Cummins/Onan HDKBC Generator Set

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

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

⚠ Toxic Hazard — contact with used engine oil can cause cancer or reproductive toxicity.

1. Run the generator set under load to operating temperature, stop it, and disconnect the negative (–) battery cable.
2. Remove the oil fill cap.
3. Place a pan under the oil drain hole and open the drain valve; drain all oil.
4. Close the drain valve.
5. Spin off the oil filter and wipe the mounting surface.
6. Apply a film of oil to the new filter gasket and spin it on by hand until the gasket touches; tighten 1/2 to 3/4 of a turn.
7. Refill with 1.9 liters (2 qts) of oil; check level.
8. Screw the oil fill cap on securely.
9. Reconnect the negative battery cable.
10. Run the generator a few minutes, shut down, recheck oil level and leaks.
11. Dispose of used oil and filter per local regulations.

⚠ A hot muffler can cause severe burns.

⚠ Grass or brush in contact with the exhaust system can cause fire.

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

⚠ Hot coolant spray can cause severe burns. Let the engine cool before releasing the pressure cap.

⚠ Ethylene glycol antifreeze is considered toxic.

1. Relieve remaining pressure by turning the cap slowly without pushing down.
2. Push down on the cap and turn it the rest of the way to withdraw it.
3. Remove the bottom access cover.
4. Open the radiator drain cock and drain coolant into a suitable container.
5. Flush and clean the cooling system before refilling.

⚠ Fire Hazard — flames, sparks, or arcing at battery terminals can ignite battery gas.

Tools: Battery terminal puller

1. Keep the battery case and terminals clean and dry.
2. Keep the battery terminals tight.
3. Remove battery cables with a battery terminal puller.
4. Always remove the negative (–) cable first and reconnect it last.

1. Install the coolant drain plug using pipe thread sealant.
2. Tighten it just enough to prevent leaks when running and warmed up.
3. Pull the pressure cap hose out as far and high as it will go and fill with coolant.
4. When coolant reaches the fill opening, start and operate the generator set a few minutes, then shut down.
5. Add more coolant if necessary.
6. Secure the pressure cap.

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

⚠ Hot Surfaces — contact with hot surfaces can cause severe burns.

1. Remove the front access cover.
2. Unscrew the 2 wingnuts on the filter housing and pull away the air filter housing and element.
3. Wipe the sealing surfaces clean and install the new air filter element; slide back into position.
4. Turn the wingnuts hand tight.
5. Replace the front access cover.

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

⚠ Diesel fuel is combustible and can cause severe personal injury or death.

Tools: Two flarenut wrenches

1. Let engine cool down to prevent igniting spilled fuel.
2. Remove the fuel line from the fuel filter; plug the line.
3. Disconnect the negative (–) cable at the battery.
4. Disconnect the two fittings at the fuel filter using two flarenut wrenches.
5. Remove the filter mounting nut and two bracket mounting screws.
6. Remove old fuel filter.
7. Loosely secure the bracket to the new fuel filter.
8. Loosely secure the new filter and bracket to the base with two screws.
9. Reconnect the fuel fittings by hand; tighten one flat past seating.
10. Tighten the bracket and mounting screws.
11. Prime the engine for at least 1 minute to fill the new filter; check for leaks.
12. Tighten connections if necessary.
13. Connect the negative (–) cable at the battery.
14. Dispose of the old filter per local regulations.

1. Check the oil tag and change the oil if the viscosity is not appropriate for expected temperatures.
2. Reconnect the starting battery (negative [–] cable last).
3. Replace the air filter element 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.

⚠ Carbon monoxide is deadly and can accumulate to dangerous levels in garages and other confined spaces.

1. Disable the automatic generator set starting feature.
2. Change the engine oil and attach a tag indicating the oil grade viscosity.
3. Disconnect the battery cables, negative (–) first, and store the battery per manufacturer's recommendations.
4. Position the line circuit breaker to OFF.

⚠ EXHAUST GAS IS DEADLY! Exhaust gases contain carbon monoxide, an odorless, colorless gas.

1. Make sure all vehicle CO detectors are working properly.
2. Remove access cover.
3. Inspect the generator set as instructed in Chapter 5.
4. Perform any maintenance due.
5. Keep a maintenance log.
6. Check for signs of fuel and exhaust leaks and for damage to the exhaust system.
7. Replace access cover.
8. Turn off the air conditioner and other large appliances.

1. Position the control switch to STOP/PRIME for 30 seconds.
2. The status indicator stays on while the pump is on.

⚠ Short circuits in electrical equipment can cause fire and electrical shock leading to severe personal injury or death.

1. Disconnect or turn off as many electrical loads as possible.
2. Reset the circuit breaker.
3. If it trips right away, call a qualified electrician.
4. If it does not trip right away, reconnect loads one-by-one without overloading.