Page 1
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)
Page 2
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
Page 3
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
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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
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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
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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
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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
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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
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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.
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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).
Page 13
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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.) If the circuit
breaker trips right away, either the electrical distribution system has a short or the circuit breaker is
faulty. Call a qualified electrician.
If the circuit breaker does not trip, reconnect the appliances, one by one, up to a total load that does not
overload the genset or cause the circuit breaker to
trip. If a circuit breaker trips right away when an appliance is connected, the appliance probably has a
short.
Electrical appliances and tools must be used and
maintained properly and be properly grounded to
cause the line circuit breakers to trip when short circuits occur.
WARNING
Short circuits in electrical appliances and tools can cause fire and electrical
shock leading to severe personal injury or
death. Read and follow the equipment and tool
manufacturer’s instructions and warnings regarding use, maintenance and proper grounding.
CONNECTING TO UTILITY POWER
When the vehicle has provisions for connecting to
utility power, such as a cord for plugging into a power outlet receptacle, it must also have an approved
device to keep the genset and utility from being interconnected. See the genset Installation Manual
for more information.
WARNING
Interconnecting the genset and the
public utility (or any other power source) can
lead to the electrocution of personnel working
on the utility lines, damage to equipment and
fire. An approved switching device must be
used to prevent interconnections.
LINE CIRCUIT
BREAKER
FIGURE 4. LINE CIRCUIT BREAKER
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10
OPERATING IN COLD WEATHER
Make sure the engine oil viscosity is appropriate for
the cold weather temperatures. See ENGINE OIL
RECOMMENDATIONS (Page 5). Be sure to
change the oil if a sudden drop in temperature occurs.
OPERATING IN HOT WEATHER
Pay particular attention to the following items when
operating the genset in hot weather:
1. Make sure nothing blocks airflow to and from
the genset.
2. Make sure engine oil viscosity is appropriate for
the ambient temperatures. See ENGINE OIL
RECOMMENDATIONS (Page 5).
3. Keep the genset clean.
4. Perform maintenance due. See PERIODIC
MAINTENANCE SCHEDULE (Page 12).
OPERATING AT HIGH ALTITUDE
For the effect of altitude on maximum power, see
LOADING THE GENSET (Page 8).
OPERATING IN DUSTY ENVIRONMENTS
Pay particular attention to the following items when
operating the genset in dusty environments:
1. Do not let dirt and debris accumulate inside the
genset compartment. Keep the genset clean.
2. Perform air cleaner maintenance more often.
See PERIODIC MAINTENANCE SCHEDULE
(Page 12).
3. Change engine oil more often. See PERIODIC
MAINTENANCE SCHEDULE (Page 12).
4. Keep containers of engine oil that have been
opened tightly closed to keep out dust.
BREAKING IN A NEW ENGINE
Proper engine break-in on a new genset or on one
with a rebuilt engine is essential for top engine performance and acceptable oil consumption. Run the
genset at approximately 1/2 rated power for the first
2 hours and then at 3/4 rated power for 2 more
hours. See LOADING THE GENSET (Page 8).
Proper engine oil and oil level are especially critical
during break-in because of the higher engine temperatures that can be expected. Change the oil if not
appropriate for the ambient temperatures during
break-in. See ENGINE OIL RECOMMENDATIONS
(Page 5). Check oil level twice a day or every
4 hours during the first 24 hours of operation and
change the oil and oil filter after the first 50 hours of
operation.
EXERCISING THE GENSET
Exercise the genset at least 2 hours each month if
use is infrequent. Run the genset at approximately
1/2 rated power. See LOADING THE GENSET
(Page 8). A single two hour exercise period is better than several shorter periods.
Exercising a genset drives off moisture, re-lubricates the engine, replaces stale fuel and removes
oxides from electrical contacts. The result is better
starting, more reliable operation and longer engine
life.
Page 15
11
STORING THE GENSET
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.
Storing the Genset
1. Push the genset line circuit breaker OFF
(Page 9).
2. Change the engine oil and attach a tag indicating oil viscosity. See ENGINE OIL RECOMMENDATIONS (Page 5).
3. Disconnect the battery cables (negative [−]
cable first) from the starting battery and store
the battery according to the battery manufacturer’s recommendations. See MAINTAINING
THE BATTERY AND BATTERY CONNECTIONS (Page 16).
