CUMMINS HDKAH, HDKAJ, HDKAK, HDKAV, HDKAT Operator's Manual
...
Operator Manual
RV Generator Set
HDKAH (Spec A−M)
HDKAJ (Spec A−M)
HDKAK (Spec A−M)
HDKAT (Spec A−M)
HDKAU (Spec A−M)
HDKAV (Spec A−M)
English − Original Instructions 5−2010 981−0161 (Issue 7)
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.
diesel warnings
Table of Contents
SAFETY PRECAUTIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About This Manual 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model Identification 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Genset 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Recommendations 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Recommendations 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Batteries 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator’s Console 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Panel 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conducting the Pre-Start Checks 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
priming the Fuel System 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Genset 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Genset 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Restarting the Genset 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading the Genset 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting Circuit Breakers 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting to Utility Power 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Cold Weather 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Hot Weather 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating at High Altitude 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Dusty Environments 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Breaking in a New Engine 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercising the Genset 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storing the Genset 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conducting General Inspections 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Engine Oil Level 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Engine Oil and Oil Filter 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining the Battery and Battery Connections 17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Air Filter Element 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Spark Arrestor 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Fuel Filter 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Coolant 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INFORMATION FOR CALIFORNIA GENSET USERS 33. . . . . . . . . . . . . . . . . . . . . . . . . . .
HOW TO OBTAIN SERVICE 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE RECORD 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
1
Safety Precautions
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.
The following symbols in this manual alert you to potential hazards to the operator, service person and
equipment.
alerts you to an immediate hazard
that will result in severe personal injury or
death.
WARNING
alerts you to a hazard or unsafe
practice that can result in severe personal injury
or death.
CAUTION
alerts you to a hazard or unsafe
practice that can result in personal injury or
equipment damage.
When equipped with an integral or add−on Auto−
matic Generator Starting System (AGS) control,exhaust carbon monoxide (CO), electric shock, andmoving parts hazards are possible due to unex−
pected starting. Turn off AGS whenever performingmaintenance or service, when the vehicle is storedbetween uses, is awaiting service, or is parked in
agarage or other confined area.
Electricity, fuel, exhaust, moving parts and batteries
present hazards which can result in severe personal
injury or death.
ENGINE EXHAUST IS DEADLY
• Inspect for exhaust leaks at every startup and
after every eight hours of running.
• Learn the symptoms of carbon monoxide poisoning in the Operator’s Manual.
• Never sleep in the vehicle while the genset is
running unless the vehicle is equipped with a
working carbon monoxide detector.
• Do not operate the genset when the vehicle is
in a confined space, such as a garage.
• Disable the automatic genset starting feature of
an inverter-charger or other automatic starting
device before storing the vehicle or parking it in
a garage or other confined space.
• The exhaust system must be installed in accordance with the genset Installation Manual.
• Engine cooling air must not be used for heating
working or living spaces or compartments.
GENERATOR VOLTAGE IS DEADLY
• Disable the automatic genset starting feature(AGS) of an inverter−charger or other automatic starting device before servicing the genset to avoid electric shock from an unexpected
start.
• Generator electrical output connections must
be made by a trained and experienced electrician in accordance with applicable codes.
• The genset must not be connected to the public
utility or any other source of electrical power.
Back-feed could lead to electrocution of utility
personnel and damage to equipment. An approved switching device must be used to prevent interconnections.
• Use caution when working on live electrical
equipment. Remove jewelry, make sure clothing and shoes are dry, stand on a dry wooden
platform or rubber insulating mat and use tools
with insulated handles.
DIESEL FUEL IS COMBUSTIBLE
• Do not smoke or turn electrical switches ON or
OFF where fuel fumes are present or in areas
sharing ventilation with fuel tanks or equipment. Keep flames, sparks, pilot lights, arc-producing equipment and all other sources of ignition well away.
• Fuel lines must be secured, free of leaks and
separated or shielded from electrical wiring.
2
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
• Disable the automatic genset starting feature(AGS) of an inverter−charger or other automatic starting device before servicing the genset to avoid unexpected starting.
• Do not wear loose clothing or jewelry near moving parts such as PTO shafts, fans, belts and
pulleys.
• Keep hands away from moving parts.
BATTERY GAS IS EXPLOSIVE
• Wear safety glasses.
• Do not smoke.
