Cummins/Onan QSK78 Engine

1. Use the two air filter straps to install a new air cleaner on the mounting platform.
2. Reinstall the hose clamp to secure the air cleaner to the hump hose.

⚠ Holes, loose-end seals, dented sealing surfaces or corrosion render the air cleaner inoperative.

1. Loosen the hose clamp securing the air cleaner to the hump hose.
2. Remove the air cleaner and the two air filter straps from the mounting platform.
3. Remove the air filter straps from the air cleaner.
4. Dispose of the old air cleaner in accordance with local environmental requirements.

⚠ Avoid prolonged skin contact with used oil.

Tools: Suitable container

1. With the generator set not in operation, open the drain valve and drain oil into a suitable container.
2. Close the drain valve when completed.
3. Clean the area of any spills and dispose of waste per local regulations.

⚠ Crankcase pressure can blow out hot oil; do not check oil while running.

Tools: Lint free cloth, Funnel (where possible)

1. Remove the dipstick and wipe it clean with a lint free cloth.
2. Fully replace the dipstick.
3. Remove the dipstick and check oil level against the High and Low marks.
4. Top up to the High mark with the correct grade of oil.
5. Replace the dipstick and oil filler cap.
6. Start the engine, idle for five minutes, switch off and wait five minutes.
7. Check oil level and repeat if oil needs to be added.

⚠ Do not allow fuel to drain onto the ground.

⚠ Do not permit any open flame near the fuel system.

Tools: Collar/vent cap wrench, Suitable container

1. Shut down the engine.
2. Close the fuel supply shutoff valve.
3. Place a suitable container under the filter to be replaced.
4. Use the collar/vent cap wrench to open the vent cap and break the air lock.
5. Open the drain valve and drain fuel below the collar.
6. Close the drain valve.
7. Loosen the collar with the collar/vent cap wrench.
8. Remove the clear cover, filter spring, fuel filter element, o-ring and sealing grommet.

⚠ Do not permit any open flame near the fuel system.

1. Install a new o-ring, filter element (with sealing grommet), filter spring and clear cover.
2. Install the vent cap and collar onto the clear cover.
3. Hand tighten; do not use tools to tighten the collar.

⚠ Diesel fuel is a fire and explosion hazard.

⚠ Drained liquids must be disposed of per local environmental regulations.

Tools: Suitable container

1. Shut off the engine.
2. Place a suitable container under the fuel filter.
3. With the fuel supply valve closed, open the vent cap to break the airlock.
4. Turn the valve counterclockwise until it drops about 25 mm (1 in). Drain until clear fuel is visible.
5. Push the valve up and turn clockwise to close the drain valve.
6. Open the fuel supply valve before starting the engine.
7. If more than 60 ml (2 oz) is drained, refill the filter to prevent hard starting.

⚠ Accidental or remote starting can cause severe personal injury or death.

Tools: Insulated wrench, Warning notices

1. Press the Off mode switch on the operator panel to shut down the generator set.
2. Press the Emergency Stop button to prevent starting from any source.
3. Thoroughly ventilate the plant room before disconnecting any leads.
4. Isolate and lock off the supply to the heater, where fitted.
5. Isolate and lock off the supply to the battery charger, where fitted.
6. Isolate the fuel supply to the engine.
7. Using an insulated wrench, disconnect the negative (–) battery cable first.
8. Fit warning notices to indicate Maintenance in Progress – Plant Immobilized.

⚠ Contact with hot oil can cause severe burns; allow engine to cool before maintenance.

Tools: Oil sampling kit

1. Remove the cap from the sample bottle and attach the live sampling cap.
2. Remove the oil sampling drain valve cap from the valve.
3. With the engine running at normal operating temperature, screw the live sampling cap onto the drain valve.
4. Fill the sample bottle as directed by the sampling kit/laboratory instructions.
5. Remove the sample bottle and replace the valve cap.
6. Remove the live sampling cap from the sample bottle and replace the bottle cap; send for analysis.
7. Clean up any spillage per local regulations.

⚠ Do not use the Emergency Stop button for normal shut-down; it prevents a cooling down run.

1. Pull, or twist and pull, the button out.
2. Press the Stop button on the operator panel to acknowledge.
3. Press the Reset button.
4. Press the Auto or Manual Run button as previously determined.

⚠ Make sure all pre-start checks are carried out before starting.

⚠ Warn all others in the vicinity that the generator set is about to start.

1. Make sure the main circuit breaker is in the open position.
2. Press the Manual button, then press the Start button within ten seconds.
3. Allow the engine to warm up and reach rated speed and voltage.
4. Close the main circuit breaker and apply load as required.

⚠ Avoid hot shutdown under load to help prolong reliability.

1. Remove the load.
2. Open the main circuit breaker.
3. Press the stop button on the HMI operator panel to initiate cool down.
4. Once the cool down timer expires, the generator set shuts off and enters Off mode.