3000 6-28
Blender 450-700 3.3-5.8
Broiler 1400-1700 11.6-14
Broom/Vacuum 1000-1440 8.3-12
CD/mp3 Player & Speakers 85 0.7
Coffeepot 900-1200 7.5-10
Computer 60-270 0.5-2.25
Laptop 20-50 0.16-0.41
Converter 500-1000 4-8
Curling Iron 20-50 0.16-0.41
Dishwasher 1200-2400 10-20
Drill 250-1000 2-8
Electric Blanket 60-100 0.5-0.8
Fan 10-175 0.08-1.45
Flat Iron 40-80 0.3-0.6
Frying Pan/Wok 1000-1350 8-11.25
Game Console 19-200 0.16-1.6
Hair Dryer 1200-1875 10-15.6
Iron 1000-1800 8-15
Light Bulbs 13-100 0.1-0.8
Microwave/Convection Oven 750-1100 6.25-9.2
Radio 50-200 0.4-1.6
Refrigerator 400-1000 3.3-8
Shaver 15-20 0.12-0.16
Space Heater 750-1500 6.25-12.5
Stove 900-2500 7.5-20.8

4. Operation 5-2016
Appliance Average Required Wattage Amps

Television 43-600 0.35-5
Toaster 800-1400 6.6-11.6
VCR/DVD/Blu-ray Player 6-30 0.05-0.25
Washer/Dryer 350-500/1800-5000 3-4/15-42
Water Heater 1000-1500 8-12.5
Water Pump 250-1100 2-9.16
1
Battery chargers can be a source of significant load and will be on whether they are connected to shore power or
the generator set.
4.4.1 Power Versus Altitude

The generator set is rated at standard barometric pressure, humidity, and air temperature (reference ISO
3046). Low barometric pressure (high altitude) or high ambient temperature decreases engine power.
• As ambient temperature increases, rated generator set engine power decreases approximately 1%
for every 5.5 °C (10 °F) above 25 °C (77 °F).
• Power decreases approximately 3.5% of rated power each 305 m (1000 ft) of increase in elevation.
Refer to the table below for typical elevation/generator set power calculations.
NOTICE
It may be necessary to run fewer appliances at higher altitudes and ambient temperatures.
TABLE 6. POWER VERSUS ALTITUDE
Elevation Above Mean Sea Maximum Generator Set Power1 Maximum Generator Set Power1
Level (Generator Set Rated 10.0 kW) (Generator Set Rated 12.5 kW)
Up to 152 m (500 ft) 10,000 Watts (rated) 12,500 Watts (rated)
762 m (2500 ft) 9,300 Watts 11,625 Watts
1676 m (5500 ft) 8,250 Watts 10,312.5 Watts
8250 Watts minus 350 Watts each 305 10,312.5 Watts minus 437.5 Watts each
Above 1676 m (5500 ft)
m (1000 ft) 305 m (1000 ft)
1. - Does not take into account the effect circuit breakers may have in limiting maximum power.
4.5 Exercising the Generator Set

Exercise the generator set at least 2 hours each month if use is infrequent. Run the generator set at
approximately 1/2 rated power. A single 2-hour exercise period is better than several shorter periods.
Exercising a generator set drives off moisture, relubricates the engine, replaces stale fuel in fuel lines, and
removes oxides from electrical contacts and generator slip rings. The result is better starting, longer
engine life, and greater reliability.

5-2016 4. Operation
4.6 Resetting Line Circuit Breakers

If a generator set line circuit breaker or a circuit breaker in the power distribution panel trips, either a short
circuit has occurred or too many loads were connected.
NOTICE
The generator set continues to run if its circuit breaker trips.
If a circuit breaker trips:

1. Disconnect or turn off as many electrical loads as possible.
2. Reset the circuit breaker.
3. If the circuit breaker trips right away, either the appliance (or electrical load) has a short or the circuit
breaker is faulty. Call a qualified electrician.
NOTICE
It may be necessary to push the circuit breaker OFF to reset it and ON to reconnect the
circuit.
4. If the circuit breaker does not trip right away, reconnect loads one-by-one making sure not to
overload the generator set or cause a circuit breaker to trip. If a circuit breaker trips right away when
an appliance is connected, that appliance or circuit probably has a short.
FIGURE 5. CIRCUIT BREAKER CONNECTIONS
WARNING
Short circuits in electrical equipment can cause fire and electrical shock leading to severe
personal injury or death. Electrical equipment and its grounding must be maintained properly to
protect against short circuits.
Electrical equipment must be used and maintained properly, and be properly grounded, to cause the line
circuit breakers to trip when short circuits occur.
Electrical appliances and tools must be used and maintained in accordance with their manufacturer's
instructions and safety precautions. Proper grounding is needed to reduce the risk of electric shock and
fire.

4. Operation 5-2016
4.7 Connecting to Shore Power

WARNING
Interconnecting the generator set and shore power can lead to electrocution of utility line
workers, equipment damage, and fire. Use an approved switching device to prevent
interconnections.
A vehicle with provisions for connecting to utility power must have an approved device to keep the
generator set and utility from being interconnected.

