HDKAH, HDKAJ, HDKAK, HDKAT, HDKAU, HDKAV Printed in U.S.A.
California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Table of Contents SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions • Engine cooling air must not be used for heating working or living spaces or compartments. Thoroughly read the OPERATOR’S MANUAL before operating the genset. Safe operation and top performance can only be obtained when equipment is operated and maintained properly. GENERATOR VOLTAGE IS DEADLY • Disable the automatic genset starting feature of an inverter-charger or other automatic starting device before servicing the genset.
BATTERY GAS IS EXPLOSIVE • Keep the genset and its compartment clean. Excess oil and oily rags can catch fire. Dirt and gear stowed in the compartment can restrict cooling air. • Wear safety glasses. • Do not smoke. • Make sure all fasteners are secure and torqued properly. • To reduce arcing when disconnecting or reconnecting battery cables, always disconnect the negative (−) battery cable first and reconnect it last.
Introduction ABOUT THIS MANUAL This manual covers the operation and maintenance of the generator set (genset) models on the front cover. Study this manual carefully and observe all of its instructions and precautions. Keep this manual and the genset Installation Manual with the other vehicle manuals. 80HDKAK11454J F990 123456 Operation, Periodic Maintenance and Troubleshooting provide the instructions necessary for operating the genset and maintaining it at top performance.
TYPICAL GENSET features of a typical genset are shown in Figure 2. See the PERIODIC MAINTENANCE SCHEDULE (Page 13). The operator’s console, the components requiring attention during periodic maintenance and other AC TERMINAL BOX COVER LIFTING EYE ACCESS COVER OPERATOR’S CONSOLE ACCESS DOOR FOR OIL AND FUEL FILTERS OIL DRAIN PLUG BATTERY CONNECTIONS COOLING AIR INLET GRILLE ACCESS TO AIR FILTER FUEL CONNECTIONS COOLANT DRAIN CAP WARM AIR DISCHARGE OPENING FIGURE 2.
FUEL RECOMMENDATIONS SAE (Society of Automotive Engineers) viscosity grade. Referring to Chart 1, choose the viscosity grade appropriate for the outdoor ambient temperatures expected until the next scheduled oil change. WARNING Diesel fuel is combustible and can cause severe personal injury or death. Do not smoke near diesel fuel tanks or equipment. Keep flames, sparks, pilot lights, electrical arcs, switches and arc-producing equipment and all other sources of ignition well away.
OPERATOR’S CONSOLE REMOTE CONTROL PANEL The operator’s console (Figure 3) has the following features: The vehicle may be equipped with a remote control panel having a Control Switch and Preheat/Diagnostics Light. In addition, it may have an hour meter and the following engine gauges: Control Switch − This switch is used to start and stop the genset, prime the engine fuel system and restore the fault code (blinking status light).
Operation WARNING EXHAUST GAS IS DEADLY! Exhaust gases contain carbon monoxide, an odorless, colorless gas. Carbon monoxide is poisonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning include: • • • Dizziness Muscular Twitching Weakness and Sleepiness • • • Throbbing in Temples Headache Inability to Think Clearly • • Nausea Vomiting IF YOU OR ANYONE ELSE EXPERIENCES ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY.
STOPPING THE GENSET TABLE 1. TYPICAL APPLIANCE LOADS Appliance Air Conditioner Battery Charger DC Converter Refrigerator Microwave Oven Electric Frying Pan or Wok Electric Stove Element Electric Water Heater Electric Iron Electric Hair Dryer Coffee Percolator Television Radio Electric Drill Electric Broom Electric Blanket Turn off the air conditioner and other large appliances and let the genset run for two minutes to cool down. Then press the switch to STOP to stop the genset.
RESETTING CIRCUIT BREAKERS If a circuit breaker in the main power distribution panel of the vehicle or on the genset (Figure 4) trips, either a circuit shorted or too many appliances were running. Note that the genset will continue to run after a circuit breaker trips. If a circuit breaker trips, disconnect or turn off as many loads as possible and reset the circuit breaker. (Push the circuit breaker to OFF to reset it and then to ON to reconnect the circuit.
OPERATING IN COLD WEATHER 3. Change engine oil more often. See PERIODIC MAINTENANCE SCHEDULE (Page 13). Make sure the engine oil viscosity is appropriate for the cold weather temperatures. See ENGINE OIL RECOMMENDATIONS (Page 6). Be sure to change the oil if a sudden drop in temperature occurs. 4. Keep containers of engine oil that have been opened tightly closed to keep out dust.
