Operator's Manual

Detector
Control
Generator Sets

Models
DFEB, DFEC, DFFB

Printed in U.S.A. 960-0139 2-2003

Table of Contents

SECTION TITLE PAGE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Generator AC Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Engine Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
No-Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Exercise Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
High/Low Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Power Rating Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Generator Set Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
6 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Electric Governor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

i
 IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS – This manual contains EXHAUST GASES ARE DEADLY
important instructions that should be followed during
installation and maintenance of the generator and batter- • Provide an adequate exhaust system to properly
ies. expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
Before operating the generator set (genset), read the likely to congregate. Visually and audibly inspect
Operator’s Manual and become familiar with it and the the exhaust daily for leaks per the maintenance
equipment. Safe and efficient operation can be schedule. Make sure that exhaust manifolds are se-
achieved only if the equipment is properly operated cured and not warped. Do not use exhaust gases to
and maintained. Many accidents are caused by failure heat a compartment.
to follow fundamental rules and precautions.
• Be sure the unit is well ventilated.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the oper-
• Engine exhaust and some of its constituents are
known to the state of California to cause cancer,
ator, service personnel, or the equipment.
birth defects, and other reproductive harm.
This symbol warns of immediate
MOVING PARTS CAN CAUSE SEVERE
hazards which will result in severe personal in-
jury or death. PERSONAL INJURY OR DEATH
• Keep your hands, clothing, and jewelry away from
WARNING This symbol refers to a hazard or un- moving parts.
safe practice which can result in severe person-
al injury or death. • Before starting work on the generator set, discon-
nect battery charger from its AC source, then dis-
CAUTION This symbol refers to a hazard or un- connect starting batteries, negative (–) cable first.
safe practice which can result in personal injury This will prevent accidental starting.
or product or property damage. • Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep guards
FUEL AND FUMES ARE FLAMMABLE in position over fans, drive belts, etc.
Fire, explosion, and personal injury or death can result • Do not wear loose clothing or jewelry in the vicinity of
from improper practices. moving parts, or while working on electrical equip-
ment. Loose clothing and jewelry can become
• DO NOT fill fuel tanks while engine is running, un- caught in moving parts.
less tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a potential • If adjustment must be made while the unit is run-
fire hazard. ning, use extreme caution around hot manifolds,
moving parts, etc.
• DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition source DO NOT OPERATE IN FLAMMABLE AND
near the generator set or fuel tank.
EXPLOSIVE ENVIRONMENTS
• Fuel lines must be adequately secured and free of
leaks. Fuel connection at the engine should be Flammable vapor can cause an engine to overspeed and
made with an approved flexible line. Do not use zinc become difficult to stop, resulting in possible fire, explo-
coated or copper fuel lines with diesel fuel. sion, severe personal injury and death. Do not operate a
genset where a flammable vapor environment can be
• Be sure all fuel supplies have a positive shutoff created by fuel spill, leak, etc., unless the genset is
valve. equipped with an automatic safety device to block the air
• Be sure battery area has been well-ventilated prior intake and stop the engine. The owners and operators of
to servicing near it. Lead-acid batteries emit a highly the genset are solely responsible for operating the gen-
explosive hydrogen gas that can be ignited by arc- set safely. Contact your authorized Cummins Power
ing, sparking, smoking, etc. Generation distributor for more information.

LS-14M
iii
ELECTRICAL SHOCK CAN CAUSE GENERAL SAFETY PRECAUTIONS
SEVERE PERSONAL INJURY OR DEATH • Coolants under pressure have a higher boiling point
than water. DO NOT open a radiator or heat ex-
• Remove electric power before removing protective changer pressure cap while the engine is running.
shields or touching electrical equipment. Use rub- Allow the generator set to cool and bleed the system
ber insulative mats placed on dry wood platforms pressure first.
over floors that are metal or concrete when around
electrical equipment. Do not wear damp clothing • Used engine oils have been identified by some state
(particularly wet shoes) or allow skin surface to be or federal agencies as causing cancer or reproduc-
damp when handling electrical equipment. Do not tive toxicity. When checking or changing engine oil,
wear jewelry. Jewelry can short out electrical con- take care not to ingest, breathe the fumes, or con-
tacts and cause shock or burning. tact used oil.

• Use extreme caution when working on electrical • Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials
components. High voltages can cause injury or
such as wood and cloth; Class B fires, combustible
death. DO NOT tamper with interlocks.
and flammable liquid fuels and gaseous fuels; Class
• Follow all applicable state and local electrical C fires, live electrical equipment. (ref. NFPA No. 10).
codes. Have all electrical installations performed by • Make sure that rags are not left on or near the en-
a qualified licensed electrician. Tag and lock open gine.
switches to avoid accidental closure.
• Make sure generator set is mounted in a manner to
• DO NOT CONNECT GENERATOR SET DIRECT- prevent combustible materials from accumulating
LY TO ANY BUILDING ELECTRICAL SYSTEM. under the unit.
Hazardous voltages can flow from the generator set • Remove all unnecessary grease and oil from the
into the utility line. This creates a potential for elec- unit. Accumulated grease and oil can cause over-
trocution or property damage. Connect only heating and engine damage which present a poten-
through an approved isolation switch or an ap- tial fire hazard.
proved paralleling device.
• Keep the generator set and the surrounding area
clean and free from obstructions. Remove any de-
MEDIUM VOLTAGE GENERATOR SETS
bris from the set and keep the floor clean and dry.
(601V to 15kV) • Do not work on this equipment when mentally or
physically fatigued, or after consuming any alcohol
• Medium voltage acts differently than low voltage. or drug that makes the operation of equipment un-
Special equipment and training is required to work safe.
on or around medium voltage equipment. Operation • Substances in exhaust gases have been identified
and maintenance must be done only by persons by some state or federal agencies as causing can-
trained and qualified to work on such devices. Im- cer or reproductive toxicity. Take care not to breath
proper use or procedures will result in severe per- or ingest or come into contact with exhaust gases.
sonal injury or death.
• Do not store any flammable liquids, such as fuel,
• Do not work on energized equipment. Unauthorized cleaners, oil, etc., near the generator set. A fire or
personnel must not be permitted near energized explosion could result.
equipment. Due to the nature of medium voltage
electrical equipment, induced voltage remains even
• Wear hearing protection when going near an oper-
after the equipment is disconnected from the power ating generator set.
source. Plan the time for maintenance with autho- • To prevent serious burns, avoid contact with hot
rized personnel so that the equipment can be de-en- metal parts such as radiator, turbo charger and ex-
ergized and safely grounded. haust system.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

iv
 1. Introduction
ABOUT THIS MANUAL For the name of your local Cummins/Onan or
Onan-only distributor in the United States or
This manual provides general information for Canada, call 1-800-888-ONAN (this automated
operating and maintaining your generator set. service utilizes touch-tone phones only). By
Study this manual carefully and observe all entering your area code and the first three digits of
warnings and cautions. Using the generator set your local telephone number, you will receive the
properly and following a regular maintenance name and telephone number of the distributor
schedule will contribute to longer unit life, better nearest you.
performance and safer operation.
For the name of your local Cummins-only
HOW TO OBTAIN SERVICE distributor, or if you need more assistance, please
call Onan Corporation, 1-612-574-5000, 7:30 AM
When the generator set requires servicing, contact to 4:00 PM, Central Standard Time, Monday
your nearest dealer or distributor. Factory-trained through Friday.
Parts and Service representatives are ready to
handle all your service needs. When contacting your distributor, always supply the
complete Model Number and Serial Number as
If unable to locate a dealer or distributor, consult the shown on the generator set nameplate.
Yellow Pages. Typically, our distributors are listed
under:

GENERATORS-ELECTRIC,
ENGINES-GASOLINE OR DIESEL, OR
RECREATIONAL VEHICLES-EQUIPMENT,
PARTS AND SERVICE.