1 Generator Set 4 To Vehicle AC Distribution Panel
2 Transfer Switch 5 Generator
3 50 Amp Shore Power
FIGURE 6. TYPICAL CONNECTIONS WITH TRANSFER SWITCH AND UTILITY
4.8 Operating in Weather Extremes

Pay particular attention to the following items when operating the generator set in cold or hot weather.
1. Make sure nothing blocks airflow to and from the generator set.
2. Make sure engine oil viscosity is appropriate for the ambient temperature. See Section 5.5 on page
34 for engine oil recommendations.
3. Keep the generator set clean.
4. Perform maintenance due. See Section 5.1 on page 31.

5-2016 4. Operation
4.9 Operating in Dusty Environments

Pay particular attention to the following items when operating the generator set in dusty environments.
1. Do not let dirt and debris accumulate inside the generator set compartment. Keep the generator set
clean.
2. Perform air filter element maintenance more often.
3. Change engine oil more often.
4.10 Care of New or Rebuilt Engine

Proper engine break-in on a new generator set or on one with a rebuilt engine is essential for top engine
performance and acceptable oil consumption. Run the generator set at approximately 1/2 rated power for
the first 2 hours and at 3/4 rated power for 2 more hours.
Proper engine oil and oil level are especially critical during break-in because of the higher engine
temperatures that can be expected. Change the oil if the oil is not appropriate for the ambient
temperatures during break-in. See Section 5.5 on page 34 for engine oil recommendations.
Check oil level twice a day or every 4 hours during the first 24 hours of operation and change the oil after
the first 50 hours of operation.

4. Operation 5-2016

5 Maintenance
WARNING
Only authorized and competent personnel who are familiar with the equipment and its operation
should carry out maintenance.
5.1 Periodic Maintenance

WARNING
Accidental starting can cause severe personal injury or death. Turn off the AGS whenever
performing maintenance or service, when the vehicle is stored between uses, is awaiting service,
or is parked in a garage or other confined area.
Periodic maintenance is essential for top performance and long generator set life. Use the Periodic
Maintenance Schedule below for normal periodic maintenance. In hot and dusty environments some
maintenance procedures should be performed more frequently, as indicated by the footnotes in the
schedule. Keeping a log of maintenance performed and hours run will help keep generator set
maintenance regular and provide a basis for supporting warranty claims (see Chapter 7 on page 55).
Maintenance, replacement, or repair of emission control devices and systems may be performed by any
engine repair establishment or individual. However, warranty work must be completed by an authorized
Cummins Onan Service Representative.
5.1.1 Periodic Maintenance Schedule

TABLE 7. PERIODIC MAINTENANCE SCHEDUL E
MAINTENANCE FREQUENCY
Every
MAINTENANCE PROCEDURE After Every Every Every Every
Day or Every
First 50 250 500 800 1500
Every 8 Month
Hours Hours Hours Hours Hours
Hours
General Inspection X
Check Engine Oil Level X
Check Engine Coolant Level X
Check Battery and Battery
X
Connections
Change Engine Oil and Oil Filter X1,2,3 X1,2,3
Check V-Belt Tension X4,6
Clean Spark Arrester X3,6
Replace Engine Air Filter Element X2
Replace Fuel Filter X5,8
Adjust Engine Valve Lash X6

5. Maintenance 5-2016
MAINTENANCE FREQUENCY
Every
MAINTENANCE PROCEDURE After Every Every Every Every
Day or Every
First 50 250 500 800 1500
Every 8 Month
Hours Hours Hours Hours Hours
Hours
Check Generator Slip Rings and
X2,6
Brushes
Flush Coolant System X5
Replace Coolant Pressure Cap X5
Replace V-Belts and Coolant
X5,6
Hoses
Check Fuel Injector Pressure X6,7
1 - Perform more often when operating in hot weather.
2 - Perform more often when operating in dusty environments.
3 - Perform at least once a year.
4 - Tighten or replace the belt in accordance with the Service Manual if it can be deflected more than 12 mm (1/2 in)
by thumb.
5 - Perform at least once every 5 years.
6 - Must be performed by a qualified mechanic (authorized Cummins Onan Service Representative).
7 - EPA requirement.
8 - Perform every 250 hours when using B20 Bio-diesel fuel.
5.2 Consumable Parts

The following is a list of consumables associated with the generator models covered in this manual:
TABLE 8. CONSUMABLE PARTS
Part Number Description Quantity

0167-1638 Spark Plug 1
0167-1652 Spark Plug 1
0149-2661 Fuel Filter 1
0147-0860 Fuel Filter, EFI 1
0149-2629 Fuel Filter, Gasoline 2
0149-2637 Fuel Filter, LPG 1
0149-2513 Filter, Fuel 1
A030Y328 Filter, Air 1
0140-3116 Element, Air Cleaner 1
0140-3351 Element, Air Cleaner 1
0140-3071 Filter, Air 1
A043H188 Brush Block 1

5-2016 5. Maintenance
Part Number Description Quantity

0212-1285-S0 Block, Brush 1
0212-1285 Block, Brush 1
0212-1303 Block, Brush 1
0122-0386 Oil Filter 1
0122-0893 Filter, Oil 1
0187-1000 Filter, Oil 1
0185-7444 Filter, Oil 1
5.3 General Inspection

1. Check battery connections (Section 5.4 on page 33).
2. Check engine oil level (Section 5.5 on page 34).
3. Check engine coolant level (Section 5.7 on page 40).
4. Check fuel system (Section 5.6 on page 37).
5. Check exhaust system (Section 5.8 on page 42).
6. Check mechanical system (Section 5.9 on page 43).
5.4 Maintaining the Battery