STORING THE GENSET 5. Close the fuel supply valve (if so equipped). Proper storage is essential for preserving top genset performance and reliability when the genset cannot be exercised regularly and will be idle for more than 120 days. Returning the Genset to Service 1. Check the oil tag on the genset and change the oil if the viscosity indicated is not appropriate for the temperatures expected. See ENGINE OIL RECOMMENDATIONS (Page 6). Storing the Genset 2.
Periodic Maintenance Periodic maintenance is essential for top performance and long genset life. Use Table 3 as a guide for normal periodic maintenance. In hot and dusty environments some maintenance procedures should be performed more frequently, as indicated by the footnotes in the table. Keeping a log of maintenance performed and hours run (Page 35) will help you keep genset maintenance regular and provide a basis for supporting warranty claims.
CONDUCTING GENERAL INSPECTIONS Inspect the genset before the first start of the day and after every eight hours of operation. Do not operate power ventilators or exhaust fans while the vehicle is standing with the genset running. The ventilator or fan can draw exhaust gases into the vehicle. Oil Level Fuel System Check engine oil level (Page 15). Check for leaks at hose, tube and pipe fittings in the fuel supply system while the genset is running and while it is stopped.
CHECKING ENGINE OIL LEVEL WARNING State and federal agencies have determined that contact with used engine oil can cause cancer or reproductive toxicity. Try to avoid skin contact and breathing of vapors. Use rubber gloves and wash exposed skin. Park the vehicle on level ground and shut off the genset before checking the engine oil level. 1. Unscrew the oil fill cap, pull out the dipstick and wipe off the oil (Figure 5).
CHANGING ENGINE OIL AND OIL FILTER old gasket if it does not come off with the filter canister. WARNING State and federal agencies have determined that contact with used engine oil can cause cancer or reproductive toxicity. Avoid skin contact and breathing of vapors. Use rubber gloves and wash exposed skin. 6. Make sure the new gasket is in place on the new filter canister and apply a thin film of oil to the gasket.
MAINTAINING THE BATTERY AND BATTERY CONNECTIONS 2. Remove battery cables with a battery terminal puller. Arcing at battery terminals or in light switches or other equipment, and flames or sparks, can ignite battery gas causing severe personal injury. 3. Make sure which terminal is positive (+) and which is negative (−) before making battery connections, always removing the negative (−) cable first and reconnecting it last to reduce arcing.
CLEANING THE SPARK ARRESTOR fler, accessible through the air outlet opening in the bottom of the genset. Clean out the spark arrestor muffler as follows: Refer to Table 3 for scheduled cleaning of the spark arrestor muffler (which meets U.S. Forest Service requirements). Cleaning is required for maximum genset performance. 1. Remove the cleanout plug from the muffler (Figure 8). A hot muffler can cause severe burns. Let the muffler cool down before removing or installing the cleanout plug. 2.
REPLACING THE FUEL FILTER Removing the Fuel Filter: To remove the filter, disconnect the two fittings at the filter and remove the mounting nut. Apply a wrench on the filter fitting as well as on the flare nut so as not to stress the fitting. Flare nut wrenches should be used on the flare nuts so as not to round the corners on the nuts. Dispose of the fuel filter according to local regulations. Refer to Table 3 for scheduled replacement of the fuel filter (Figure 9).
CHANGING COOLANT down and turning it until it can be withdrawn. Then get a suitable container and drain the coolant by removing the system drain cap (Figure 10). Refer to Table 3 for scheduled maintenance. The engine cooling system is filled with a 50/50 mixture of ethylene glycol anti-freeze and water when the genset leaves the factory, which is suitable for temperatures down to -34° F (-37° C). Ethylene glycol antifreeze is considered toxic.
PRESSURE CAP AND SYSTEM FILL OPENING COOLANT RECOVERY TANK FILL CAP (BLUE) COOLING SYSTEM DRAIN CAP FIGURE 10.
Troubleshooting • Two blinks indicates shutdown due to a loss of Hot engine parts can cause severe burns. Always allow the engine time to cool before performing any maintenance or service. WARNING engine oil pressure • Three blinks indicates shutdown due to some other abnormal condition. TABLE 4. TROUBLESHOOTING lists the Fault Codes in numerical order along with step-by-step instructions for corrective action.
TABLE 4. TROUBLESHOOTING WARNING Some genset service procedures present hazards that can result in severe personal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions.
