Cummins/Onan DQFAD Generator Set

⚠ Batteries should not be left on Boost Charge for extended periods.

1. Do not put a filled battery into storage without first giving the battery a commissioning charge.
2. Give batteries a further charge every six months at the normal initial charge rate until voltage ceases to rise.
3. If the charger has a Boost Charge switch, select Boost at intervals detailed by the battery manufacturer (normally every 6 months).
4. Reduce the charge rate to normal bench rate if electrolyte temperature exceeds 43 °C (109 °F) or battery volts reach 15 V (12 V battery).
5. At the end of charging, check electrolyte levels and restore if necessary with electrolyte of correct SG.
6. Replace vent caps.

⚠ Do not open the pressure cap while the engine is running; let the engine cool down and relieve pressure first.

⚠ Do not add cold coolant to a hot engine; allow engine to cool to below 50 °C (122 °F).

1. Isolate the generator set to prevent accidental starting whilst filling the radiator.
2. Slowly remove the radiator filler cap.
3. Coolant level should be level with the bottom of the filler neck.
4. Slowly fill with a 50/50 mixture of fully formulated coolant and DCA4 until level reaches bottom of filler neck.
5. Replace the radiator cap securely - push down and twist clockwise until cap lip hits stop flange.
6. Start the generator set and check for leaks.

1. Visually inspect the belt through the guarding.
2. Check for intersecting cracks (longitudinal cracks intersecting transverse cracks are NOT acceptable).
3. Check for frays or pieces of material missing.
4. Check for glazed or cracked side walls and uneven sidewall wear.
5. Visually inspect sheaves through the guarding for damaged or worn grooves, broken flanges and missing material.
6. Contact your authorized distributor to have worn belts or sheaves replaced.

⚠ Do not check oil while the generator set is operating; crankcase pressure can blow out hot oil.

Tools: Lint free cloth, Funnel

1. Remove the dipstick and wipe clean with a lint free cloth.
2. Fully replace the dipstick.
3. Remove the dipstick and check oil level against High and Low marks.
4. Top up to the High mark if necessary with the correct grade of oil.
5. Remove filler cap, place lint free cloth beneath filler neck, use a funnel to pour oil.
6. Check oil level with dipstick; do not overfill.
7. Replace dipstick and oil filler cap.
8. Remove cloth, start engine, idle five minutes, switch off and wait five minutes.
9. Check oil level; repeat if oil needs to be added.

⚠ Diesel fuel is a fire and explosion hazard; do not permit any open flame or igniter near the fuel system.

Tools: Collar/vent cap wrench

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 to break the air lock in the filter.
5. Open the drain valve and allow fuel level to drain 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, and o-ring.
9. Remove the sealing grommet.
10. Discard the o-ring and grommet.

⚠ Diesel fuel is a fire and explosion hazard; do not permit any open flame or igniter near the fuel system.

1. Shut off the engine.
2. Wait 1 minute to remove any pressure in the fuel line.
3. Place a suitable container under the fuel filter.
4. Turn the valve clockwise four complete turns until the valve drops down one inch; drain until clear fuel is visible.
5. When clear fuel flows, push the valve up and turn counterclockwise to close drain valve.
6. Before starting the engine, remove the container and clean up any fuel spillage.
7. Start the engine and check for leaks.

1. Inspect all seals before installing new air cleaner elements.
2. Install the Secondary inner air cleaner element first; secure using the inner wing nut with sealing washers.
3. Install the Primary outer air cleaner element.
4. Install the end cap and secure using the outer wing nut with sealing washers.
5. Check for any leaks in the air intake system.

⚠ Cummins does not recommend cleaning paper-type air cleaner elements.

1. Before disassembly, wipe dirt from the cover and upper portion of the air cleaner.
2. Remove the outer wing nut and the end cap; sealing washers will need to be re-used.
3. Remove the Primary outer air cleaner element.
4. Remove the inner wing nut and remove the Secondary air cleaner element; sealing washers will need to be re-used.

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

Tools: Insulated wrench

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 regardless of start signal 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 (-) cable first on the starting and control batteries.
8. Fit warning notices at each point to indicate Maintenance in Progress.

1. Secure the new air cleaner using the 2 air cleaner housing clamps.
2. Install the coupler and secure the clamp to the intake tube.
3. Check for any leaks in the air intake system.

⚠ Holes, loose-end seals, dented sealing surfaces, corrosion of pipes and other damage require immediate element replacement.

1. Before disassembly, wipe dirt from the cover and upper portion of the air cleaner.
2. Note that normal duty air cleaners do not have serviceable filter elements; the entire cleaner is replaced.
3. Remove the clamp securing the intake coupler to the air cleaner and slide the coupler off.
4. Loosen or remove the 2 clamps securing the air cleaner.
5. Remove the air cleaner from the generator set.

⚠ Before carrying out any maintenance, isolate all supplies and disconnect the battery.

1. Complete lock out procedure to ensure safe working environment.
2. Refer to Engine Operation & Maintenance Manual for correct oil grade.
3. Fill the engine to the correct level with clean engine oil.
4. Check oil level on dipstick; level must be on the high (H) mark. Do not overfill.
5. Return the generator set to the proper operating conditions.
6. Operate the generator set at idle speed and check for leaks.
7. Shut down the generator set.
8. Wait approximately 5 minutes to allow oil to drain from upper parts of engine.
9. Rectify any leaks; check the oil level; add oil as necessary to reach H mark.
10. Dispose of waste material in accordance with local regulations.