CUMMINS HDKAL Series, HDKAS Series Operator's Manual
Operator Manual
Commercial Mobile Generator Set
HDKAL (Spec B−J)
HDKAS (Spec B−F)
English
Original Instructions 10-2016 981−0104 (Issue 9)
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 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABOUT THIS MANUAL 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODEL IDENTIFICATION 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL RECOMMENDATIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BIO−DIESEL FUELS B5 − B20 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL RECOMMENDATIONS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERIES 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENSET-MOUNTED CONTROL PANEL 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOTE CONTROL PANELS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRE-START CHECKS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STOPPING 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWERING APPLIANCES 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTIONS to UTILITY POWER 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESETTING LINE CIRCUIT BREAKERS 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE BREAK-IN 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NO-LOAD OPERATION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENSET EXERCISE 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENSET STORAGE 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RETURNING GENSET to SERVICE 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE SCHEDULE 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE PROCEDURES 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INSPECTION 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING OIL AND OIL FILTER 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CLEANER MAINTENANCE 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARK ARRESTOR CLEANING 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERIES 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE COOLING SYSTEM 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Copyright 2016 Cummins Inc.
Table of Contents
TROUBLESHOOTING 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT CODE BLINKING 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESTORING FAULT CODE BLINKING 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE DOES NOT CRANK 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE CRANKS BUT DOES NOT START 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE LACKS POWER OR UNSTABLE 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NO OUTPUT VOLTAGE 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INFORMATION FOR CALIFORNIA GENSET USERS 27 . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOW TO OBTAIN SERVICE 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE RECORD 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Copyright 2016 Cummins Inc.
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Safety Precautions
Thoroughly read the OPERAT OR’S MANUAL before operating the genset. Safe operation and top
performance can be obtained only by proper operation and maintenance.
The following symbols in this Manual alert you to potential hazards to the operator, service personnel
and equipment.
alerts you to an immediate hazard
which will result in severe personal injury or
death.
WARNING
tice which can result in severe personal injury or
death.
CAUTION
tice which can result in personal injury or equipment damage.
Electricity, fuel, exhaust, moving parts and batteries
present hazards which can result in severe personal
injury or death.
alerts you to a hazard or unsafe prac-
alerts you to a hazard or unsafe prac-
GENERAL PRECAUTIONS
Use caution when making 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
state and federal agencies as causing cancer or
reproductive toxicity. Do not ingest, inhale, or
contact used oil or its vapors.
Do not work on the genset when mentally or
physically fatigued or after consuming alcohol or
drugs.
Carefully follow all applicable local, state and
federal codes.
GENERATOR VOLTAGE IS DEADLY!
Generator output connections must be made by
a qualified electrician in accordance with applicable codes.
The genset must not be connected to the public
utility or any other source of electrical power.
Connection could lead to electrocution of utility
workers, damage to equipment and fire. An approved switching device must be used to prevent interconnections.
Keep ABC fire extinguishers handy.
Make sure all fasteners are secure and torqued
properly.
Keep the genset and its compartment clean. Ex-
cess oil and oily rags can catch fire. Dirt and gear
stowed in the compartment can restrict cooling
air.
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.
Before working on the genset, disconnect the
negative (−) battery cable at the battery to pre-
vent starting.
Use caution when working on live electrical
equipment. Remove jewelry, make sure clothing
and shoes are dry and stand on a dry wooden
platform on the ground or floor.
FUEL IS FLAMMABLE AND EXPLOSIVE
Keep flames, cigarettes, sparks, pilot lights,
electrical arc-producing equipment and
switches and all other sources of ignition well
away from areas where fuel fumes are present
and areas sharing ventilation.
Fuel lines must be secured, free of leaks and
separated or shielded from electrical wiring.
Use approved non-conductive flexible fuel hose
for fuel connections at the genset.
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ENGINE EXHAUST IS DEADLY!
Learn the symptoms of carbon monoxide poi-
soning in this manual.