The generator set requires a 12 Volt battery to power its control and starting circuits. Reliable generator
set starting and starter service life depend upon adequate battery system capacity and maintenance.
WARNING
Flames, sparks, or arcing at battery terminals, light switches, or other equipment can ignite
battery gas, causing severe personal injury. Ventilate the battery area before working on or near
a battery, wear safety glasses, and do not smoke. Turn work light on or off away from the battery.
When performing maintenance procedures or when servicing a battery, stop the generator set
and disconnect the charger before disconnecting battery cables. Using an insulated wrench,
disconnect the negative (–) cable first and reconnect it last.
Refer to Section 5.1 on page 31 for the battery maintenance schedule and follow the battery
manufacturer's instructions. Have the battery charging system serviced if DC system voltage is
consistently low or high.
Check the battery terminals for clean, tight connections. Loose or corroded connections have high
electrical resistance which makes starting harder.
1. Keep the battery case and terminals clean and dry.
2. Keep the battery terminals tight.
3. Remove battery cables with a battery terminal puller.
4. Make sure which terminal is positive (+) and which is negative (–) before making battery
connections, always removing the negative (–) cable first and reconnecting it last to reduce arcing.

5.5 Maintaining the Lubrication System

Keep dirt, water, and other contaminants from entering the lubrication system and corroding or clogging
lubrication components.
5.5.1 Oil Level

Park the vehicle on level ground and stop the generator set before checking engine oil level.
WARNING
Engine components (drains, filters, hoses, etc.) can be hot and cause severe burns, lacerations
of the skin, and liquid splash. Use personal protective equipment when working with or around
hazardous materials. Examples of personal protective equipment include (but are not limited to)
safety glasses, protective gloves, hard hats, steel toed boots, and protective clothing.
WARNING
Crankcase pressure can blow hot engine oil out the fill opening causing, severe burns. Always
stop the generator set before removing the oil fill cap.
WARNING
State and federal agencies have determined that contact with used engine oil can cause cancer
or reproductive toxicity. Avoid skin contact and breathing of vapors. Use rubber gloves and
wash exposed skin.
CAUTION
Too little oil can cause severe engine damage. Too much oil can cause high oil consumption.
Keep the oil level between the high and low beads (or markings) on the dipstick.
1. Pull out the dipstick.

2. Wipe off the dipstick and reinsert it.
3. Pull it out again to check oil level.
4. Add or drain oil as necessary. Keep the oil level between the full and add marks.
5. Insert the dipstick and secure the oil fill cap.
5.5.2 Engine Oil Recommendations

• Use API (American Petroleum Institute) performance Class SJ, SH or SG engine oil, which may be
in combination with performance Class CH-4, CG-4 or CF-4 (for example: SJ/CH-4).
• Look for the SAE (Society of Automotive Engineers) viscosity grade. Choose the viscosity grade
appropriate for the ambient temperatures expected until the next scheduled oil change.
• Single-grade SAE 30 oil is preferable when temperatures are consistently above freezing. Multigrade
oils are better when wide temperature variations are expected.

TABLE 9. OIL VISCOSITY VS. TEMPERATURE
EXPECTED AMBIENT TEMPERATURES SAE VISCOSITY GRADE

0 °C (32 °F) and higher 30 (OnaMax)
–12 to 38 °C (10 to 100 °F) 15W-40 (OnaMax)
–18 to 27 °C (0 to 80 °F) 10W-30 10W-40
–28 to 10 °C (–20 to 50 °F) 5W-30
5.5.3 Changing Engine Oil and Oil Filter

WARNING
Accidental or remote starting can cause severe personal injury or death. Before removing a
panel or access door, or before working on the generator set, use an insulated wrench to
disconnect the negative (-) cable from the battery to prevent accidental starting.
WARNING
WARNING
State and federal agencies have determined that contact with used engine oil can cause cancer
or reproductive toxicity. Avoid skin contact and breathing of vapors. Use rubber gloves and
wash exposed skin.
Refer to Section 5.1 on page 31 for the engine oil change schedule. Change oil more often in hot or
dusty environments.
1. Park the vehicle on level ground and set the parking brake.
2. Run the generator set until it is warm and shutdown the generator set.
3. Place a pan large enough to hold the full oil capacity of the engine under the oil drain plug (see Oil
Change Values and Drain Plug Location below).
WARNING
Crankcase pressure can blow hot engine oil out the fill opening causing, severe burns.
Always stop the generator set before removing the oil fill cap.
4. Remove the front access door and remove the oil fill cap.
5. Remove the oil drain plug using the appropriate size socket (see Oil Change Values and Drain Plug
Location below) and breaker bar. Allow all the oil to drain from the engine.
6. Reinstall the oil drain plug (see Oil Change Values and Drain Plug Location below for torque value).
7. Spin off the oil filter and drain off oil.
8. Thoroughly wipe off the filter mounting surface and remove the old gasket if it does not come off with
the oil filter.