4. Plug the exhaust tail pipe to keep out dirt, moisture, bugs, etc.
5. Close the fuel supply valve (if so equipped).
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 5).
2. Reconnect the starting battery (negative [−]
cable last). See MAINTAINING THE BATTERY
AND BATTERY CONNECTIONS (Page 16).
3. Remove the plug from the exhaust tailpipe.
4. Change the air filter element if it is dirty
(Page 16).
5. Open the fuel supply valve (if so equipped).
6. Inspect the genset. See CONDUCTING GENERAL INSPECTIONS (Page 13).
7. Push the genset line circuit breaker ON
(Page 9) when the genset is ready to power
appliances.
Page 16
12
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 34) will
help you keep genset maintenance regular and provide a basis for supporting warranty claims.
Maintenance, replacement or repair of emission
control devices and systems may be performed by
any engine repair establishment or individual. However, warranty work must be completed by an authorized Onan dealer.
TABLE 3. PERIODIC MAINTENANCE SCHEDULE
MAINTENANCE PROCEDURE
MAINTENANCE FREQUENCY
Every
Day
After First
50 Hours
Every
Month
Every
150
Hours
Every
500
Hours
Every
1000
Hours
P
a
g
e
General Inspection X 13
Check Engine Oil Level X 14
Check Engine Coolant Level X 19
Clean and Check Battery X
3
16
Change Engine Oil and Filter X
1
X
2, 3, 4
15
Clean Spark Arrestor X
4
17
Replace Engine Air Filter X
2, 4
16
Replace Fuel Filter X 18
Check Coolant Anti-freeze Protection X 19
Flush Coolant System X
5
19
Replace Coolant Pressure Cap X
5
19
Replace Engine V-belt X
6,7
−
Clean Crankcase Breather X
6,7
−
Replace Coolant Hoses and Thermostat X
6, 7
−
1 − As a part of engine break-in, change the engine oil after the first 50 hours of operation.
2 − Perform more often when operating in dusty conditions.
3 − Perform more often when operating in hot weather.
4 − Perform at least once a year.
5 − Perform at least once every two years.
6 − Perform at least once every five years.
7 − Must be performed by a qualified mechanic (authorized Onan dealer).
Page 17
13
CONDUCTING GENERAL INSPECTIONS
Inspect the genset before the first start of the day
and after every eight hours of operation.
Oil Level
Check engine oil level (Page 14).
Engine Coolant System
CAUTION
Operating the genset when coolant
level is low can cause serious engine damage.
Check the coolant level and look for coolant leaks
around the bottom of the genset and on the ground
below. Minor leaks that can be replenished by daily
additions of coolant to the recovery tank should be
repaired by a qualified service technician as soon as
possible. Larger leaks are cause for shutting down
the genset until it can be repaired.
Exhaust System
WARNING
EXHAUST GAS IS DEADLY! Do not
operate the genset if there is an exhaust leak or
any danger of exhaust gases entering or being
drawn into the vehicle.
Look and listen for exhaust system leaks while the
genset is running. Shut down the genset if a leak is
found and have it repaired before operating the genset again.
Look for openings or holes between the genset
compartment and vehicle cab or living space if the
genset engine sounds louder than usual. Have all
such openings or holes closed off or sealed to prevent exhaust gases from entering the vehicle.
Replace dented, bent or severely rusted sections of
the tailpipe and make sure the tailpipe extends at
least 1 inch (25.4 mm) beyond the perimeter of the
vehicle.
WARNING
Do not park the vehicle in high grass
or brush. Contact with the exhaust system can
cause a fire.
Park the vehicle so that the genset exhaust gases
can disperse away from the vehicle. Barriers such
as walls, snow banks, high grass and brush and other vehicles can cause exhaust gases to accumulate
in and around the vehicle.
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.
Fuel System
Check for leaks at hose, tube and pipe fittings in the
fuel supply system while the genset is running and
while it is stopped. Check flexible fuel hose sections
for cuts, cracks, and abrasions. Make sure the fuel
line is not rubbing against other parts. Replace worn
or damaged fuel line parts before leaks occur.