WARNING

INCORRECT SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE PERSONAL

INJURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE
QUALIFIED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.

Onan is a registered trademark of Onan Corporation.

Cummins is a registered trademark of Cummins Engine Company, Inc.

1-1
1-2
2. Specifications

Model Number 400 DFEB 450 DFEC 500 DFFB

Engine
Cummins Diesel Series KTA19-G2 KTA19-G3 KTTA19-G2

Generator
3 Phase, 60 Hz 400 kW 450 kW 500 kW
(kVA @ 0.8 PF) (500) (562.5) (625)

3 Phase, 50 Hz 330 kW 400 kW –

(kVA @ 0.8 PF) (412.5) (500) –

Electrical System
Starting Voltage 24 Volts DC 24 Volts DC 24 Volts DC
Battery Two, 12-Volt Two, 12-Volt Two, 12-Volt

Cooling System 24 Gallons 24 Gallons 24 Gallons

Capacity (Std. Radiator) (90 L) (90 L) (90 L)

Lubricating System 48 Quarts 48 Quarts 48 Quarts

Oil Capacity with Filters (45 L) (45 L) (45 L)

Oil Type
-13° F to 95° F (-25° C to 35° C) SAE 10W-30 SAE 10W-30 SAE 10W-30
14° F (-10° C) and above SAE 15W-40 SAE 15W-40 SAE 15W-40
32° F (0° C) and above SAE 20W-40 SAE 20W-40 SAE 20W-40

2-1
2-2
 3. Operation
GENERAL Coolant
Check the engine coolant level. The coolant should
This section covers prestart checks, starting and be about two inches (50 mm) below the radiator cap
stopping and operating the generator set. Each op- opening. Do not check while the engine is hot.
erator should read through this entire section before
WARNING Contact with hot coolant can result in
attempting to start the set. It is essential that the op-
severe burns. Do not bleed hot, pressurized coolant
erator be completely familiar with the set for safe
from a closed cooling system.
operation.
Fuel
PRESTART CHECKS Make sure the fuel tanks have sufficient fuel and
that fuel system is primed.
Before starting, be sure the following checks have CONTROL PANEL
been made and the unit is ready for operation. Refer
to the Maintenance section for the recommended The following describes the function and operation
procedures. of the standard Detector 7 and optional Detector 12
generator set control. All instruments and control
switches are located on the face of the control panel
Lubrication as illustrated in Figures 3-1 through 3-3. The control
panel is separated into a DC panel for monitoring
Check the engine oil level. Keep the oil level near as the engine and an AC panel for monitoring the gen-
possible to the dipstick high mark without overfilling. erator.

3-1
 PANEL LAMP

OIL PRESSURE RUN/STOP/REMOTE

GAUGE SWITCH

RESET/LAMP
TEST/ PANEL
LAMP SWITCH
COOLANT
TEMPERATURE INDICATOR
GAUGE LAMPS

FREQUENCY
DC VOLTMETER ADJUST

OIL RUNNING
TEMPERATURE TIME METER
GAUGE
EMERGENCY STOP
PUSHBUTTON

TACHOMETER

539-0741c1

FIGURE 3-1. DC CONTROL PANEL (DETECTOR 12 SHOWN)

DC Panel Reset/Lamp Test/Panel Lamp Switch: Resets

the fault circuit only when the Run/Stop/Remote
Panel Lamp: Illuminates control panel.
switch is in the Stop (Reset) position. Tests fault
Oil Pressure Gauge: Indicates pressure of lubri- lamps and turns on the control panel lamp.
cating oil in engine (wired to a sensor located on the
engine). Tachometer (Optional): Provides constant moni-
toring of engine r/min.
Coolant Temperature Gauge: Indicates tempera-
ture of circulating coolant in engine (wired to a sen- Speed Adjusting Rheostat (Optional): Used in
sor located on engine). conjunction with an optional electronic governor to
adjust engine speed.
DC Voltmeter: Indicates the battery charging sys-
tem voltage. Oil Temperature Gauge (Optional): Indicates
Run/Stop/Remote Switch: Starts and stops the temperature of lubricating oil in engine (wired to a
set locally, or from a remote location wired to the sensor located on the engine).
control engine monitor board.
Emergency Stop Button (Optional): Push-in
Running Time Meter: Registers the total number switch for emergency shutdown of the engine. To
of hours the unit has run. Use it to keep a record of reset, pull switch out and move Run/Stop/Remote
periodic servicing. Time is cumulative; meter can- switch to Stop position. Then push test switch to Re-
not be reset. set/Lamp Test position.

3-2
Detector 7 Indicator Lamps: The standard control
panel has seven indicator lamps which are de-
scribed as follows:

• RUN (green) lamp comes on when starter cir-

cuit opens after set starting.

• PRE LO OIL PRES (yellow) indicates engine

oil pressure is marginally low.

• PRE HI ENG TEMP (yellow) indicates engine

temperature is marginally high.

• LO OIL PRES (red) indicates engine has shut

down because of critically low oil pressure.

• HI ENG TEMP (red) indicates engine has shut

down because of critically high engine temper-
ature.

• OVERSPEED (red) indicates engine has shut

down because of excessive speed.

• OVERCRANK (red) indicates engine has

failed to start during the cranking period.

Detector 12 Indicator Lamps: The optional twelve

lamp control includes all the features of the seven
lamp control plus the following:

• FAULT 1 (red) lamp indicates an undedicated

fault. May be field programmed as a shutdown
or non-shutdown, and as a timed or non-timed
fault. (Normally set for timed shutdown).

• FAULT 2 (red) lamp indicates same features as 539-0741c2

Fault 1 (normally set for timed shutdown).

• LOW ENG TEMP (yellow) lamp lights if engine

temperature is marginally low for starting. It
may indicate an inoperative coolant heater.

• LO FUEL (yellow) indicates fuel supply is mar-

ginally low.

• SWITCH OFF (flashing red) indicates genera- FIGURE 3-2. INDICATOR LAMPS
tor set is not in automatic start mode.