TABLE 4. TROUBLESHOOTING (CONT.) WARNING Some genset service procedures present hazards that can result in severe personal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. STARTING BATTERIES RUN DOWN (Marginal battery, battery connections, or charging system; or parasitic loads) Corrective Action: 1.
TABLE 4. TROUBLESHOOTING (CONT.) WARNING Some genset service procedures present hazards that can result in severe personal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. HIGH TEMPERATURE—FAULT CODE NO. 1 (Engine coolant or inverter heat sink temperature exceeded design limit) Corrective Action: Check the second-level fault code by touching Stop. The second-level fault will be either No.
TABLE 4. TROUBLESHOOTING (CONT.) WARNING Some genset service procedures present hazards that can result in severe personal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. INVERTER OVERVOLTAGE FAULT—CODE NO. 12 (Controller not able to regulate to rated voltage) Corrective Action: Check whether the vehicle engine and genset share the same starting battery.
TABLE 4. TROUBLESHOOTING (CONT.) WARNING Some genset service procedures present hazards that can result in severe personal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. LOW OIL PRESSURE CUTOFF SWITCH FAULT—CODE NO. 23 (Controller sensed switch still open during start—not a running fault) Corrective Action: See an authorized Onan dealer. COOLANT TEMPERATURE SENDER FAULT—CODE NO.
TABLE 4. TROUBLESHOOTING (CONT.) WARNING Some genset service procedures present hazards that can result in severe personal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. HIGH BATTERY VOLTAGE FAULT—CODE NO. 29 (Voltage across battery system greater than 17.5 volts) Corrective Action: 1.
TABLE 4. TROUBLESHOOTING (CONT.) WARNING Some genset service procedures present hazards that can result in severe personal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. HIGH INVERTER TEMPERATURE FAULT—CODE NO. 34 (Inverter heat sink temperature exceeded design limit*) Corrective Action: 1.
TABLE 4. TROUBLESHOOTING (CONT.) WARNING Some genset service procedures present hazards that can result in severe personal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. PROCESSOR FAULT—CODE NO. 43 ((Microprocessor RAM error during self-test) Corrective Action: See an authorized Onan dealer. INVERTER POWER SUPPLY FAULT—CODE NO.
Specifications HDKAH HDKAJ HDKAK GENSET CONTROLLER: Integrated Microprocessor Based Engine and Generator Controller GENERATOR: Brushless, Exciterless, Bearingless, Permanent Magnet Alternator AC OUTPUT RATINGS: Power (@1.0 power factor) 6000 W 7500 W 8000 W Voltage 120 volts 120 volts 120 volts 60 Hz 60 Hz 60 Hz 1 1 1 50.0 ampere 62.5 ampere 66.
HDKAV HDKAT HDKAU GENSET CONTROLLER: Integrated Microprocessor Based Engine and Generator Controller GENERATOR: Brushless, Exciterless, Bearingless, Permanent Magnet Alternator AC OUTPUT RATINGS: Power (@1.0 power factor) Voltage Frequency Number of Phases Current Line Circuit Breaker(s) 6000 W 120 volts 60 Hz 1 50.0 ampere 2-pole, 30 amp 7500 W 120 volts 60 Hz 1 62.5 ampere 2-pole, 30 or 35 amp 8000 W 120 volts 60 Hz 1 66.
Information for California Genset Users These gensets meet the requirements of California’s Exhaust Emissions Standards as stated on the nameplate (Page 4). You should carefully review Operator (Owner), Installation and other manuals and information you receive with your genset. If you are unsure that the installation, use, maintenance or service of your genset is authorized, you should seek assistance from an approved Onan dealer.
How to Obtain Service When you need parts or service for your genset contact the nearest authorized dealer or distributor. Onan has factory-trained representatives to handle your needs for genset parts and service. To locate the nearest authorized distributor: rectory of authorized RV servicing dealers: RV Sales and Service Directory F-919. To get service, contact the authorized dealer or distributor nearest you, explain the problem and make an appointment.
Maintenance Record Record all periodic and unscheduled maintenance and service. See Periodic Maintenance (Page 13). DATE HOUR METER READING MAINTENANCE OR SERVICE PERFORMED Record the name, address, and phone number of your authorized Onan service center.
Cummins Power Generation 1400 73rd Avenue N.E. Minneapolis, MN 55432 763-574-5000 Fax: 763-528-7229 Cummins and Onan are registered trademarks of Cummins Inc.