• To reduce arcing when disconnecting or recon-
necting battery cables, always disconnect the
negative (−) battery cable first and reconnect it
last.
FLAMMABLE VAPOR CAN CAUSE A
DIESEL ENGINE TO OVERSPEED
Flammable vapor can cause a diesel engine to
overspeed and become difficult to stop, resulting in
possible fire, explosion, severe personal injury and
death. Do not operate a diesel-powered genset
where a flammable vapor environment can be
created by fuel spill, leak, etc. The owners and op-
erators of the genset are solely responsible for operating the genset safely.
GENERAL PRECAUTIONS
• Keep children away from the genset.
• Do not use evaporative starting fluids. They are
highly explosive.
• To prevent accidental or remote starting while
working on the genset, disconnect the negative (−) battery cable at the battery.
• Let the engine cool down before removing the
coolant pressure cap or opening the coolant
drain. Hot coolant under pressure can spray
out and cause severe burns.
• 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.
• Make sure all fasteners are secure and torqued
properly.
• Do not work on the genset when mentally or
physically fatigued or after consuming alcohol
or drugs.
• You must be trained and experienced to make
adjustments while the genset is running—hot,
moving or electrically live parts can cause severe personal injury or death.
• Used engine oil has been identified by some
U. S. state and federal agencies as causing
cancer or reproductive toxicity. Do not ingest,
inhale, or contact used oil or its vapors.
• Ethylene glycol, used as engine antifreeze, is
toxic to humans and animals. Clean up spills
and dispose of used engine coolant in accordance with local environmental regulations.
• Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials such as wood and cloth; Class B fires,
combustible and flammable liquid fuels and
gaseous fuels; Class C fires, live electrical
equipment. (ref. NFPA No. 10)
• Genset installation and operation must comply
with all applicable local, state and federal codes
and regulations.
• Keep guards in place over fans, belts, pulleys,
and other moving parts.
Mobile-8
3
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.
Operation, Periodic Maintenance and Troubleshooting provide the instructions necessary for op-
erating the genset and maintaining it at top performance. The owner is responsible for performing
maintenance in accordance with the PERIODIC
MAINTENANCE SCHEDULE (Page 12). This
manual also includes genset specifications, information on how to obtain service and information for
California users.
WARNING
This genset is not a life support system. It can stop without warning. Children, persons with physical or mental limitations, and
pets could suffer personal injury or death. A personal attendant, redundant power or an alarm
system must be used if genset operation is critical.
MODEL IDENTIFICATION
When contacting an Onan dealer for parts, service
or product information, be ready to provide the model and serial numbers on the genset nameplate. Figure 1 illustrates the nameplate and its location. The
numbers in the gray boxes are typical model and serial numbers. Every character in these numbers is
significant. (The last character of the model number
is the specification letter, which is important for obtaining the right parts.) Record the model and serial
numbers in the boxes in Figure 1 so that they are
easy to find when you need them.
RECORD NUMBERS HERE
MODEL NUMBER:
SERIAL NUMBER:
SKB719U6D2RA 719 cc
80HDKAK11454J
F990 123456
FIGURE 1. TYPICAL NAMEPLATE
4
TYPICAL GENSET
The operator’s console, the components requiring
attention during periodic maintenance and other
features of a typical genset are shown in Figure 2.
See the PERIODIC MAINTENANCE SCHEDULE
(Page 12).
OPERATOR’S
CONSOLE
AC TERMINAL
BOX COVER
LIFTING EYE
ACCESS COVER
ACCESS TO
AIR FILTER
COOLING
AIR INLET
GRILLE
OIL DRAIN
PLUG
ACCESS DOOR FOR
OIL AND FUEL FILTERS
FUEL
CONNECTIONS
BATTERY
CONNECTIONS
COOLANT
DRAIN CAP
WARM AIR DISCHARGE
OPENING
EXHAUST TAILPIPE
FLANGE
(NOT VISIBLE)
FIGURE 2. TYPICAL GENSET
5
FUEL RECOMMENDATIONS
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. Keep a type
ABC fire extinguisher in the vehicle.
Use clean, fresh No. 2 diesel fuel (ASTM 2-D) when
the outdoor ambient temperature is above freezing,
and No. 1 diesel fuel (ASTM 1-D) when below freezing. The fuel should have a Cetane number of at
least 45 for reliable starting.