3-3
 AC VOLTMETER UPPER AND LOWER
SCALE INDICATOR

A-C VOLTS

VOLTAGE
AC AMMETER ADJUST

A-C AMPERES

EXCITATION
FREQUENCY/ FIELD BREAKER
RPM METER RPM

HERTZ PHASE
SELECTOR
SWITCH
WATTMETER OTHER OPTIONAL
METERS

539-0741c3

FIGURE 3-3. AC CONTROL PANEL

AC Panel Voltage Adjusting Rheostat (Optional): Provides

approximately plus or minus five percent adjust-
AC Voltmeter (Optional): Dual range instrument ment of the rated output voltage.
indicating AC voltage. Measurement range in use
shown on indicator lamp. Upper and Lower Scale Indicator Lamps (Op-
tional): Indicates which scale to use on the AC volt-
AC Ammeter (Optional): Dual range instrument meter and ammeter.
indicates AC generator line current.
Phase Selector Switch (Optional): Selects
Wattmeter (Optional): Continuously gives reading phases of generator output to be measured by AC
of the generator output in kilowatts. voltmeter and ammeter.
Power Factor Meter (Optional): Indicates percent Engine Pyrometers (Optional): Indicate engine
power factor of AC output. exhaust and inlet air temperatures.
Frequency/RPM Meter (Optional): Indicates gen- Field Breaker: Provides generator exciter and reg-
erator output frequency in hertz and engine speed ulator protection from overheating in the event of
in revolutions-per-minute (RPM). certain failure modes of generator, exciter and volt-
age regulator.

3-4
GENERATOR AC VOLTAGE REGULATOR above 222° F (106° C) and lights a fault lamp.
The fault is time-delayed about 10 seconds fol-
The solid-state regulator controls AC output voltage lowing starter disconnect and inhibited during
from the generator at a predetermined level regard- cranking. This delay allows coolant in a hot en-
less of load. Voltage regulation is plus or minus two gine time to circulate and return the water jack-
percent from no load to full load. Random voltage et to normal before the electronic control mod-
variation is plus or minus one percent for constant ule monitors this system.
loads.
A pre-high engine temperature sensor and
ENGINE CONTROL MODULE lamp provides an alarm that engine tempera-
ture is marginally high, 215° F (102° C). The
Electronic and relay components of the engine cause should be found and corrected as soon
monitoring circuit are on a circuit board assembly. as possible.
Sensor inputs are connected by the wiring harness
to plug connectors on the board. The control mod-
ule provides the following functions of unit protec-
tion.
CAUTION The high engine temperature shut-
• Overcrank - Limits engine cranking to 75 sec- down system will not operate if the coolant level
onds. If engine fails to start, the module lights a is too low. The high engine temperature sensor
fault lamp and opens the cranking circuit. The monitors coolant temperature. Loss of coolant
cycle cranking option allows three 15-second will prevent sensor operation and allow the en-
cranking cycles with two 15-second rest peri- gine to overheat causing severe damage to the
ods on the 12-lamp control. engine. Therefore, maintain adequate coolant
level for proper operation of the high engine
• Overspeed - Shuts down the engine immedi- temperature shutdown system.
ately if overspeed occurs and lights a fault
lamp. The sensor switch is mounted in the end
bell on the generator shaft. It is factory ad-
• Low Coolant Level Shutdown (Optional) – An
justed to shut down 60 hertz units at 2100 ±90
r/min, 50 hertz units at 1850+50 r/min. electronic switch that provides engine shut-
down if coolant level falls too low. It also turns
• Low Oil Pressure - Shuts down the engine im- on the high engine temperature fault lamp.
mediately if oil pressure drops below 14 psi (97
kPA) and lights a fault lamp. The fault is time-
delayed about 10 seconds following starter dis- STARTING
connect and inhibited during cranking. The
delay allows oil pressure to rise to normal be- The following sections cover the three systems
fore the electronic control module monitors this used to start the generator set.
system.
Starting at Control Panel
A pre-low oil pressure sensor and lamp provides
an alarm that oil pressure is marginally low, 20 Move the Run-Stop-Remote switch on the DC pan-
psi (137 kPA) or less. The cause should be el to the RUN position. This will activate the engine
found and corrected as soon as possible. control system and the starting system. The starter
will begin cranking and after a few seconds the en-
• High Engine Temperature - shuts down the en- gine should start. The starter will disconnect when
gine immediately if coolant temperature rises the engine reaches a speed of 450 to 570 RPM.

3-5
If the engine does not start, the starter will disen- erator set may start, it may not be able to accept
gage after a specified period of time and the control load within 10 seconds. When this condition occurs,
will indicate an overcrank fault. Generator sets with check the coolant heaters for proper operation. If
the standard overcrank control will crank continu- the coolant heaters are operating properly, other
ously for up to 75 seconds before disengaging the precautions might be necessary to warm the engine
starter. Generator sets with the cycle cranking op- before applying a load.
tion will crank for 15 seconds in each cycle until 3
cycles have been completed. To clear an overcrank STOPPING
fault, place the Run-Stop-Remote switch in the
STOP position and momentarily depress the Reset Before Stopping
switch. Wait two minutes for the starter motor to Run the generator set at no load for three to five
cool and then repeat the starting procedure. If the minutes before stopping. This allows the lubricating
engine does not run after a second attempt at start- oil and engine coolant to carry heat away from the
ing, refer to the Troubleshooting section. combustion chamber and bearings.
Starting From Remote Location To Stop
Move the Run/Stop/Remote switch on the genera- If the set was started at the set control panel or at a
tor set DC panel to the REMOTE position. This al- remote control panel, move the Run/Stop/Remote
lows the generator set to be started from a remote switch or remote starting switch to the STOP posi-
switch. Closing the remote switch initiates the start- tion. If the set was started by an automatic transfer
ing sequence described in the previous section. switch, the set will automatically stop about 15 min-
utes after the normal power source returns.
Automatic Starting
Emergency Stop
Place the Run/Stop/Remote switch on the genera-
tor set DC panel in the REMOTE position if an auto- An optional emergency stop button is located on the
matic transfer switch is used. This allows the trans- right side of control panel (Figure 3-1). Push button
fer switch to start the generator set if a power out- in for emergency stop. To reset, pull switch out and
age occurs and stop it when the power returns. move Run/Stop/Remote switch to Stop position.
Then push test switch to Reset/Lamp Test position.
Cold Starting With Loads
In accordance with NFPA 110, Onan recommends BREAK-IN
installing diesel standby generator sets (life safety Drain and replace the crankcase oil after the first 50
systems) equipped with coolant heaters in locations hours of operation on new generator sets. Refer to
where the minimum ambient temperature is above the Maintenance section of this manual for the rec-
40°F (4°C). NFPA also requires that the engine ommended procedures.
coolant be maintained at a minimum of 90°F (32°C)
and for most applications, accept the emergency NO-LOAD OPERATION
load in 10 seconds or less. Although most Onan
generator sets will start in temperatures down to Periods of no load operation should be held to a
-25°F (-32°C) when equipped with coolant heaters, minimum. If it is necessary to keep the engine run-
it might take some running time to warm the engine ning for long periods of time when no electric output
up before a load can be applied when ambient tem- is required, best engine performance will be ob-
peratures are below 40°F (4°C). tained by connecting a “dummy” electrical load.
Such a load could consist of heater element, etc.
The Low Engine Temperature (LET) lamp on the
Onan Detector 12 control is provided to meet the re-
quirements of NFPA 110. The LET sensor alarms EXERCISE PERIOD
when the engine coolant temperature falls below
70°F (21°C). In applications where the ambient Generator sets on continuous standby must be able
temperature falls below 40°F (4°C), the LET may to go from a cold start to being fully operational in a
be lit even though the coolant heaters are con- matter of seconds. This can impose a severe bur-
nected. Under these conditions, although the gen- den on engine parts.

