Cummins/Onan 3.6 KY Generator Set

⚠ Batteries give off explosive gases that can cause severe personal injury. Do not smoke near batteries.

⚠ Battery electrolyte can cause severe eye damage and skin burns. Wear goggles, rubber gloves and a protective apron.

Tools: terminal puller tool, battery hydrometer, goggles, rubber gloves, protective apron

1. Keep the battery case clean and dry
2. Make certain the battery cable connections are clean and tight
3. Always remove the negative (-) cable first and connect it last
4. To remove corrosion wash terminals with an ammonia solution or baking soda solution
5. If not maintenance-free, add distilled water to each cell to the split-level marker
6. Use a hydrometer to check specific gravity; charge if below 1.215; stop charging at 1.260 at 80°F (27°C)

⚠ Crankcase pressure can blow hot oil out the fill opening, causing severe burns

⚠ Used engine oil can cause cancer or reproductive toxicity

Tools: 14 mm socket

1. Run the generator set under load until at operating temperature, stop it, disconnect negative battery cable
2. Remove the oil fill cap
3. Place a pan under the oil drain plug and remove the plug with a socket, drain all oil
4. Replace the plug and tighten to 27 Nm (21 ft-lbs)
5. Refill with oil per Oil Change Values; check level and add or drain as necessary
6. Screw the oil fill cap on securely
7. Reconnect the negative battery cable
8. Run the generator a few minutes, shut down, recheck oil level and leaks
9. Dispose of used oil per local regulations

⚠ Crankcase pressure can blow hot engine oil out the fill opening causing severe burns. Always stop the genset before removing the oil fill cap.

⚠ Too much oil can cause high oil consumption, high operating temperatures and oil foaming. Too little oil can cause severe engine damage.

1. Park the vehicle on level ground and shut off the genset
2. Remove the oil fill cap/dipstick and wipe it clean
3. Screw the oil fill cap back on and remove it to check the oil level
4. Add oil as necessary until the full mark is reached
5. Do not fill above the full mark; drain excess oil if too much was added
6. Screw the oil fill cap on securely to prevent oil leakage

⚠ A hot muffler can cause severe burns

1. Remove the cleanout plug
2. Start and load the generator set to near full power for about 5 minutes to expel soot
3. Stop the generator set, allow the muffler to cool, and reinstall the plug

⚠ A hot muffler can cause severe burns. Let the muffler cool down before removing or installing the cleanout plugs.

1. Let the muffler cool down, then remove the cleanout plugs from the bottom of the muffler
2. Restart the genset and load it nearly to full power
3. Let the genset run for about five minutes to expel the soot in the muffler
4. Stop the genset, allow the muffler to cool down, then reinstall the plugs

⚠ Do not overtighten wing nuts, can distort the filter element

1. Remove the front access cover
2. Remove the wing nut securing the air filter housing cover and remove the cover
3. Remove the wing nut securing the filter cover plate and remove the cover plate
4. Remove the air filter element
5. Install the new air filter, centered over the carburetor air inlet
6. Replace the filter cover plate and tighten wing nut
7. Replace the air filter housing cover and tighten wing nut
8. Replace the front access cover

⚠ Gasoline is highly flammable and explosive

Tools: 11/16-inch deep socket

1. Let engine cool down
2. Remove the fuel line from the fuel filter and plug the line
3. Run the generator set until it runs out of fuel and let it cool down
4. Disconnect the negative battery cable
5. Unscrew the filter from the fuel pump using a deep 11/16-inch socket
6. Install the new fuel filter by hand and tighten securely
7. Connect the fuel filter to the fuel line
8. Prime the engine for at least 30 seconds; check for leaks while running
9. Tighten connections if necessary
10. Connect the negative battery cable
11. Dispose of the old filter per local regulations

Tools: torque wrench

1. Remove the front access cover
2. Unscrew the spark plug and remove
3. Thread the spark plug in by hand until it seats; tighten to 17 Nm (13 ft-lbs)
4. Replace the front access cover

1. Check the oil tag on the genset and change the oil if the viscosity is not appropriate
2. Reconnect the starting battery (negative cable last)
3. Remove the plug from the exhaust tailpipe
4. Open the fuel supply valve (if so equipped)
5. Inspect the genset
6. Start the genset at the genset control panel
7. Push the genset line circuit breaker ON when ready to power appliances

⚠ Gasoline preservatives are toxic

⚠ Do not open the carburetor drain when the engine is hot

1. Fill the fuel tank with fresh fuel and add a fuel preservative (gasoline models)
2. Run the generator set about 30 minutes plus 2 minutes per foot of fuel line at about 1/2 rated power
3. Change the engine oil and tag the oil grade/viscosity
4. Remove the air filter, restart, and spray engine fogger into the carburetor while running
5. Stop the generator set
6. Disconnect all appliances
7. Disconnect battery cables (negative first) and store the battery
8. Cap the exhaust tail pipe
9. Close the fuel supply valve if equipped
10. Position the line circuit breaker to OFF
11. Drain the carburetor float bowl (gasoline models)

⚠ Gasoline preservatives (stabilizers) are toxic. Follow the instructions on the container label. Avoid skin contact.

1. Gasoline models only: fill the fuel tank with fresh fuel and add a fuel preservative (OnaFresh)
2. Run the genset about 10 minutes at approximately 1/2 rated power
3. Turn off large loads, push the line circuit breaker OFF and stop the genset
4. Remove the air filter, restart the genset and spray an engine fogger (OnaGard) into the carburetor, then stop
5. Change the air filter element if it is dirty
6. Change the engine oil and attach a tag indicating its oil viscosity
7. Disconnect the battery cables (negative cable first) and store the battery
8. Plug the exhaust tail pipe to keep out dirt, moisture and bugs
9. Close the fuel supply valve (if so equipped)

1. Verify oil viscosity is appropriate for expected temperatures; change if not
2. Reconnect the starting battery (negative cable last)
3. Inspect the air filter element; replace if dirty
4. Inspect the generator set
5. Prime the fuel system by positioning the control switch to STOP/PRIME for 30 seconds
6. Start the generator set
7. Position the line circuit breaker to ON when ready to power loads