9. Make sure the new gasket is in place on the new oil filter and apply a thin film of clean oil to the
gasket. Spin the new filter on by hand until the gasket just touches the mounting surface and turn the
filter an additional 1/2 to 3/4 turn. Do not over tighten.
CAUTION
Too little oil can cause severe engine damage. Too much oil can cause high oil
consumption. Keep the oil level between the high and low beads (or markings) on the
dipstick.
10. Refill with oil (see Oil Change Values below). Check the oil level and add or drain oil as necessary.
11. Screw the oil fill cap on securely and reinstall the front access door.
12. Dispose of the used oil and oil filter in accordance with local environmental regulations.
5.5.3.1 Oil Change Values and Drain Plug Location

TABLE 10. OIL CHANGE VALUES
Drain Plug Bolt Plug Torque Oil Amount

22 mm Hex Head Bolt 43.39 Nm (32 ft-lbs) 5.6 liters (5.9 qt)

1 Oil Filter 3 Oil Fill Cap
2 Oil Dipstick 4 Oil Drain Plug
FIGURE 7. OIL DRAIN PLUG AND FILTER

5.6 Maintaining the Fuel System

Keep dirt, water, and other contaminants from entering the fuel system and corroding or clogging fuel
system components.
5.6.1 Fuel System

WARNING
Diesel fuel leaks can lead to fire. Do not operate the generator set if operation causes fuel to
leak.
1. Check for leaks at the hose, tube, and pipe fittings in the fuel supply system while the generator set
is running and while it is stopped.
2. Check flexible fuel hoses sections for cuts, cracks, abrasions, and loose hose clamps.
3. Make sure the fuel line does not rub against other parts of the vehicle or generator set.
4. Replace worn or damaged fuel line parts before leaks occur.
5.6.2 Fuel Recommendations

WARNING
Diesel fuel is combustible and can cause severe personal injury or death. Do not smoke near fuel
tanks or fuel-burning equipment, or in areas sharing ventilation with such equipment. Keep
flames, sparks, pilot flames, electrical arcs and switches, and all other sources of ignition well
away. Keep a multi-class ABC fire extinguisher handy.
• When the outdoor ambient temperature is above freezing, use clean, fresh No. 2 diesel fuel (ASTM
2-D).
• When the outdoor ambient temperature is below freezing, use No. 1 diesel fuel (ASTM 1-D).
The fuel should have a Cetane number of at least 45 for reliable starting.
5.6.2.1 Bio-diesel Fuels B5 – B20

B5 bio-diesel fuel that meets industry specifications and quality is suitable for use with this generator set.
Before using bio-diesel fuel blends above B5 and up to B20, the following conditions must be verified:
• The vehicle propulsion engine is capable of using B20 when sharing the same fuel tank.
• The OEM has installed a B20 compatible fuel line from the fuel tank to the generator set.
• The OEM has installed a water separator in the fuel line just before the generator set.
For bio-diesel blends above B5 and up to B20, Cummins Onan recommends that the fuel meet the
specifications outlined in ASTM D7467. The bio-diesel component of this fuel blend must meet ASTM
D6751 or EN14214, and the petroleum diesel component must meet ASTM D975. Blended bio-diesel
fuels should be pre-blended and not made by customers.
CAUTION
Market applications contain properties that can affect engine operating characteristics. It is
highly recommended that use of these bio-diesel fuel blends be avoided or exercised with extra
care. Use standard fuels in applications that experience seasonal usage, storage for periods
exceeding 90 days, and extreme temperatures or humidity.

The following bio-diesel fuel properties can affect engine performance:

• Poor oxidation stability can accelerate fuel oxidation. Fuel oxidation reduces generator performance.
This effect is accelerated at increased ambient temperatures.
• Properties change at temperatures below –5 oC (23 oF). Necessary precautions must be taken when
operating the generator with bio-diesel blends in low ambient temperatures.
◦ Fuel heater
◦ Hose insulation
◦ Additional anti-gel fuel additives.
• Bio-diesel fuel blends are an excellent medium for microbial growth. Microbes cause fuel system
corrosion and premature filter plugging. The effectiveness of all commercially available conventional
anti-microbial additives, when used in bio-diesel fuel, is not known. Consult your fuel and additive
supplier for assistance.
If bio-diesel fuel is used for seasonal applications (stored more than 90 days), the generator must be
purged before storage by running the engine on pure diesel fuel meeting ASTM D975 for a minimum of 30
minutes.
NOTICE
The Cummins Onan Warranty covers failures that are a direct result of defects in material or
factory workmanship. Generator damage, service issues, and/or performance issues determined
by Cummins Onan to be caused by bio-diesel fuel blends not meeting the specifications outlined
in the applicable Installation, Operator, and Service Manuals are not considered to be defects in
material or workmanship and may affect your generator's warranty.
5.6.3 Replacing the Fuel Filter

WARNING
WARNING
WARNING
Diesel fuel is combustible and can cause severe personal injury or death. Do not smoke near
diesel fuel tanks or equipment. Keep flames, sparks, pilot lights, electrical switches, arc-
producing equipment, and all other sources of ignition well away. Keep a type ABC fire
extinguisher in the vehicle.
Refer to Section 5.1 on page 31 for scheduled fuel filter replacement. Replace the fuel filter if the engine
lacks power.
1. Disconnect the negative (–) cable at the battery to prevent the engine from starting.
2. Remove the access door.