3-6
Regular exercising keeps engine parts lubricated, CAUTION To avoid damage to heater, be sure
prevents oxidation of electrical contacts and in gen- the cooling system is full before applying power
eral helps provide reliable engine starting. Exercise to the heater.
the generator set at least once a week for a mini-
mum of 30 minutes with load so the engine reaches
normal operating temperatures.
POWER RATING FACTORS
Onan automatic transfer switches have as an op-
tion an exerciser that can be preset to provide regu-
The generator set power rating applies to sets used
lar exercise periods. Typically the exerciser can be
set for time of start, length of run, and day of week. in standby applications. The set will operate at the
stated rating for the duration of normal utility power
HIGH/LOW OPERATING TEMPERATURES interruptions. The rating was established for a stan-
dard radiator cooled set running on diesel fuel and
Use a coolant heater if a separate source of power
is available. The optional heater available from operating at an altitude of 300 feet (92 m) with an
Onan will help provide reliable starting under ad- ambient temperature of 81°F (27°C). For a rating
verse weather conditions. Be sure the voltage of relative to other applications, altitudes, cooling sys-
the separate power source is correct for the heater tems, or ambient temperatures, contact your autho-
element rating. rized distributor.

3-7
3-8
 4. Troubleshooting
The generator set has sensors that continuously started. Place the Run/Stop/Remote switch in the
monitor the engine for abnormal conditions, such as STOP position and remove the negative battery
low oil pressure or high coolant temperature. If cable from the set starting battery.
these conditions occur, the engine monitor acti-
vates a fault lamp, and may also stop the engine WARNING Accidental starting of the generator set
(depending on the condition). If the generator set is during troubleshooting can cause severe personal
stopped for this reason, the operator may be able to injury or death. Disable the generator set before
restart the set after making adjustments or correc- troubleshooting.
tions. This section describes the fault condition sys-
tem, and suggests troubleshooting procedures. When a fault lamp turns on during operation, follow
the procedures listed below to locate and correct
The standard seven-light control has a single green the problem. For any symptom not listed, contact
light to indicate RUN, two amber pre-fault lights and an authorized service center for assistance.
four red fault lights. The optional twelve-light con-
trol has a single green light to indicate RUN, four Resetting the Control
amber lights and seven red fault lights. Both con-
trols also have a terminal connection for an audible The external alarm and fault lamp may be deacti-
alarm, which sounds when a fault occurs. vated by moving the Run/Stop/Remote switch to
the Stop position and pressing the Reset/Lamp
Test/Preheat switch. Locate the problem and cor-
SAFETY CONSIDERATIONS rect it before restarting the set. While pressing the
High voltages are present inside the control box and Reset/Lamp Test/Preheat switch, make certain that
generator output box when the set is running. Do all lamps light.
not open the control box or generator output box
while the set is running. Line Circuit Breaker (Optional)
The optional line circuit breaker mounts on the gen-
WARNING Contacting high voltage components
can cause electrocution, resulting in severe person-
erator output box. If the load exceeds the generator
al injury or death. Keep control and output box cov- current rating, the line circuit breaker will open, pre-
ers in place during troubleshooting. venting the generator from being overloaded. If the
circuit breaker trips, locate the source of the over-
When troubleshooting a set that is shut down, make load and correct as necessary. Manually reset the
certain the generator set cannot be accidentally re- breaker to reconnect the load to the generator.

4-1
 TABLE 4-1. TROUBLESHOOTING
Many troubleshooting procedures present hazards which can result in severe personal
injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery
hazards should perform service procedures. Review safety precautions on pages ii and iii.
SYMPTOM CORRECTIVE ACTION
1. Green RUN lamp lights following engine 1. Indicates all engine systems are normal. No correc-
startup. tive action required.
2. PRE HI ENGINE TEMP lamp lights. En- 2. Indicates engine has begun to overheat and engine
gine continues to operate. temperature has risen to approximately 215°F (102°
C). If generator is powering non-critical and critical
loads and cannot be shut down, use the following:

a. Reduce load if possible by turning off non-critical

loads.

b. Check air inlets and outlets and remove any ob-

structions to airflow.

If engine can be stopped, follow procedure in

step 3.
3. HI ENG TEMP lamp lights. Engine 3. Indicates engine has overheated (engine tempera-
shuts down. ture has risen above 222°F/106°C) or coolant level is
low (sets with coolant level sensor). Allow engine to
cool down completely before proceeding with the fol-
lowing checks:

a. Check coolant level and replenish if low. Look

for possible coolant leakage points and repair if
necessary.

b. Check for obstructions to cooling airflow and

correct as necessary.

c. Check for a slipping fan belt and tighten if loose.

d. Reset control and restart after locating and cor-

recting problem. Contact an authorized service
center if none of the above.

4. PRE LO OIL PRES lamp lights. Engine 4. Indicates engine oil pressure has dropped to 20 psi
continues to operate. (138 kPa). If generator is powering critical loads and
cannot be shut down, wait until next shutdown period
and then follow step 5 procedure. If engine can be
stopped, follow procedures in step 5.
5. LO OIL PRES lamp lights. Engine shuts 5. Indicates engine oil pressure has dropped to 14 psi
down. NOTE: See also step 6. (97 kPa). Check oil level, lines and filters. If oil system
is OK but oil level is low, replenish. Reset control and
restart. Contact an authorized service center if oil
pressure is not in the range of 25 to 40 psi (172 to 275
kPa).

4-2
 TABLE 4-1. TROUBLESHOOTING (continued)
Many troubleshooting procedures present hazards which can result in severe personal
injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery
hazards should perform service procedures. Review safety precautions on pages ii and iii.
SYMPTOM CORRECTIVE ACTION
6. OVERCRANK lamp lights and engine 6. Indicates possible fuel system problem.
stops cranking.
a. Check for empty fuel tank, fuel leaks, or plugged
or fuel lines and correct as required.

Engine runs, shuts down, and LO OIL b. Check for dirty fuel filter and replace if necessary
PRES lamp lights.. (see Maintenance section).

c. Check for dirty or plugged air filter and replace if

necessary (see Maintenance section).

d. Reset the control and restart after correcting the

problem. Contact an authorized service center
for service if none of the above.

7. Engine runs and then shuts down, 7. Indicates engine has exceeded normal operating
OVERSPEED lamp lights. speed. Contact an authorized service center for ser-
vice.
*8. SWITCH OFF lamp flashes. 8. Indicates Run/Stop/Remote switch is in the Stop
position which will prevent automatic starting if an au-
tomatic transfer switch is used. Move the Run/Stop/
Remote switch to the Remote position for automatic
starting.
*9. LO FUEL lamp lights. Engine continues 9. Indicates diesel fuel supply is running low. Check
to run. fuel supply and replenish as required.
*10. LO FUEL LAMP lights. Engine shuts 10. Indicates engine has run out of fuel. Check fuel level
down and LO OIL PRES lamp lights. and replenish as required.