Prior to every startup and after every eight hours
of running, all carbon monoxide detectors must
be tested and confirmed to be working in accordance with the manufacturer’s instructions or
owners manual.
Never occupy in the vehicle while the genset is
running unless the vehicle has a working carbon
monoxide detector.
The exhaust system must be installed in accor-
dance with the genset Installation Manual.
Keep guards in place over fans, belts, pulleys,
etc.
BATTERY GAS IS EXPLOSIVE
Wear safety glasses and do not smoke while
servicing batteries.
When disconnecting or reconnecting battery
cables, always disconnect the negative (−) bat-
tery cable first and reconnect it last to reduce
arcing.
DO NOT OPERATE IN FLAMMABLE AND
EXPLOSIVE ENVIRONMENTS
Do not use engine cooling air to heat the vehicle
interior.
Make sure there is ample fresh air when operat-
ing the genset in a confined area.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
Do not wear loose clothing or jewelry near mov-
ing parts such as PTO shafts, fans, belts and
pulleys.
Keep hands away from moving parts.
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., unless the genset
is equipped with an automatic safety device to
block the air intake and stop the engine. The own-
ers and operators of the genset are solely responsible for operating the genset safely. Contact your authorized Cummins Onan dealer or distributor for
more information.
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Copyright 2016 Cummins Inc.
Introduction
ABOUT THIS MANUAL
This manual covers operation and maintenance of
the model HDKAL and HDKAS generator sets (gensets). Study this manual carefully and observe all of
its instructions and precautions. Using the genset
properly and maintaining it regularly will promote longer genset life, better performance, and safer operation. Each operator should become thoroughly familiar with this manual. Keep this manual in a
convenient location for quick reference.
MODEL IDENTIFICATION
When you call for service or parts have the genset
model number and serial number ready (Figure 1).
For ready reference, record these numbers in the
boxes shown.
FUEL RECOMMENDATIONS
WARNING
Diesel fuel is combustible and can
cause severe personal injury or death. Do not
smoke near fuel tanks or fuel-burning equipment
or in areas sharing ventilation with such equipment. Keep flames, sparks, pilot flames, electrical arcs and switches and all other sources of
ignition well away. Keep a type ABC fire extinguisher handy.
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.
Note: Only low sulfer diesel or Ultra Low Sulfur Diesel
(ULSD) fuel that meets the ASTM D975 or EN 590 standard for lubricity may be used with this engine. The 1
to 2 percent less energy content of the fuel can have a
slight effect on maximum engine power.
Note: B5 Bio-Diesel fuel that meets industry specifications and quality is suitable for use with this engine.
RECORD MODEL AND SERIAL NUMBERS HERE
MODEL NUMBER
SERIAL NUMBER
FIGURE 1. TYPICAL NAMEPLATE
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BIO−DIESEL FUELS B5 − B20
B5 bio−diesel fuel that meets industry specifications
and quality is suitable for use with this generator set.
Bio−Diesel Above B5 and up to B20
Bio−Diesel Blends
The following must be verified before using bio−die-
sel blends up to B20:
For model HDKAL, the generator set is at Spec
G or higher.
The vehicle propulsion engine is capable of us-
ing B20 when sharing the same fuel tank.
The OEM has installed B20 compatible fuel line
from fuel tank to generator set.
The OEM has installed a water separator in the
fuel line just before the generator set.
Approved Bio−Diesel Fuel:
For bio−diesel blends above B5 and up to B20,
Cummins Onan requires that the fuel meet the
specifications outlined in ASTM D7467.
The bio−diesel component of this fuel blend
must meet ASTM D6751 or EN14214 and the
petroleum−diesel component must meet ASTM
D975.
Blended bio−diesels fuels should be bought
pre−blended and not made by customers.
generator with bio−diesel blends in low ambient
temperatures, such as a fuel heater, hose insulation, or additional anti−gel fuel additives.