3. Let engine cool down to prevent igniting any fuel that may be spilled when disconnecting the fuel
filter.
CAUTION
Dirt in the fuel system can cause equipment damage. Wipe dirt off the fuel hose fittings at
the fuel filter before disconnecting the hoses.
4. Disconnect the fuel hose fittings using a wrench. Plug the fuel lines to prevent fuel leakage and
vapor accumulation.
NOTICE
Flare nut wrenches should be used on the flare nuts to prevent stress on the fitting and
rounding of nut corners.
5. Unscrew the fuel filter mounting nut and remove the fuel filter.
NOTICE
Fuel filter removal may be easier if the filter mounting bracket screws are removed.
6. Rotate the filter half a turn around its mounting stud if the fittings interfere with the bracket. It only fits
one way.
7. Connect the fuel fittings before tightening the fuel filter mounting nut. Take care not to crossthread
the fuel fittings. Thread them in by hand and tighten one flat past seating with two wrenches.
8. Prime the engine for at least 30 seconds to fill the new fuel filter. Check for leaks as the generator
set runs for several minutes.
9. Replace the access door.
10. Connect the negative (–) cable at the battery.
11. Dispose of the old filter in accordance with local environmental regulations.


1 Fuel Filter Mounting Nut 3 Filter Mounting Bracket Screws
2 Fuel Hose Fitting
FIGURE 8. FUEL FILTER
5.7 Maintaining the Cooling System

The engine cooling system is filled with a 50/50 mixture of ethylene glycol antifreeze and water when the
generator set leaves the factory. The mixture is suitable for temperatures down to –37 oC (–34 oF).
5.7.1 Cooling System

CAUTION
Operating the generator set when coolant level is low can cause serious engine damage.
Check the engine coolant level and look for coolant leaks around the bottom of the generator set and on
the ground below. Minor leaks that can be replenished by daily additions of coolant to the recovery tank
should be repaired by a qualified service technician as soon as possible. Larger leaks are cause for
shutting down the generator set until it can be repaired.


1 Coolant Level 4 Pressure Cap and System Fill Opening
2 Coolant Recovery Tank Fill Cap 5 Coolant Drain Plug (1/4 in Hex Socket)
3 Coolant Recovery Tank
FIGURE 9. COOLING SYSTEM
5.7.2 Coolant Level

Check coolant level in the recovery tank before the first startup of each day and fill to the "COLD" mark if
necessary.
5.7.3 Coolant Recommendations

Use the best quality ethylene glycol antifreeze available.
• Antifreeze should be fully formulated with rust inhibitors and coolant stabilizers.

• Mixed with fresh (distilled) water that is low in minerals and corrosive chemicals.
A 50/50 mixture is recommended for all climates and is suitable for temperatures down to –37 oC (–34 oF).
5.7.4 Draining and Cleaning Cooling System

WARNING
Hot coolant spray can cause severe burns. Let the engine cool before releasing the pressure cap
or removing the drain plug.
Let the engine cool before removing the pressure cap.

1. Relieve any remaining pressure by turning the cap slowly, without pushing down.
2. When the pressure has been relieved, push down on the cap and turn it the rest of the way to
withdraw it.
WARNING
Ethylene glycol antifreeze is considered toxic. Dispose of it according to local regulations
for hazardous substances.
3. Remove the coolant drain plug and drain the coolant into a suitable container.
Flush and clean the cooling system before refilling. Radiator cleaning chemicals are available at local auto
parts stores. Follow cleaning and flushing instructions on the product.
5.7.5 Refilling Cooling System

1. Install the coolant drain plug using pipe thread sealant.
2. Tighten it just enough to prevent leaks when the generator set is running and has warmed up.
3. Pull the hose connected to the pressure cap assembly out as far and high as it will go, and fill the
system with coolant.
4. When the coolant level reaches the fill opening, start and operate the generator set for a few minutes
and shut it down.
5. Add more coolant if necessary.
6. Secure the pressure cap.
5.8 Exhaust System

WARNING
EXHAUST GAS IS DEADLY! Do not operate the generator set if there is an exhaust leak or any
danger of exhaust gasses entering or being drawn into the vehicle.
WARNING
Grass or brush in contact with the exhaust system can cause fire. Do not park the vehicle in high
grass or brush.
1. Look and listen for exhaust system leaks while the generator set is running. Shut down the generator
set if a leak is found and have it repaired before operating.

2. Look for openings or holes between the generator set compartment and vehicle cab or living space if
the generator set engine sounds louder than usual. Have all such openings or holes closed off and
sealed to prevent exhaust gases from entering the vehicle.
3. Replace dented, bent, or severely rusted sections of the tailpipe and make sure the tailpipe extends
at least 25.4 mm (1 in) beyond the perimeter of the vehicle.
4. Park the vehicle so that generator set exhaust gases disperse away from the vehicle. Barriers such
as walls, snow banks, high grass, brush, and other vehicles can cause exhaust gases to accumulate
in and around the vehicle.
5. Do not operate power ventilators or exhaust fans while the vehicle is standing with the generator set
running. The ventilator or fan can draw exhaust gases into the vehicle.
6. Check all CO monitors to assure proper operation.
5.9 Mechanical System

WARNING
Compressed air, pressure washers, and steam cleaners can cause severe eye injury. Always
wear safety glasses when using.
1. Look for mechanical damage and listen for unusual noises and vibrations.
2. Check the generator set mounting bolts.
3. Check to see that the generator set air inlet and outlet openings are not clogged with debris or
blocked.
4. Clean accumulated dust and dirt from the generator set. Do not clean the generator set while it is
running or still hot. Protect the generator, air cleaner, control panel, and electrical connections from
water, soap, and cleaning solvents.
5.10 Replacing the Air Filter Element

WARNING
WARNING
Refer to Section 5.1 on page 31 for scheduled air filter element replacement. Under dusty operating
conditions, inspect and replace more often.
1. Remove the front access cover.
2. Loosen the 3 screws that secure the coolant recovery tank to the housing top panel and move it out
of the way.