*11. LO ENG TEMP lamp lights. Set is in 11. Indicates engine coolant heater is not operating or is
standby mode but is not operating. not circulating coolant. Check for the following condi-
tions:
(Lamp lights when engine coolant tem-
perature is 70° F (21° C) or lower. Since a. Coolant heater not connected to power supply.
the lamp goes out after the engine Check for blown fuse or disconnected heater
warms up, there should be no cause for cord and correct as required.
alarm even during initial generator set
b. Check for low coolant level and replenish if re-
operation.)
quired. Look for possible coolant leakage points
and repair as required.

c. Contact an authorized service center if none of

the above.

* 12-Light Control Only.

4-3
 TABLE 4-1. TROUBLESHOOTING (continued)
Many troubleshooting procedures present hazards which can result in severe personal
injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery
hazards should perform service procedures. Review safety precautions on pages ii and iii.
SYMPTOM CORRECTIVE ACTION
*12. The FAULT 1 or FAULT 2 fault lamp 12. The standard undesignated fault functions are pro-
lights. Engine shuts down immediately, grammed to shut down the set when a fault is sensed.
engine runs for several seconds and Fault 1 is time delayed while Fault 2 is immediate.
then shuts down, or engine continues to The nature of the fault is an optional selection that is
run. determined when the set installation is designed.
The undesignated fault functions may also be pro-
grammed for non-shutdown or non-time delay.

13. Fault lamp lights but no fault exists. En- 13. The monitor board or a sensor may be at fault. Con-
gine gauges show oil pressure, engine tact an authorized service center for service.
temperature, and frequency (speed) are
within normal limits.

14. Engine starts from generator control 14. Remote circuit breaker is tripped. Reset breaker and
panel but will not start automatically or restart. Contact an authorized service center if
from a remote panel. (Note: The Run/ breaker trips after resetting.
Stop/Remote switch must be in the Re-
mote position for automatic or remote
starting).

15. Engine will not crank. 15. Indicates possible fault with control or starting sys-
tem. Check for the following conditions:

a. Fault lamp on. Correct fault and reset control.

b. Poor battery cable connections. Clean the bat-

tery cable terminals and tighten all connections.

c. Discharged or defective battery. Recharge or

replace the battery.

d. Emergency stop button (if equipped) pushed in.

To reset, pull switch out and move Run/Stop/Re-
mote switch to Stop position. Then push test
switch to Reset/ Lamp position.
e. Contact an authorized service center if none of
the above.

16. No AC output voltage. 16. Field breaker is tripped. Reset breaker. Contact an
authorized service center if voltage buildup causes
breaker to trip.

17. Green RUN lamp does not light follow- 17. Indicates possible Start/Disconnect relay failure.
ing engine startup. Contact an authorized service center for assistance.

* 12-Light Panel Only.

4-4
 5. Maintenance
Establish and adhere to a definite schedule for Consult with an authorized distributor if the genera-
maintenance and service based on the application tor set will be subjected to any extreme operating
and severity of the environment. The table below conditions and determine a suitable schedule of
covers the recommended service intervals for a maintenance. Use the running time meter to keep
generator set on STANDBY service. If the set will be an accurate log of all service performed for warranty
support. Perform all service at the time period indi-
subjected to extreme operating conditions, the ser-
cated or after the number of operating hours indi-
vice intervals should be reduced accordingly. Some
cated, whichever comes first. Use Table 5-1 to de-
of the factors that can affect the maintenance termine the maintenance required and then refer to
schedule are the following: the sections that follow for the correct service pro-
cedures.
• Use for continuous duty (prime power) WARNING Accidental starting of the set can
• Extremes in ambient temperature cause severe personal injury or death. Discon-
• Exposure to elements nect the battery cables (negative first) when re-
• Exposure to salt water pairs are made to the engine, controls, or gener-
• Exposure to windblown dust or sand ator.

5-1
 TABLE 5-1. MAINTENANCE SCHEDULE

SERVICE TIME
Daily Weekly Monthly 6 Months Yearly
or or or or or
after after after after after
MAINTENANCE CHECKS 8 hours 50 hours 100 hours 250 hours 500 hours
Inspect Set x1
Check Coolant Heater x
Check Oil Level x
Check Coolant Level x
Check Air Cleaner (clean if required) x2
Check Battery Charging System x
Drain Fuel Filter(s) x4
Drain Water and Sediment from Fuel Tanks x4
Check Anti-freeze and DCA Concentration x
Check Drive Belt Tension x3
Check Fuel Level x
Drain Exhaust Condensate Trap x
Check Battery Level and Specific Gravity x
Check Generator Air Outlet x
Clean Generator Assembly x
Change Crankcase Oil and Filter x2
Check Heat Exchanger Plugs (if equipped) x
Change Coolant Filter x
Clean Crankcase Breather x2
Change Air Cleaner Element x2
Check Governor Linkage x
Change Fuel Filters x
Clean Cooling System x
1 - Check for oil, fuel, cooling, and exhaust system leaks. Check exhaust system audibly and visually with set running and
repair any leaks immediately.
2 - Perform more often in extremely dusty conditions.
3 - Visually check belts for evidence of slippage.
4 - Drain 1 cup or more of fuel to remove water and sediment.

GENERATOR SET INSPECTION exhaust manifold, muffler, and exhaust pipe. Check
for leaks at all connections, welds, gaskets, and
During operation, be alert for mechanical problems joints and also make sure that exhaust pipes are not
that could create unsafe or hazardous conditions. heating surrounding areas excessively. If any leaks
The following sections cover several areas that are detected, shut down the generator set and have
should be frequently inspected to ensure continued leaks corrected immediately.
safe operation.

Exhaust System WARNING Inhalation of exhaust gases can re-

sult in serious personal injury or death. Be sure
With the generator set operating, inspect the entire deadly exhaust gas is piped outside and away
exhaust system visually and audibly including the from windows, doors or other inlets to building.

