Cummins/Onan 40.0DDB-515R Generator Set

1. Back off the high speed stop screw.
2. Screw in the low speed adjusting screw until the frequency meter reads 60 Hz (generator on load).
3. Turn in the high speed adjusting screw until it bottoms; secure the locknuts.
4. Adjust governor sensitivity (droop) with the external knurled knob at rear of injector pump housing.

⚠ Instructions do not apply to 347/600 (9X) or 120/240 (3R) models; those connections are made at the factory.

1. Remove either right, left or top panel from control box.
2. Connect wires T1 through T12 together as shown on panel and Figure 13 for voltage desired.
3. Open hinged control panel doors. Connect lead from terminal 63 to correct terminal H2, H3, H4, H5 or H6.
4. Close front panel and secure with 1/4 turn fasteners.
5. Connect load wires to generator leads.

⚠ Avoid skin or clothing contact with electrolyte.

Tools: hydrometer, filler bulb

1. Fully charge the battery.
2. With battery still on charge, draw off electrolyte above the plates in each cell (do not pour off).
3. Refill each cell with distilled water to normal level.
4. Continue charging for 1 hour at a 4 to 6 hour rate.
5. Test each cell; repeat steps 2-4 until specific gravity is 1.225.

⚠ Do not smoke while servicing batteries; lead acid batteries give off explosive gases while being charged.

Tools: hydrometer

1. Verify cable connections are secure; coat connections with petroleum-based or non-conductive grease.
2. Check electrolyte level to split ring mark.
3. Measure specific gravity; should be 1.280 at 80°F.
4. If distilled water was added or SG is less than 1.280, place batteries on charge until reading reached; do not overcharge.

1. Run set until thoroughly warm.
2. Drain oil from oil base while still warm; refill and attach warning tag stating oil viscosity used.
3. Remove each injector; pour 1 ounce (two tablespoons) rust inhibitor or SAE #10 oil into each cylinder.
4. Crank engine over several times; install injectors.
5. Service air cleaner.
6. Clean throttle linkage and protect with a clean cloth.
7. Plug exhaust outlets to prevent moisture, bugs and dirt.
8. Wipe entire unit; coat rust-susceptible parts with light film of grease or oil.
9. Disconnect battery and follow standard battery storage procedure.
10. Provide a suitable cover for the entire unit.

⚠ If primer lever will not pump, turn engine over with starter to change position of fuel pump drive lobe on camshaft.

1. Loosen bleed plug on top of fuel filter.
2. Pump primer lever until a solid stream of fuel, free of air bubbles, flows from bleed plug.
3. Secure bleed plug.
4. Loosen inlet fuel line on injector pump.
5. Operate primer lever on fuel transfer pump until solid fuel flows from inlet line opening.
6. Secure injector pump fuel inlet line.
7. Leave fuel transfer pump priming lever at lowest point of stroke.

1. Verify crankcase filled.
2. Verify cooling system filled and input solenoid valve open.
3. Verify batteries charged and connected.
4. Verify fuel solenoid valve open.
5. Move run-stop/reset-remote switch to the run position.
6. Observe oil pressure gauge; normal oil pressure is 45 to 65 psi.
7. Check DC ammeter (10 to 30 amperes), AC voltmeter and frequency meter.

1. Run engine at no load for three to five minutes to reduce and stabilize temperatures.
2. Move run-stop/reset-remote switch to stop position.