3. Loosen the 2 screws that secure the air filter housing to the housing top panel to unlatch the spring
clips securing the filter housing end cap.
4. Remove the end cap and remove air filter element from the end cap.
5. Install new air filter element into the end cap.
6. Secure the filter housing and coolant tank.
7. Replace the front access cover.

1 Coolant Recovery Tank (shown cut away) 2 Air Filter Housing End Cap
FIGURE 10. AIR FILTER ELEMENT
5.11 Cleaning the Spark Arrester

WARNING
A hot muffler can cause severe burns. Let the muffler cool down before removing or installing
spark arrester cleanout plugs or screens.
WARNING
Grass or brush in contact with the exhaust system can cause fire. Do not park the vehicle in high
grass or brush.
Refer to Section 5.1 on page 31 for scheduled spark arrester muffler cleaning (meets U.S. Forest Service
requirements). Cleaning is required for maximum generator set performance.
1. Remove the cleanout plug.
2. Start and load the generator set to near full power. Let the generator set run for about 5 minutes to
expel the soot in the muffler.
3. Stop the generator set, allow the muffler to cool, and reinstall the plug.

FIGURE 11. SPARK ARRESTER CLEANOUT PLUG
5.12 Storing the Generator Set

Proper storage is essential for preserving top generator set performance and reliability. If the generator set
is not going to be exercised on a regular basis and not be used for more than 120 days, the generator set
should be prepared for storage.
WARNING
Carbon monoxide is deadly and can accumulate to dangerous levels in garages and other
confined spaces. Disable the automatic generator starting feature before storing the vehicle.
1. Disable the automatic generator set starting feature.

2. Change the engine oil and attach a tag indicating the oil grade viscosity.
3. Disconnect the battery cables, negative (–) cable first, from the starting battery and store the battery
according to the battery manufacturer's recommendations.
4. Position the line circuit breaker to OFF.
5.13 Returning the Generator Set to Service

1. Check the oil tag on the generator set and change the oil if the viscosity indicated is not appropriate
for the temperatures expected.
2. Reconnect the starting battery (negative [–] cable last).
3. Replace the air filter element. Use new air filter element if it is dirty.
4. Inspect the generator set.

5. Prime the generator set fuel system by positioning the control switch to STOP/PRIME for 30
seconds. The status indicator stays on while the pump is on.
6. Start the generator set.
7. Position the line circuit breaker to ON when the generator set is ready to power loads.

6 Troubleshooting
6.1 Overview
WARNING
Hot engine parts can cause severe burns. Always allow the engine to cool down before
performing any maintenance or service.
The following paragraphs provide fault code faults and symptom-based faults. If a problem is not resolved
after taking the corrective actions suggested, contact a local dealer or distributor. See Section 2.4 on
page 11.
NOTICE
Maintaining engine oil level, keeping battery connections clean and tight, watching the fuel
gauge, not overloading the generator set, etc. will prevent most shutdowns.
NOTICE
When the generator set and vehicle engine share a common fuel tank, the fuel dip tubes are
usually arranged so that the generator set will run out of fuel first. Marking the generator set
empty point on the fuel gauge will make it easier to tell when to stop the generator set before
running it out of fuel.
6.2 Fault Codes

The generator set control contains extensive diagnostics to detect shutdown faults. Following a fault
shutdown, the control indicates the fault code by flashing the numeric code on the status indicator in the
control switch.
Determine the fault code as follows:
• 1 flash indicates a high engine coolant temperature.
• 2 flashes indicates a low oil pressure fault (Code 2 fault).
• 3 flashes indicates a service fault (Code 3 fault).
1. Press STOP/PRIME on the control switch once to have the 2-digit service fault code flash.
The 2-digit code consists of two sets of flashes. The first set is of flashes represents the 10s
digit of the code. After a brief pause, the second digit of the code flashes representing the unit
digit of the code. This is followed by a long pause before repeating the flashing of the fault
code.
For example, Fault Code 36 appears as: blink-blink-blink—pause—blink-blink-blink-blink-blink-
blink—long pause—repeat
2. Press STOP/PRIME to stop flashing the fault code.
• 4 flashes indicates that cranking exceeded 30 seconds without the engine starting (Code 4 fault).