5-2
Fuel System DC Electrical System
Check the terminals on the battery for clean and
With the generator set operating, inspect the fuel tight connections. Loose or corroded connections
supply lines, return lines, filters, and fittings for create resistance which can hinder starting. Clean
leaks. Check any flexible sections for cuts, cracks and reconnect the battery cables if loose. Always
and abrasions and make sure they are not rubbing disconnect both ends of the negative battery cable.
against anything that could cause breakage. If any Reconnect one end of the cable to the negative bat-
leaks are detected, have them corrected immedi- tery terminal and the other end to ground. This will
ately. ensure that any arcing will be away from the battery
and least likely to ignite explosive battery gases.
WARNING Ignition of fuel can cause serious WARNING Ignition of explosive battery gases
personal injury or death by fire or explosion. Do can cause severe personal injury. Do not smoke
not permit any flame, cigarette, or other igniter while servicing batteries.
near the fuel system.
WARNING Accidental starting of the generator
set can cause severe personal injury or death.
AC Electric System Place the control switch in STOP position and
disconnect the battery cable before inspecting
Check the following while the generator set is oper- generator set.
ating; otherwise measure load lines L1, L2, and L3
using the appropriate AC meter. With the generator set stopped, check for loose
belts and fittings, leaking gaskets and hoses, or any
signs of mechanical damage. If any problems are
Frequency Meter: The generator frequency found, have them corrected immediately. With the
should be stable and the reading should be the set running, listen for any unusual noises that may
same as the nameplate rating. indicate mechanical problems and check the oil
pressure frequently. Investigate anything that indi-
AC Voltmeter: Turn the phase selector switch to cates possible mechanical problems.
each line-to-line phase selection shown on the volts
scale (L1-L2, L2-L3, and L3-L1). Read the AC volt- LUBRICATION SYSTEM
meter using the upper or lower scale as indicated by The engine lubrication system must be primed and
the scale indicator light. At no load, the line-to-line filled with oil of the recommended classification and
voltage(s) should be the same as the set nameplate viscosity. Refer to the SPECIFICATIONS section
rating. for the lubricating oil capacity.

AC Ammeter: Turn the phase selector switch to Oil API Classification

each phase selection shown on the amps scale (L1, The lubricating oil recommended for turbocharged
L2, and L3). Read the ammeter using the upper or diesel engines is API (American Petroleum Insti-
lower scale as indicated by the scale indicator light. tute) Class CC/CD with a maximum sulphated ash
At no load, the current readings should be zero. content of 1.85 percent. Oils in this class satisfy the
With a load applied, each line current should be engine manufacturer’s recommendations for satis-
about the same. factory operation under most conditions. A book en-
titled “Lubricating Oils Data Book” is available from
Fault Lamps (Two or Twelve-Fault Lamp Pan- EMA (Engine Manufacturers Association) that lists
els): Push the Reset/Lamp switch on the control the commercially available oils by brand name and
panel. All indicator lamps should light. Verify that all the corresponding API classification. Once an oil is
of the bulbs are on and then release the switch. Re- selected, do not mix it with oils of another classifica-
place any bulbs that are burned out. tion or brand.

5-3
Oil Viscosity
The viscosity of an oil is a measure of its resistance TABLE 5-2
to flow at certain specified temperatures. Oils that
can meet both low (0° F or -18° C) and high (212° F AMBIENT TEMPERATURE SAE VISCOSITY GRADE
or 100° C) temperature flow requirements are la- -13° F (-25° C) and below See following section
beled as multigrade or multiviscosity oils. Multi-
-13° F to 95° F (-25° C to 35° C) 10W-30
grade oils that meet the API classification require-
ments are recommended for use in the engine by 14° F (-10° C) and above 15W-40
the engine manufacturer. The use of a multigrade 32° F (0° C) and above 20W-40
oil will improve oil control, improve engine cranking
in cold weather, maintain adequate lubrication, and
can also contribute to improved fuel economy. When selecting the oil viscosity, pick the grade that
Table 5-2 shows the oil viscosity grades that are is right for the lowest temperature expected. Oil that
recommended for various ambient temperatures. is too thick may result in a lack of lubrication when
Use only the viscosity grades shown in the table. the engine is started. Use a lower grade of oil as the
The engine manufacturer does not recommend the ambient temperature reaches the lower end of the
use of a single grade oil. scale.

5-4
Oil Viscosity for Extreme Cold

The engine manufacturer recommends using a

synthetic lubricating oil when the ambient tempera- OIL FILL
ture is consistently below -13° F (-25° C) and there
is no provision to keep the engine warm. Use an OIL FILTERS
SAE5W grade synthetic oil provided it meets the fol-
lowing requirements:

• API class CC/CD

• Sulphated ash content does not exceed 1.85
percent.
• Pour point is 9° F (5° C) below the lowest
expected temperature (minimum)
• Viscosity is 10,000 mPa•s (maximum) at -31° F
(-35° C) and 4.1 mm2/s (minimum) at 212° F
(100° C).

Do not use a petroleum base 5W grade oil for ex-

treme cold since it usually will not perform satisfac-
torily.
DIPSTICK
Engine Oil Level

Check the engine oil level during engine shutdown LS10631s

periods at the intervals specified in the Mainte-

nance Table. The oil dipstick, oil fill and oil filter are
FIGURE 5-1. OIL FILTER AND DIPSTICK LOCATION
located on the same side of the engine (see Figure
5-1). The dipstick is stamped with high and low
marks to indicate the level of oil in the crankcase.
For accurate readings, shut off the engine and wait
approximately 15 minutes before checking the oil
level. This allows oil in the upper portion of the en-
gine to drain back into the crankcase.

WARNING Crankcase pressure can blow out

hot oil and cause serious burns. Do NOT check
oil while the generator set is operating.

Keep the oil level as near as possible to the high

mark on the dipstick. Remove the oil fill cap and add
oil of the same API and brand when necessary.

CAUTION Do not operate the engine with the

oil level below the low mark or above the high
mark. Overfilling can cause foaming or aeration
of the oil while operation below the low mark
can cause loss of oil pressure.

5-5
Oil and Filter Change

Change the oil and filter at the intervals recom-

OIL FILL
mended in Table 5-1. Use oil that meets the API
Classification and viscosity requirements.
OIL FILTERS
1. Start the generator set and allow engine to
warm up to operating temperature and then
shut generator set off. Ensure that Automatic
Start switch is at OFF position and the negative
(-) battery cable is disconnected to avoid acci-
dental start-up and during this procedure.
2. Remove the oil drain plug or open the drain
valve and collect the engine oil in a suitable
size waste container. When the crankcase is
drained, replace the oil drain plug or close the
drain valve. Torque the oil drain plug to 60-70
ft-lb (81-95 N•m).
3. Unscrew the oil filter and discard.
4. Apply a light coat of oil to the gasket sealing DIPSTICK
surface of the new filter and fill filter with clean,
new oil.
5. Install filter and tighten 2/3 turn by hand after LS10631s
the seal touches the sealing surface of the
bracket. Do not overtighten. FIGURE 5-2. LUBRICATION OIL FILTER
6. Fill the crankcase with the amount of oil to
achieve reading at high mark of dipstick.
7. Reconnect the negative (-) starting battery
cable, start the engine and check for oil leaks.
8. Shut off the engine, wait 15 minutes, and then
check the oil level. Add oil if required.

WARNING Crankcase pressure can blow

out hot oil and cause serious burns. Do
NOT check oil while the generator set is op-
erating.