ENGINE OIL RECOMMENDATIONS
Use API (American Petroleum Institute) performance Class CH-4, CG-4 or CF-4 engine oil, which
may be in combination with performance Class SJ,
SH or SG (for example: CH-4/SJ). Also look for the
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.
STARTING BATTERIES
These gensets have a 12 volt, direct current (DC)
starting and control system. See Specifications
(Page 30) for minimum battery requirements (cold
cranking amperes) for genset starting.
Regular, monthly maintenance of batteries may be
required. See MAINTAINING THE BATTERY AND
BATTERY CONNECTIONS (Page 16) and any instructions available from the vehicle manufacturer
or battery manufacturer. Either the vehicle or the
genset will be equipped with a battery charger.
Reliable genset starting and starter service life depend upon adequate battery system capacity and
proper maintenance.
CHART 1. OIL VISCOSITY VS. TEMPERATURE
Anticipated Ambient Temperature
6
OPERATOR’S CONSOLE
The operator’s console (Figure 3) has the following
features:
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).
Status Light − This is an LED (light emitting diode)
in the control switch which blinks rapidly during preheat and cranking. (Preheat is the period of time
prior to engine cranking when the glow plugs preheat the combustion chambers. The time is automatically varied by the genset controller on the basis of engine temperature.) After the genset starts
up, this light stays on continuously, indicating that
the genset is running and that the starter has disconnected. Also, if the genset shuts down, this light
blinks in a coded fashion to indicate the nature of the
shutdown (see Troubleshooting, Page 21).
Line Circuit Breaker(s) − The line circuit break-
er(s) protect the AC power leads connected to the
genset.
Engine Oil Fill Cap/Dipstick − The oil dipstick is at-
tached to the fill cap and is marked ADD and FULL.
Coolant Recovery Tank Fill Cap − The recovery
tank provides for coolant expansion. Replenish the
normal loss of coolant by filling here.
Coolant Pressure Cap − The coolant pressure cap
is accessible by removing the access plate on the
control console. It provides for a pressurized engine
cooling system. Fill coolant here when refilling the
system.
Fuses F1, F2 and F3 − These fuses are accessible
by removing the access plate on the control console. They protect the control circuits of the genset.
Hour Meter (Optional)− The hour meter records
the total running time of the genset. It cannot be reset.
REMOTE CONTROL PANEL
The vehicle may be equipped with a remote control
panel having a Control Switch and Preheat/Diag-
nostics Light. In addition, it may have an hour meter and the following engine gauges:
Oil Pressure Gauge − The oil pressure gauge indi-
cates the presence of engine oil pressure.
Water Temperature Gauge − The water tempera-
ture gauge indicates engine coolant temperature.
Voltmeter − The voltmeter indicates battery volt-
age.
ACCESS
PLATE
COOLANT
RECOVERY TANK
FILL CAP (BLUE)
OIL FILL CAP
AND DIP STICK
(YELLOW)
LINE CIRCUIT
BREAKER
HOUR METER
(OPTIONAL)
CONTROL
SWITCH AND
STATUS LIGHT
FIGURE 3. OPERATOR’S CONSOLE
7
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 • Throbbing in Temples • Nausea
• Muscular Twitching • Headache • Vomiting
• Weakness and Sleepiness • Inability to Think Clearly
IF YOU OR ANYONE ELSE EXPERIENCES ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH
AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the genset and do not operate it until it has been inspected and repaired.
Never sleep in the vehicle with the genset running unless the vehicle is equipped with a working carbon monoxide detector. Primary protection against poisoning due to inhaling carbon monoxide, however, consists of proper installation of the exhaust system and inspections every day (every eight
hours of operation) for visible and audible exhaust system leaks.
CONDUCTING THE PRE-START CHECKS
Before the first start of the day and after every eight
hours of operation, inspect the genset as instructed
under CONDUCTING GENERAL INSPECTIONS
(Page 13). Keep a log of maintenance and the hours
run and perform any maintenance that may be due.
See Returning the Genset to Service (Page 11) if
the vehicle has been in storage.
Before each start:
1. Make sure all vehicle CO detectors are working.
2. Check for signs of fuel and exhaust leaks and
for damage to the exhaust system.