6. Troubleshooting 5-2016
NOTICE
Fault codes 33 and 34 are not assigned as fault codes. Be careful of interpreting Fault
Codes 3 and 4 as second-level faults.
The fault code stops flashing after 5 minutes. Pressing STOP/PRIME 3 times within 5 seconds causes the
fault code to resume flashing.
NOTICE
The last fault logged continues to flash even though the condition that caused the shutdown has
been corrected.
6.2.1 Code 1 - Engine Over Temperature

Indicates that, during normal operation, the engine coolant temperature exceeded 115 oC (239 oF) for 10
seconds.
6.2.1.1 Check Engine Coolant Level

If coolant level is low, add coolant as necessary and repair any leaks.
6.2.1.2 Check for Blockages

1. If an air inlet or outlet opening on the bottom of the generator set is blocked, remove objects.
2. If dirt is fouling the radiation fins, clean dirt out.
NOTICE
Compressed air or washing with water can be helpful in removing debris from heat
exchangers. Do not allow copious amounts of water to enter generator set components. A
pressure washer is NOT advised for cleaning heat exchangers.
6.2.1.3 Reduce Load

Reduce the number of connected appliances, especially air conditioners and battery chargers. (Review
load management in Loading the Generator Set.)
6.2.2 Code 2 - Low Oil Pressure

Indicates that the low oil pressure cutoff switch did not open.
A. Check Engine Oil Level

1. If the dipstick indicates oil is low, add oil.
2. If oil is above the full mark on dipstick, drain excess oil.
6.2.3 Code 3 - Service Check

See second-level fault code.
6.2.4 Code 4 - Over Crank

Indicates that cranking exceeded 30 seconds without engine starting.

5-2016 6. Troubleshooting
A. Check Fuel Level

1. If fuel level is low, fill the fuel tank.
NOTICE
The generator set fuel pickup tube could be higher up in the fuel tank than the vehicle
engine pickup.
2. Prime the engine fuel system by positioning the control switch to STOP/PRIME for 30 seconds.
B. Check Air Filter Element

Replace the air filter if dirty.
6.2.4.1 Replace Engine Oil

Replace engine oil with oil of proper viscosity for the ambient temperature.
NOTICE
High oil viscosity can slow down cranking speed.
6.2.4.2 Check Fuel Fittings

1. Tighten any fuel fitting if there is a fuel or air leak.
2. Reprime the engine fuel system by positioning the control switch to STOP/PRIME for 30 seconds.
6.2.4.3 Replace Fuel Filter
6.2.5 Code 12 - Over Voltage

Indicates the control is unable to maintain rated voltage.
A. Contact Local Dealer or Distributor
6.2.6 Code 13 - Under Voltage

Indicates the control is unable to maintain rated voltage.
A. Reduce Load
Reduce the number of connected appliances, especially air conditioners and battery chargers.
(Review load management in Loading the Generator Set.)
6.2.7 Code 14 - Over Frequency

Indicates the engine governor is unable to maintain rated frequency.
6.2.8 Code 15 - Under Frequency

Indicates the engine governor is unable to maintain rated frequency.

A. Reduce Load
6.2.9 Code 19 - Governor Actuator

Indicates the control sensed an open or shorted circuit.
6.2.10 Code 22 - Governor Actuator Overload

Indicates the duration of operation is near full-duty cycle beyond design limit.
A. Reduce Load

C. Check Exhaust System

If exhaust system is blocked, remove blockage.
6.2.11 Code 27 - Voltage Sense

Indicates the control is unable to sense output voltage.
6.2.12 Code 29 - High Battery Voltage

Indicates that voltage across the battery system is greater than 19 Volts.
A. Check Battery
1. Check battery bank connections and reconnect if necessary so that the 12 Volt batteries
serving the generator set are connected in parallel (12 Volt) rather than in series (24 Volt).
2. Select a lower battery boost charge rate.
6.2.13 Code 32 - Low Cranking Speed

Indicates that cranking speed is less than 180 RPM for more than 2 seconds.
A. Check Battery
1. Clean and tighten the positive (+) and negative (–) battery cable connections at the battery and
at the generator set.
2. Recharge or replace the battery. Refer to the battery manufacturer's recommendations.

B. Replace Engine Oil

Replace engine oil with oil of proper viscosity for the ambient temperature.
NOTICE
High oil viscosity can slow down cranking speed.
6.2.14 Code 35 - Control Card Failure

Indicates that a microprocessor EEPROM error occurred during self test.
6.2.15 Code 36 - Engine Stopped

Indicates that the engine stopped without receiving a command from the control.
A. Check Fuel Level

1. If fuel level is low, fill the fuel tank.
NOTICE
The generator set fuel pickup tube could be higher up in the fuel tank than the vehicle
engine pickup.
2. Prime the engine fuel system by positioning the control switch to STOP/PRIME for 30 seconds.

C. Check for Mechanical Damage
6.2.16 Code 38 - Over Current (Field Overload)

Indicates low power factor loads.
A. Reduce Load
B. Check Appliances for Proper Operation

Have air conditioners and other appliances checked for proper operation.
6.2.17 Code 41 - Generator Rotor

Indicates control is unable to sense field or output voltage.