WARNING
Diesel fuel leaks can lead to fire. Do
not operate the genset if operation causes fuel
to leak.
Battery Connections
Check the battery terminals for clean, tight connections. Loose or corroded connections have high
electrical resistance which makes starting harder.
See MAINTAINING THE BATTERY AND BATTERY
CONNECTIONS (Page 16).
WARNING
Arcing at battery terminals or in
light switches or other equipment, and flames or
sparks, can ignite battery gas causing severe
personal injury.
Ventilate battery area before working on or near
battery—Wear safety glasses—Do not smoke—
Switch trouble light ON or OFF away from battery—Stop genset and disconnect charger before disconnecting battery cables—Disconnect
negative (−) cable first and reconnect last.
Mechanical
Look for mechanical damage. Start the genset and
look and listen for any unusual noises and vibrations.
Check the genset mounting bolts to make sure they
are secure.
Check to see that the genset air inlet and outlet
openings are not clogged with debris or blocked.
Check the engine gauges from time to time while the
genset is running (if so equipped).
Page 18
14
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). Reinsert the dipstick,
screw the cap back on, remove the dipstick
again and check the oil level on the dip stick.
2. Add or drain oil as necessary. See ENGINE OIL
RECOMMENDATIONS (Page 5). Keep the
oil level between the FULL and ADD marks.
CAUTION
Too much oil can cause high oil
consumption. Too little oil can cause severe
engine damage. Keep the oil level between
the FULL and ADD marks.
3. Reinsert the dipstick and screw the oil fill cap
back on securely.
FIGURE 5. CHECKING ENGINE OIL LEVEL
Page 19
15
CHANGING ENGINE OIL AND OIL FILTER
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.
Refer to Table 3 for scheduled engine oil change.
Change oil more often in hot and dusty environments.
1. Run the engine until warm, stop it and remove
the oil fill cap and dipstick (Figure 5).
2. Place a pan underneath the genset and unscrew the oil drain plug (Figure 6). Let all oil
drain from the engine.
3. Reinstall the oil drain plug and tighten it securely to prevent oil leakage.
4. Squeeze the access door latches together and
let the door swing down (Figure 6).
5. Spin off the oil filter canister. Thoroughly wipe
off the filter mounting surface and remove the
old gasket if it does not come off with the filter
canister.
6. Make sure the new gasket is in place on the
new filter canister and apply a thin film of oil to
the gasket. (The replacement filter canister has
a larger diameter than the original filter cannister, but will fit.)
7. Spin on the new filter canister by hand until the
gasket just touches the mounting pad and then
turn it an additional 1/2 to 3/4 turn. Do not overtighten. Close the access door, making sure it
latches securely.
8. Refill with 3 quarts (2.6 l) of oil. See ENGINE
OIL RECOMMENDATIONS (Page 5). Check
the oil level and add or drain oil as necessary.
CAUTION
Too much oil can cause high oil
consumption. Too little oil can cause severe
engine damage. Keep the oil level between
the FULL and ADD marks.
9. Reinsert the dipstick and screw the oil fill cap
back on securely.
10. Dispose of the used oil and oil filter in accordance with local environmental regulations.
OIL DRAIN PLUG
OIL FILTERACCESS DOOR
FIGURE 6. OIL DRAIN PLUG AND OIL FILTER
Page 20
16
MAINTAINING THE BATTERY AND
BATTERY CONNECTIONS
WARNING
Arcing at battery terminals or in
light switches or other equipment, and flames or
sparks, can ignite battery gas causing severe
personal injury.
Ventilate battery area before working on or near
battery—Wear safety glasses—Do not smoke—
Switch trouble light ON or OFF away from battery—Stop genset and disconnect charger before disconnecting battery cables—Disconnect
negative (−) cable first and reconnect last.
Refer to Table 3 for scheduled battery maintenance,
and follow the battery manufacturer’s instructions.
Have the battery charging system serviced if DC
system voltage is consistently low or high. Always:
1. Keep the battery case and terminals clean and
dry and the terminals tight.