3. Turn off the air conditioner and other large appliances.
PRIMING THE FUEL SYSTEM
The fuel system should be primed after replacing
the fuel filter or running the genset out of fuel. To
prime the fuel system hold the control switch down
in its Stop position for at least 1 minute.
STARTING THE GENSET
Start the genset from the genset control panel or remote control panel inside the vehicle.
1. Push and hold the switch at START until the
genset starts. The status indicator light on the
switch flashes during preheat and cranking. It
will come on solid when the starter disconnects,
indicating that the genset is running. (Depending on how cold it is, preheat can take up to 15
seconds, extending the time that the light
blinks.)
CAUTION
Excessive cranking can overheat and damage the starter motor. Do not
crank for more than 20 seconds at a time.
Wait at least 2 minutes before trying again.
2. See Troubleshooting (Page 21) if the genset
does not start after three tries.
3. For top performance and engine life, especially
in colder weather, let the engine warm up for
two minutes before connecting appliances.
4. Monitor the engine gauges if the remote panel
is so equipped. Normal readings during operation are as follows:
Oil Pressure: Approximate center of scale
Temperature: 160
°-220° F (71°-104° C)
DC Voltage: 14-15 volts.
5. Check for fuel, exhaust and coolant leaks. Stop
the genset immediately if there is a fuel, exhaust or coolant leak and have it repaired.
8
STOPPING THE GENSET
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.
RESTARTING THE GENSET
See Troubleshooting (Page 21) if the genset shuts
down abnormally.
LOADING THE GENSET
The genset can power AC motors, air conditioners,
AC/DC converters, battery chargers and other appliances. How much appliance load* can be powered depends upon the genset power rating. The
genset will shut down or its circuit breakers will trip if
the sum of the loads exceeds genset power. (If the
genset shuts down, the status light will probably display Fault Code No. 11, 13, 22 or 38. See Trouble-
shooting, Page 21.)
To avoid overloading the genset and causing shutdowns, compare the sum of the loads of the appliances that are likely to be used at the same time to
the power rating of the genset. Use Table 1 or the
ratings on the appliances themselves (if so marked)
to obtain the individual appliance loads. It may be
necessary to run fewer appliances at the same
time—the sum of the loads must not be greater
than genset rating.
The genset may shut down due to overload when a
large motor or air conditioner is started or cycles off
and then on again, even though the sum of the loads
is less than genset rating. The reason for this is that
a motor’s startup load is much larger than its running
load. It may be necessary to run fewer ap-
pliances when large motors and air conditioners are cycling on and off.
Maximum power decreases as altitude increases
because air density decreases. For every 1000-foot
(305 m) increase in elevation you can expect power
to decrease approximately 3 percent. Table 2
shows the results of typical calculations. It may be
necessary to run fewer appliances at higher altitudes.
TABLE 1. TYPICAL APPLIANCE LOADS
Appliance Load (watts)
Air Conditioner 1400-2000
Battery Charger Up to 2000
DC Converter 300-1200
Refrigerator 600-1000
Microwave Oven 1000-1500
Electric Frying Pan or Wok 1000-1500
Electric Stove Element 350-1000
Electric Water Heater 1000-1500
Electric Iron 500-1200
Electric Hair Dryer 800-1500
Coffee Percolator 550-750
Television 200-600
Radio 50-200
Electric Drill 250-750
Electric Broom 200-500
Electric Blanket 50-200
TABLE 2. POWER VS. ALTITUDE
Elevation
above Mean
Sea Level
Max Genset
Power*
Max Genset
Power*
up to 500 ft
(152 m)
7500 watts
(rated)
8000 watts
(rated)
2500 ft
(762 m)
7050 watts 7520 watts
5500 ft
(1676 m)
6375watts 6800watts
above
5500 ft
(1676 m)
6375watts minus
225 watts ev-
ery1000 ft
(305 m)
6800watts minus
240 watts ev-
ery1000 ft
(305 m)
* This table does not take into account the effect cir-
cuit breakers may have in limiting maximum power.
Commercial Genset Applications
Maximum genset power (nameplate rating) is
7500 watts in an ambient of 85° F (29° C), but only
6000 watts in an ambient of 120° F (50° C)—the
maximum operating temperature. Also, continuous
operation at up to 80 percent of maximum power
(6000 watts) is acceptable.
* Appliance load and genset power are measured in terms of watts (W) or kilowatts (kW), where 1 kilowatt (kW) = 1000 watts (W).
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