Cummins/Onan HDKAH Generator Set

1. Loosen the stop screw locknut and back the screw out a few turns.
2. Turn the stop screw in until it just makes contact.
3. Turn the screw 1 full turn further in and set the locknut (rotor not in place procedure).
4. Alternatively with actuator in place: loosen set screw locknut, turn stop screw in until just makes contact, set locknut.

⚠ Do not let engine speed exceed 3600 RPM.

Tools: tachometer

1. Remove front housing panel.
2. Set up tachometer.
3. Remove actuator cover and reattach leads.
4. Start generator set and push actuator rotor clockwise fully (about 12 mm).
5. Adjust high-idle speed to 3500-3600 RPM.
6. For Spec A, adjust screw; for Spec B, adjust screws and set locknut.
7. Let rotor go; generator should stop and display fault code.
8. Restart and recheck high idle speed.

⚠ Touching uninsulated live parts can cause severe injury or death.

Tools: voltmeter

1. Start generator set; allow voltage and frequency to stabilize 3-5 seconds.
2. Rapidly press Start switch 6 times within first minute to enter voltage adjust mode.
3. To increase: press and quickly release Start switch; each press increases about 0.6 volts.
4. To decrease: press and hold Start switch about 1 second; each press decreases about 0.6 volts.
5. Repeat until desired voltage.
6. Wait 20 seconds for amber light to stop blinking.
7. Press Stop switch to save adjustment.

Tools: container

1. Disconnect fuel return hose and point into container.
2. Prime generator set by holding Start/Stop in STOP.
3. Flow should not be less than 200 ml per minute.
4. If low, replace fuel filter, check restrictions, air bubbles, filter body, or fuel pump.

⚠ Exhaust gas is deadly; do not run indoors or where exhaust can accumulate

Tools: Thermocouples (24 AWG max), PVC pipe thermocouple shield

1. Complete a representative installation.
2. Conduct test in a well-ventilated space protected from cross drafts.
3. Connect a large constant load, at least 3/4 full load if a load bank is available.
4. Measure generator set intake air temperature and ambient air temperature with shielded thermocouples (24 AWG).
5. Close all compartment doors and run generator set at least 90 minutes, recording temperatures at 15-minute intervals.

⚠ High currents, arcing, and moving parts.

Tools: jumper cables, vise

1. Secure starter motor assembly in vise.
2. Connect motor terminal on solenoid to positive 12V battery.
3. Connect one end of negative cable to battery negative.
4. Briefly touch other end of negative cable to motor mounting flange.
5. If motor does not spin quickly, replace starter motor; if it does, replace solenoid.

⚠ Exhaust gas is deadly

⚠ Do not use flexible pipe for tailpipe

1. Use 18-gauge 1-3/8 inch I.D. aluminized steel tubing or equivalent for the tailpipe.
2. Secure tailpipe/adapter flange to muffler flange with gasket and two 5/16-18 bolts.
3. Use U-bolt muffler clamps to connect tailpipe sections; slot overlapping pipe.
4. Use automotive-type tailpipe hangers every 600-900mm (2-3 ft), attached to steel framework.
5. Extend tailpipe minimum 25mm (1 in) beyond vehicle perimeter; support so it cannot be pushed up under skirt.
6. Do not route tailpipe closer than 76mm (3 in) to combustible material unless insulated/shielded.
7. Do not route tailpipe near fuel lines/tanks or terminate below/near a fuel fill opening.
8. Do not terminate tailpipe closer than 153mm (6 in) to any opening into the vehicle interior.
9. Do not interconnect generator set and vehicle engine exhaust systems.

⚠ Hot coolant under pressure can spray and cause severe burns

Tools: Container, Radiator cleaning chemicals (optional)

1. Allow engine to cool before releasing pressure cap.
2. Turn pressure cap slowly without pushing down until it catches.
3. Remove pressure cap.
4. Drain coolant by removing system drain cap.
5. Optionally clean and flush system.
6. Fill recovery tank with coolant mixture to COLD mark.
7. Secure system drain cap.
8. Fill cooling system through pressure cap/fill opening.
9. Start and operate genset for few minutes.
10. Shut down and add more coolant if necessary.
11. Secure the pressure cap.

⚠ Keep oil level between FULL and ADD marks

⚠ Too much oil causes high consumption

⚠ Too little oil causes engine damage

Tools: Oil drain pan, Wrench, Oil filter wrench

1. Run engine until warm, then stop
2. Remove oil fill cap and dipstick
3. Place pan underneath and unscrew oil drain plug
4. Let all oil drain completely
5. Reinstall oil drain plug and tighten securely
6. Squeeze access door latches and let door swing down
7. Spin off oil filter canister
8. Wipe filter mounting surface and remove old gasket
9. Apply thin film of oil to new filter gasket
10. Spin on new filter until gasket touches then turn 1/2 to 3/4 turn more
11. Close access door securely
12. Refill with 3 quarts of proper grade oil
13. Check oil level and adjust as needed
14. Reinsert dipstick and screw cap on securely
15. Dispose of used oil and filter per environmental regulations

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

⚠ Contact with used engine oil can cause cancer or reproductive toxicity.

Tools: Oil drain pan, Insulated wrench

1. Run the generator set under load until at operating temperature, stop it, and disconnect the negative (–) battery cable.
2. Remove the oil fill cap.
3. Place a pan underneath the oil drain plug and remove the plug. Let all oil drain.
4. Replace the plug.
5. Spin off the oil filter and thoroughly wipe off the filter mounting surface.
6. Apply a film of oil to the new filter gasket and spin the filter on by hand until the gasket just touches; tighten 1/2 to 3/4 of a turn.
7. Refill with oil, check the level, and add or drain as necessary.
8. Screw the oil fill cap on securely and reconnect the negative battery cable.
9. Run the generator a few minutes, shut it down, and recheck oil level and leaks.
10. Dispose of used oil and oil filter in accordance with local environmental regulations.

⚠ Too much oil can cause high oil consumption; too little can cause severe engine damage.

1. Park vehicle on level ground; shut off genset.
2. Unscrew oil fill cap; pull out dipstick and wipe.
3. Reinsert dipstick; screw cap back on.
4. Remove dipstick and check oil level.
5. Add or drain oil to keep between FULL and ADD marks.
6. Reinsert dipstick; screw oil fill cap on securely.

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

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