2. Remove battery cables with a battery terminal
puller.
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.
REPLACING THE AIR FILTER ELEMENT
Refer to Table 3 for scheduled air filter element replacement. In dusty environments the filter element
should be inspected and changed more frequently.
To change the filter element (Figure 7), remove the
outer and inner cover and reassemble with a new air
filter element. Turn the inner cover wingnut three to
four clicks past seating. Make sure the outer cover is
seated before tightening its wingnut. Check for
noise when the genset is running, and retighten
if necessary.
OUTER COVER INNER COVER FILTER ELEMENT SPACER SEAL HOUSING
FIGURE 7. REPLACING THE AIR FILTER ELEMENT
Page 21
17
CLEANING THE SPARK ARRESTOR
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.
WARNING
A hot muffler can cause severe
burns. Let the muffler cool down before removing or installing the cleanout plug.
The muffler is mounted inside the genset housing.
The cleanout plug is located on the side of the muf-
fler, accessible through the air outlet opening in the
bottom of the genset. Clean out the spark arrestor
muffler as follows:
1. Remove the cleanout plug from the muffler
(Figure 8).
2. Restart the genset and load it nearly to full power. See LOADING THE GENSET (Page 8).
Let the genset run for about five minutes to expel the soot in the muffler.
3. Stop the genset, allow the muffler to cool down
and then reinstall the plug.
CLEANOUT PLUG
FIGURE 8. SPARK ARRESTOR CLEANOUT PLUG
Page 22
18
REPLACING THE FUEL FILTER
Refer to Table 3 for scheduled replacement of the
fuel filter (Figure 9). A dirty fuel filter may be the
cause if the engine fails to start. The fuel filter is accessible through the maintenance access door in
the skid-base. Squeeze the latches together to
open the door.
CAUTION
Wipe dirt off the fuel hose connections at the fuel filter before disconnecting the
hoses so as to keep dirt out of the fuel system.
WARNING
Diesel fuel is combustible and can
cause severe personal injury or death. Do not
smoke. 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 handy.
Removing the Fuel Filter: To remove the filter, dis-
connect 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.
Installing the Fuel Filter: Rotate the filter half a
turn around its mounting stud if the fittings interfere
with the bracket. It only fits properly one way.
Connect the fuel fittings before tightening the filter
mounting nut. Take care not to crossthread the fuel
fittings. Thread them in by hand and tighten one flat
past seating.
Close the access door and prime the fuel system by
holding the control switch down in its Stop position
for at least 1 minute. Priming is necessary to displace the air in the new filter with fuel.
FILTER
MOUNTING
NUT
TUBING FROM
FUEL PUMP
FUEL HOSE
TO ENGINE
FUEL
FILTER
FIGURE 9. FUEL FILTER
Page 23
19
CHANGING COOLANT
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).
Replace the coolant every two years. Use ethylene
or propylene glycol anti-freeze solution that contains a rust and corrosion inhibitor. The anti-freeze
should not contain a stop-leak additive.
The water used for engine coolant should be clean,
low in minerals, and free of corrosive chemicals.
Use distilled water if available. The cooling system
has a 4.2 quart (4 l) capacity.
Pressure Cap
Replace the pressure cap (Figure 10) every two
years because its seals can deteriorate and begin to
leak. Proper cooling system pressure is essential
for optimal engine cooling and minimal coolant loss.
Draining the Cooling System
WARNING
Hot coolant spray can cause severe
burns. Let the engine cool before releasing the
pressure cap or removing the drain cap.
Allow the engine to cool before removing the pressure cap. Then relieve any remaining pressure by
turning the pressure cap slowly, without pushing
down on it, until it catches. When the pressure has
been relieved, remove the pressure cap by pushing
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).
WARNING
Ethylene glycol antifreeze is considered toxic. Dispose of it according to local
regulations for hazardous substances.
It is recommended that the system be cleaned and
flushed before refilling. Radiator cleaning chemicals
are available at local auto parts stores. Follow the
instructions for cleaning and flushing that come with
the cleaning solution.
Refilling the Cooling System
Fill the recovery tank with coolant mixture to the
COLD mark.