5-6
 COOLANT SYSTEM
The coolant system must be refilled (radiator and
heat exchanger) before being operated. The cool-
ing system capacity of the standard unit with set
mounted radiator is shown in the SPECIFI-
CATIONS section.
CAUTION The heater must not be operated
while the cooling system is empty or when the
engine is running or damage to the heater will
occur.
Coolant Level
Check the coolant level during shutdown periods at
the intervals specified in the Maintenance Table.
Remove the radiator cap after allowing the engine
to cool and if necessary, add coolant until the level is
near the top of the radiator. Use a coolant solution
that meets the engine manufacturer’s coolant re- CS1354s
quirements.
WARNING Contact with hot coolant can result
in serious burns. Allow cooling system to cool FIGURE 5-3. RADIATOR CAP
before releasing pressure and removing radia-
tor cap.
CAUTION High Engine Temperature Cutoff
will shut down engine in an overheat condition
only if coolant is sufficiently high to physically
contact shutdown switch. Loss of coolant will
allow engine to overheat without protection of
shutdown device and cause severe damage to
the engine. It is therefore imperative that ade-
quate engine levels be maintained to ensure op-
erational integrity of cooling system and engine
coolant overheat shutdown protection.

5-7
Coolant Requirements Remote Radiator Coolant Precharge
The water used for engine coolant should be clean, The large quantities of coolant used in a remote ra-
low in mineral content, and free of any corrosive diator installation will require precharging with a
chemicals such as chloride, sulphate, or acid. Gen- separate anti-corrosion additive. The precharge
erally, any water that is suitable for drinking can be water filter will not provide adequate anti-corrosion
treated for use as engine coolant. protection for the large capacities of most remote
A satisfactory engine coolant inhibits corrosion and systems.
if necessary, protects against freezing. To prevent
WARNING Diesel Coolant Additive (DCA) is an
corrosion, the water used for coolant must be pre-
charged with a chemical additive. New engines are engine corrosion inhibitor. The DCA manufac-
shipped with a precharge water filter that automati- turer rates it as moderately hazardous. That is, it
cally adds an anti-corrosion chemical to the coolant. may involve both irreversible and reversible
changes; not severe enough to cause death or
The precharge water filter is compatible with plain permanent injury.
water and all permanent type antifreezes EXCEPT
those with a methoxy propanol base. Exposure can cause irritation to eyes, nasal
passages and exposed skin. Protective rubber
Cooling systems that are subject to freezing condi- or plastic gloves, goggles and dust (3M Compa-
tions must also be protected with a permanent type ny #8710 or equal) respirators must be used
antifreeze. Mix the water and antifreeze in the pro- when handling DCA powder.
portion recommended by the supplier for the lowest
expected ambient temperature. Do not use an anti- If exposed to DCA or coolant using DCA, flush
freeze that contains anti-leak additives. The water eyes and skin with clean water. Remove con-
filter element will trap the additives and possibly be- taminated clothing and launder before use.
come clogged.
Clean area of dry spills and place DCA in an ap-
WARNING Contact with hot coolant can result proved chemical contamination container.
in serious burns. Do not bleed hot, pressurized
coolant from a closed cooling system. Engine coolant containing DCA must be dis-
posed of per local, state, and federal regula-
Filling the Cooling System tions in approved chemical contamination con-
(Standard Radiator and Heat Exchanger tainers.
Sets)
A separate precharge DCA (diesel coolant) in pow-
Remove the cooling system pressure cap and fill der, liquid or brickett is available from the engine
the system with water or a water/antifreeze mixture. manufacturer. The following recommendations are
On the initial fill, the precharge water filter will auto- provided for mixing the coolant with the engine
matically add the required anti-corrosion chemicals manufacturer’s precharge additive.
to the cooling system.
When the engine is first started, remove the pres- Testing the DCA Concentration: Over a period of
sure cap and monitor the coolant level. As trapped time, the DCA additive will become depleted and it
air is expelled from the system, the coolant level will will be necessary to add more DCA chemical to
drop and additional coolant should be added. Re- maintain adequate corrosion protection. The en-
place the pressure cap when the coolant level is gine manufacturer has a testing kit available for
stable. measuring the concentration of DCA chemical in
the system. Determine the DCA concentration be-
CAUTION Be sure the electric solenoid valve fore adding more DCA to the system. Too low a con-
used with city water cooled sets is open before centration will allow corrosion to start. Too great a
initial starting of unit to allow coolant chambers concentration may cause sludge to form in the wa-
to fill. Otherwise overheating and damage to the ter filter. Instructions for testing the coolant are pro-
engine might result. vided with the kit.

5-8
Coolant Filter
When changing the coolant filter on a new engine, SHUTOFF
VALVE
replace the DCA precharge element filter with the
DCA service element filter. After the third element
change, check the DCA concentration to ensure
that adequate corrosion protection is maintained.
Each time the cooling system (set mounted radia-
tor) is drained, install a new DCA precharge ele-
ment water filter to bring the DCA concentration up
to the recommended level.
To Service:
1. Close the shutoff valve (Figure 5-4).
2. Unscrew the coolant filter and discard.
3. Apply a light coat of lubricating oil to the gasket
surface.
4. Install a new filter and tighten by hand until the
seal just touches the filter head. Tighten an
additional one-half to three-fourths turn.
5. Open the shutoff valve.
COOLANT FILTER
CAUTION Do not use antifreeze with an anti-
leak formula. The stop leak element can prevent
or retard the coolant flow through the filter, CS1131s
thereby eliminating the filtering process com-
pletely. FIGURE 5-4. TYPICAL COOLANT FILTER
Flushing and Cleaning
The cooling system must be clean and free of rust
and scale if it is to perform properly. Use only cool-
ant that meets the engine manufacturer’s require-
ments.
CAUTION To avoid damage to coolant heater,
disconnect power to heater before flushing sys-
tem.
Chemical Cleaning: Thoroughly clean the cooling
system if rust and scale have collected on the en-
gine water jacket or in the radiator. Rust and scale
slow down heat absorption and can block the cool-
ant flow. Use a good cooling system cleaner such
as sodium bisulphate or oxalic acid and follow the
instructions provided by the supplier. Follow up by
neutralizing and flushing with clean water.

5-9
Flushing: Flush the radiator and block after clean-
ing or before refilling the system with new coolant.
Open the upper and lower radiator hose connec- OUTLET
tions and install the radiator cap. Attach a flushing
gun nozzle to the lower radiator hose connection
and let the water run until the radiator is full. When
full, gradually apply air pressure to avoid damaging
the core.
CAUTION Excessive air pressure while start-
ing the water flow could split the radiator core.
apply air pressure gradually to avoid damage.
Shut off the air and allow the radiator to refill. Re-
peat flushing procedure until the water coming from
the radiator is clean.
To flush the engine block, first remove the thermo-
stat to allow the water to fill the block. Attach the
flushing gun to the upper radiator hose and fill the
block with water. Restrict the lower radiator hose
opening until the block is filled. Apply air pressure INLET
DRAIN
and force water from the lower opening. Repeat un-
til the water coming from lower radiator hose is
clean.
Replace the thermostat and all hoses and refill cool- CS13671s
ing system.
FIGURE 5-5. COOLANT HEATER
Heat Exchanger Plugs
Check the zinc plugs in the heat exchanger and re-
place if they are eroded to less than half their origi-
nal length. The frequency of replacement is depen-
dent on the chemical reaction that occurs when the
plugs are in contact with the raw water.

Coolant Heater
Check the operation of the coolant heater by verify-
ing that hot coolant is being discharged from the
outlet hose (see Figure 5-5). For efficient operation
and maximum life, clean the coolant heater when-
ever the cooling system is drained for flushing.