Bio−diesel fuel blends are an excellent medium
for microbial growth. Microbes cause fuel system corrosion and premature filter plugging. The
effectiveness of all commercially available conventional anti−microbial additives, when used in
bio−diesel, is not known. Consult your fuel and
additive supplier for assistance.
WARNING
It is highly recommended that specific
market applications are avoided or excercised with
extra care due to some of the properties of bio−diesel fuel blends such as cold weather operation, long
term storage, material incompatibilities and other effects on engine operating characteristics. Such applications that should use standard fuels include applications that will experience seasonal usage,
storage for periods exceeding 90 days, and extreme
temperatures or humidity.
Storage Requirements:
If using bio−diesel for seasonal applications
(stored more than 90 days), the generator must
be purged before storage by running the engine
on pure diesel fuel meeting ASTM D975 for a mininmum of 30 minutes.
Warranty Coverage:
Bio−Diesel Properties:
Bio−diesel has poor oxidation stability which
can accelerate fuel oxidation. Fuel oxidation will
reduce generator performance. This effect is ac-
celerated at increased ambient temperatures.
Bio−diesel properties change at low ambient
temperatures (below 23
F/−5C). Necessary
precautions must be taken when operating the
Cummins Onan Warranty covers failures that are a
direct result of defects in material or factory workmanship. Generator damage, service issues and/or
performance issues determined by Cummins Onan
to be caused by bio−diesel fuel blends not meeting
the specifications outlined in the applicable Installation, Operator, and Service Manuals are not considered to be defects in material or workmanship and
may affect your generator’s warranty.
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Copyright 2016 Cummins Inc.
ENGINE OIL RECOMMENDATIONS
Use premium quality motor oil. Look for the API
(American Petroleum Institute) classification and
use Class CF-4 or CF or better oil. Also look for the
SAE (Society of Automotive Engineers) viscosity
FIGURE 2. SAE VISCOSITY GRADE vs. AMBIENT
TEMPERATURE
BATTERIES
The genset requires a 12 volt battery to power its
control and starting circuits. Reliable genset starting
and starter service life depend upon adequate battery system capacity and maintenance. See Specifi-
cations for battery requirements and Periodic Main-
tenance for battery care.
grade. Referring to Figure 2, choose the viscosity
grade appropriate for the range of ambient temperatures expected before the next scheduled oil change.
Multi-grade oils such as SAE 15W-40 are recommended for year-round use.
S
t
o
p
S
t
a
r
t
GENSET-MOUNTED CONTROL PANEL
Figure 3 illustrates the genset control panel.
Start-Stop-Preheat Switch (S1): Starts the genset
when held at Start and stops the genset when mo-
mentarily touched to Stop. Holding the switch at
Stop causes the glow plugs to preheat the combustions chambers.
DC Control Breaker: Protects the control circuits
from shorts to ground. Can be used as an emergency
stop switch. Reset with handle.
Hour Meter: Indicates the number of hours the genset has run. It cannot be reset.
Fault Reset Breaker: T rips and shuts down the genset when there is a low oil pressure or high coolant
temperature fault condition. Reset by pushing in the
red button.
REMOTE CONTROL PANELS
Remote control panels with a control switch and engine gauges are available.
DC
Control
Brkr
Fault
Brkr
FIGURE 3. GENSET CONTROL PANEL
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Copyright 2016 Cummins Inc.
Operation
EXHAUST GAS IS DEADLY!
Engine exhaust contains carbon monoxide, a poisonous, odorless and colorless gas that can
cause unconsciousness and death. Symptoms of carbon monoxide poisoning include:
Dizziness Throbbing in Temples Nausea
Muscular Twitching Headache Vomiting
Weakness Trouble Thinking Clearly Sleepiness
GET EVERYONE OUT INTO FRESH AIR IMMEDIATELY IF ANYONE EXPERIENCES ANY OF
THESE SYMPTOMS. Seek medical attention if symptoms persist.
Never ocupy in the vehicle when the genset is running unless the vehicle has an operating carbon monoxide detector.