6.2.18 Code 42 - Processor

Indicates that a microprocessor ROM error occurred during self test.
6.2.19 Code 43 - Processor

Indicates that a microprocessor RAM error occurred during self test.
6.2.20 Code 45 - Speed Sense

Indicates the control is unable to sense quadrature frequency.
6.2.21 Code 48 - Generator Field Sense

Indicates the control is unable to sense field voltage.
6.2.22 Code 57 - Over Prime

Indicates that priming exceeded 3 minutes.
A. Check Control Switch

Check for and remove any object that may be holding either control switch (remote or generator set)
in the STOP/PRIME position.
6.3 Symptom Based

Diagnosis of some problems involves observing system operation.
6.3.1 Status Indicator Not Working

Indicates that there could be faulty connections or no battery voltage.
A. Check Other Control Switch

Try the generator set control switch if the remote control switch start doesn't work, and vice versa.
B. Check Battery

6.3.2 Starting Batteries Run Down

Indicates problem with batteries, connections, charging system, or parasitic loads.
A. Check Battery
B. Battery Charging System

Install or service a battery charging system in the vehicle.
6.3.3 Starter Engages-Disengages

Indicates cranking voltage dips below 6 Volts.
A. Use Vehicle to Start Generator Set

Run the vehicle propulsion engine while trying to start the generator set—the battery charging
alternator may be able to maintain starting voltage high enough to start the generator set.
B. Check Battery
C. Change Battery Cables

Increase battery cable size or run parallel cables.
6.3.4 Status Indicator Goes Out While Cranking—No Start

Indicates an internal short circuit caused an automatic-reset circuit protective device to trip.
A. Try Starting Again

If the status indicator flashes and goes out again without the engine starting, call local dealer or
distributor.
6.3.5 No Power—Generator Set Running, Status Light On

Indicates line circuit breaker is OFF, or tripped due to short circuit or overload.
A. Check Line Circuit Breakers

1. Turn on or reset the line circuit breaker on the generator set.
2. Turn on or reset the line circuit breaker on the main distribution panel in the vehicle.


7 Maintenance Record
TABLE 11. MAINTENANCE RECORD
Record all periodic and unscheduled maintenance/service. See Periodic Maintenance section.
HOUR
DATE METER MAINTENANCE OR SERVICE PERFORMED
READING
Record the name, address, and phone number of your authorized Cummins Onan service center.

7. Maintenance Record 5-2016

power.cummins.com
Copyright © 2016 Cummins Inc. All rights reserved.
Cummins, Onan, the "C" logo, and "Performance you rely on." are trademarks of Cummins Inc.
Other company, product, or service names may be trademarks or service marks of others.
Specifications are subject to change without notice.

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HDKCA (Spec F-H)

A043D713 (Issue 5) i Copyright © 2016 Cummins Inc.

4.4.1 Power Versus Altitude................................................................................................ 26

Copyright © 2016 Cummins Inc. ii A043D713 (Issue 5)

6.2.10 Code 22 - Governor Actuator Overload ................................................................... 50

A043D713 (Issue 5) iii Copyright © 2016 Cummins Inc.

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Copyright © 2016 Cummins Inc. iv A043D713 (Issue 5)

1.2 Warning, Caution, and Note Styles Used in This

1.3 General Safety Precautions

A043D713 (Issue 5) 1 Copyright © 2016 Cummins Inc.

Copyright © 2016 Cummins Inc. 2 A043D713 (Issue 5)

1.4 Automatic Generator Start Control Hazards

1.5 Electrical Shock and Arc Flash Can Cause Severe

A043D713 (Issue 5) 3 Copyright © 2016 Cummins Inc.

1.6 Generator Voltage Is Deadly

1.7 Engine Exhaust/Carbon Monoxide Is Deadly

Copyright © 2016 Cummins Inc. 4 A043D713 (Issue 5)

Mild effects of CO poisoning include:

1.8 Diesel Fuel Is Combustible

1.9 Battery Gas Is Explosive

A043D713 (Issue 5) 5 Copyright © 2016 Cummins Inc.

1.10 Moving Parts Can Cause Severe Personal Injury or

1.12 Generator Set Warning Labels

Copyright © 2016 Cummins Inc. 6 A043D713 (Issue 5)

Caution or Warning of Temperature Hazard.

Caution or Warning of High Voltage Hazard.

Caution or Warning of Engine Coolant Pressure Hazard.

Caution or Warning of No Step.

Caution or Warning of Combustion or Explosion Hazard.

Caution or Warning of Belt and Rotating Part Hazard.

Caution or Warning of Chemical (ingestion or burn) Hazard.

Caution or Warning of High Voltage or Current Source Hazard.

Caution or Warning of Fan and Rotating Part Hazard.

A043D713 (Issue 5) 7 Copyright © 2016 Cummins Inc.

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Copyright © 2016 Cummins Inc. 8 A043D713 (Issue 5)

2.2 Related Literature

• Health and Safety Manual (0908-0110)

A043D713 (Issue 5) 9 Copyright © 2016 Cummins Inc.

2.3 Model Identification

Copyright © 2016 Cummins Inc. 10 A043D713 (Issue 5)

2.3.1 Nameplate Location

FIGURE 1. NAMEPLATE LOCATION

2.4 How to Obtain Service

A043D713 (Issue 5) 11 Copyright © 2016 Cummins Inc.

2.4.1 In North America

2.4.2 Outside North America

2.4.3 Information To Have Available

Copyright © 2016 Cummins Inc. 12 A043D713 (Issue 5)

3.2 Information for Generator Set Users

TABLE 1. EMISSIONS CONTROL INFORMATION

The emissions control warranty statement is located in the same

3.3 Build Standards

A043D713 (Issue 5) 13 Copyright © 2016 Cummins Inc.

Copyright © 2016 Cummins Inc. 14 A043D713 (Issue 5)

A043D713 (Issue 5) 15 Copyright © 2016 Cummins Inc.

3.5 List of Acronyms