5-10
 FUEL SYSTEM
The engine has been primarily designed to operate
on No. 2 diesel fuels since such fuels have a higher
energy content and are generally lower in cost. FUEL SUPPLY
Consult the engine manufacturer for the specific re- INLET
quirements if using a non-standard fuel.

Fuel Handling Precautions

Take appropriate precautions to prevent the en-
trance of dirt, water, or other contaminants into the
fuel system. Filter or strain the fuel as the tank is
filled.
WARNING Ignition of fuel can cause serious
SUPPLY LINE,
personal injury or death by fire or explosion. Do FILTER TO
not permit any flame, cigarette, or other igniter INJECTION
near the fuel system. PUMP

To avoid condensation problems, keep fuel supply

tanks as full as possible by filling up each time the
engine is used. In cold weather, warm fuel returning
from the injectors heats the fuel in the supply tank. If FUEL FILTERS
the fuel level is low, the upper portion of the tank
tends to form condensation. In warm weather, both
FS13861s
the fuel and the tank will be warm during the day-
time. At night, cool air tends to lower the tempera-
ture of the tank more rapidly than the temperature of FIGURE 5-6. FUEL FILTERS
the fuel. If the fuel level is low, the upper portion of
the tank will cool more rapidly and tend to form con-
densation.
Condensation (water) can cause clogging of fuel fil-
ters as well as freezing problems. In addition, water
mixing with the sulphur in the fuel forms acid which
can corrode and damage engine parts.

Fuel Filters
The filters (see Figure 5-6) are a spin-off throw-
away units. Fill the new filters with diesel fuel and
put a light coat of fuel on the sealing gasket. Install
and tighten by hand until the gasket just touches the
filter head. Tighten an additional one-half to three-
fourths of a turn.

5-11
 AIR CLEANER

The engine air intake components should be

checked at the interval indicated in Table 5-1. The STANDARD
frequency of cleaning or replacing air cleaner filter AIR CLEANER
elements is primarily determined by the conditions
that the generator set operates in. The air cleaner
contains a paper cartridge filter element which can
be cleaned and reused if not damaged, or dis-
carded and replaced.

To Service the Air Cleaner: See Figure 5-7.

1, Loosen fastener(s) and remove air cleaner
housing end cap.
2. Remove the air filter element from the filter
housing.
3. To clean, blow low pressure compressed air
(30 psi/207 kPa) through the element from the
clean side. Hold the nozzle at least 1 inch (25
mm) away to avoid damaging the element.
4. Soak the filter for at least 15 minutes in water
and Donaldsons D1400 solvent (or equivalent
other cleaning solvent) to remove soot and car- M1808
bon as well as dirt.
5. Rinse with clean water (low pressure) and al- FIGURE 5-7. STANDARD AIR CLEANER
low to air dry. Do not blow dry with compressed
air. Reinstall when the filter element is dry. Re-
place the filter after two cleanings to avoid re-
stricting the airflow.

CAUTION Filters should be handled with

care to prevent damage. If the filter does be-
come damaged, install recommended re-
placement part.

5-12
 BATTERIES
Check the condition of the starting batteries (see
Figure 5-8) at the interval specified in the Mainte-
nance Table. See that connections are clean and
tight. A light coating of non-conductive grease will
retard corrosion at terminals. Keep the electrolyte at SPECIFIC GRAVITY
the proper level above the plates by adding distilled READING SHOULD
BE 1.260 AT 80° F
water. Check specific gravity using a hydrometer
and recharge if below 1.260.
WARNING Ignition of explosive battery gases
can cause severe personal injury. Do not smoke
while servicing batteries.

B45

FIGURE 5-8. BATTERY CONNECTIONS

5-13
5-14
 6. Adjustments
ELECTRIC GOVERNOR ADJUSTMENT
Generator frequency is in direct ratio to engine
speed which is controlled by the governor. The gen-
erator set uses a Cummins model EFC electric gov-
ernor.
Governor is adjusted at the factory and should not
require field adjustment.
The governor control has four potentiometers for
making adjustments.
Gain
The gain control is a one-turn potentiometer. It is
used to adjust the sensitivity of the governor. A
clockwise rotation of the potentiometer will shorten
the response time to load changes.
Droop
The Droop control is a one-turn potentiometer. It is
adjustable for zero % (isochronous) to 5% speed
droop. Fully counterclockwise rotation will de-
crease the speed droop.
Idle Speed
The Idle Speed control is a 20-turn potentiometer
for adjusting the idle speed. A clockwise rotation will
increase the idle speed.
Run Speed
The Run Speed control is a 20-turn potentiometer
for setting the desired no-load governed speed. A
clockwise rotation will increase the run speed.
FIGURE 6-1. EFC GOVERNOR CONTROL
Preliminary Adjustments
1. Idle Speed potentiometer.
a. Turn the screw counterclockwise 20 turns.
b. Turn the screw clockwise 10 turns.
c. This will set the idle speed potentiometer
to its mid position.
2. Run Speed potentiometer.
a. Turn the screw counterclockwise 20 turns.
b. Turn the screw clockwise 10 turns.
c. This will set the run speed potentiometer
to its mid position.
3. Gain potentiometer.
a. Turn the screw fully counterclockwise.
4. Droop potentiometer.
a. Turn the screw fully counterclockwise for
isochronous operation.
b. Turn the screw to approximately 40 for 3
percent droop.
c. Turn the screw to approximately 80 for 5
percent droop.

6-1
Governed Speed Adjustment
Generators which are to operate at 60 Hz full load,
must have the engine no load governed speed ad-
justed to:
60.0 Hz (1800 RPM) for isochronous operation
61.8 Hz (1854 RPM) for 3% speed droop
63.0 Hz (1890 RPM) for 5% speed droop
For generators which are to operate at 50 Hz full
load, the engine no-load governed speed must be
adjusted to:
50.0 Hz (1500 RPM) for isochronous operation
51.5 Hz (1545 RPM) for 3% speed droop
52.5 Hz (1575 RPM) for 5% speed droop
Droop Adjustment - Isochronous
Operation
For isochronous operation, the droop potentiome-
ter must be turned fully counterclockwise and will
not require any further adjustment.
Gain Adjustment
1. Close the main line circuit breaker and apply
approximately 1/4 of the rated load.
2. Make sure the engine speed is constant. If the
engine speed is constant, turn the GAIN poten-
tiometer clockwise slowly until the engine
speed is not constant.
a. Slowly turn the potentiometer counter-
clockwise until a constant speed is
achieved. Turn the potentiometer counter-
clockwise an additional 1/2 division.
Fine Speed Adjustment
After the gain adjustment is made, the full load gov-
erned engine speed may require a minor adjust-
ment to equal the desired speed (i.e. 60 Hz, 1800
RPM, or 50 Hz, 1500 RPM). Use the SPEED AD-
JUST potentiometer on the engine instrument pan-
el for fine speed adjustments of less than + 100
RPM.

6-2
Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
1-800-888-6626
763-574-5000 International Use
Fax: 763-528-7229
Cummins is a registered trademark of Cummins Inc.