Look and listen for leaks along the entire run of the exhaust system every time you start up the
genset and every eight hours if the genset is being run continuously. Shut down the genset
immediately if there is a leak and do not run it until the leak has been repaired.
The installation of the exhaust system must be in accordance with the genset Installation
Manual.
PRE-START CHECKS
Perform General Inspection (p. 13). Check for fuel,
exhaust, oil and coolant leaks every eight hours
if the genset is being run continuously.
Check the Maintenance Record and perform any
maintenance due (Periodic Maintenance Schedule).
Also see GENSET BREAK-IN if the genset is new
and RETURNING THE GENSET TO SERVICE if the
vehicle has been in storage.
STARTING
Disconnect all loads from the genset.
Preheat − Hold the control switch in the PREHEAT
position for the following number of seconds depending on ambient temperature:
a. 10 seconds—above 50
b. 15 seconds—0
c. 20 seconds—below 0
F to 50F (−17to 10C)
F (10C)
F (−17C)
CAUTION
seconds can damage the glow plugs.
Start − Immediately after PREHEAT push the control
switch to START and hold it there until the en-
gine starts. The starter will automatically disconnect as the engine starts up.
Do not crank for more than 15 seconds at a time.
Wait two minutes before trying again. See Trou-
bleshooting if the engine does not start on the
second try.
CAUTION
heat and damage the starter. Do not crank for
more than 15 seconds at a time and wait two
minutes before trying again.
Connect the electrical loads after the genset has
warmed up for a few minutes.
Check for fuel, exhaust, oil and coolant leaks and
complete General Inspection (p. 13). Check the
engine gauges regularly (if provided) while the
genset is running.
Oil Pressure Gauge: Normal engine oil pres-
sure is 28 − 64 psi (194 − 442 kPa) at normal operating temperature.
Preheat times longer than 20
Excessive cranking can over-
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DC Voltmeter: Normal DC system voltage is
12.5 − 15 volts depending on battery condition and state-of-charge.
Coolant Temperature Gauge: Normal engine
coolant temperature is 160 −195
(71 − 91
C) depending on load and ambi-
F
ent temperature.
STOPPING
Before stopping let the genset cool down by running at no-load for three to five minutes. Then touch
the control switch momentarily to STOP.
CAUTION
Failure to let the engine cool down
before stopping can lead to engine damage. Let
the genset run three to five minutes at no-load
before stopping.
POWERING APPLIANCES
The genset can power AC motors, air conditioners,
AC/DC converters and other appliances. How much
appliance load* can be serviced 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 rating.
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 nec-
essary to run fewer appliances at the same time
so that the sum of the loads is not greater than
genset rating.
Note that air density decreases as altitude increases,
decreasing engine power . Power decreases approximately 3 percent of rated power every 1000 feet
(305 m) that elevation increases above sea level.
See Table 2 for typical calculations. It may be nec-
essary to operate fewer appliances at higher altitudes.
TABLE 1. TYPICAL APPLIANCE LOADS
Appliance Load (watt)
Air Conditioner 1400-2000
Battery Charger Up to 800
DC Converter 300-1500
Refrigerator 600-1000
Microwave Oven 1000-1500
Electric Frying Pan/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. MAXIMUM POWER VS. ALTITUDE
Note that the genset may shut down due to overload,
even though the sum of the loads is less than genset
rating, when a large motor or air conditioner is started
last or cycles off and then on again. The reason for
Elevation above Sea
Level
at/below 500 ft (152 m) 7500 W (rated)
at 2500 ft (762 m) 7050 W
Maximum Power
this is that motor startup load is much larger than running load. It may be necessary to run fewer ap-
pliances when large motors and air conditioners
are cycling on and off.
* Appliance load and genset power are measured in terms of watt (W) or kilowatt (kW), where 1 kilowatt (kW) = 1000 watt (W).
at 5500 ft (1676 m) 6375 W
above 5500 ft (1676 m)
8
6375 W minus 225 W
every 1000 ft (305 m)
Copyright 2016 Cummins Inc.
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