Secure the system drain cap. Fill the cooling system
with coolant mixture through the pressure cap/fill
opening. Pull the hose connected to the pressure
cap assembly out as far as it will go. When coolant
fills up to the fill opening, start and operate the genset for a few minutes and shut it down. (It is recommended that the air conditioners or other large loads
be turned on so that the genset will operate under
load, causing the engine to run faster and expel
trapped air.) Add more coolant if necessary and secure the pressure cap.
Coolant Level Check
Check coolant level in the recovery tank (Figure 10)
before the first startup of each day and fill to the
COLD mark if necessary.
Page 24
20
PRESSURE CAP AND
SYSTEM FILL OPENING
COOLING SYSTEM
DRAIN CAP
COOLANT RECOVERY
TANK FILL CAP (BLUE)
FIGURE 10. ENGINE COOLING SYSTEM FILL AND DRAIN CAPS
Page 25
21
Troubleshooting
WARNING
Hot engine parts can cause severe
burns. Always allow the engine time to cool before performing any maintenance or service.
TABLE 4. TROUBLESHOOTING lists the Fault
Codes in numerical order along with step-by-step
instructions for corrective action. If you fail to resolve the problem after taking the corrective actions
suggested, contact an authorized Onan dealer. See
How to Obtain Service (Page 33).
First note the following:
• Maintaining engine oil level, keeping battery
connections clean and tight, watching the fuel
gauge, not overloading the genset, etc. will
prevent most shutdowns.
• When the genset and vehicle engine share a
common fuel tank the fuel dip tubes are usually arranged so that the genset will run out of
fuel first. Marking the genset empty point on
the fuel gauge will make it easier to tell when
to stop the genset before running it out of fuel.
First-Level Fault Codes: The genset controller
provides extensive diagnostics by causing the status indicator light on the Control Switch to blink in a
coded fashion. Following a fault shutdown, the indicator light will repeatedly blink 1, 2 or 3 blinks at a
time.
• One blink indicates shut down due to high tem-
perature
• Two blinks indicates shutdown due to a loss of
engine oil pressure
• Three blinks indicates shutdown due to some
other abnormal condition.
Second-Level Fault Codes: For a 1-blink or 3-blink
first-level fault code, one touch to Stop brings up a
second-level fault code. This code consists of 1, 2, 3
or 4 blinks, a brief pause, and then 1 to 9 blinks. The
first set of blinks represents the tens digit and the
second set of blinks the units digit of the fault code
number. For example, Fault Code No. 23 would appear as:
blink-blink—pause—blink-blink-blink—...
NOTE: Fault Code Nos. 1, 2 and 3 are first-level faults.
Avoid interpreting them as second-level Fault Codes
11, 22 and 33. The pauses between repetitions of the
fault code are longer than the pauses between the
tens and units digits of the the code. For example,
Fault Code 33 would appear as:
blink-blink-blink—pause—blink-blink-blink
—longer pause—
blink-blink-blink—pause—blink-blink-blink—...
Restoring Fault Code Blinking: The fault code
stops blinking after five minutes. Press Stop three
times within five seconds to restore blinking. Note
that the last fault logged will blink, even after the
condition that caused the shutdown has been corrected.
Page 26
22
TABLE 4. TROUBLESHOOTING
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.
WARNING
GENSET WON’T STOP RUNNING—STATUS INDICATOR LIGHT ON
(Faulty Stop Switch or grounded wiring)
Removing genset panels or disconnecting fuel lines to stop a genset that won’t stop
can lead to severe personal injury or death from electrocution, contact with moving parts or fire.
Try the genset Stop Switch if the remote Stop Switch does not work, and vice versa. Otherwise, let
the genset run out of fuel.
WARNING
GENSET WON’T STOP RUNNING—STATUS INDICATOR LIGHT OFF
(Binding governor mechanism, misadjusted speed stop)
Removing genset panels or disconnecting fuel lines to stop a genset that won’t stop
can lead to severe personal injury or death from electrocution, contact with moving parts or fire.
Let the genset run out of fuel.
WARNING
STATUS INDICATOR LIGHT STAYS ON
(Reversed battery connections)
Corrective Action: Reconnect the battery correctly (Page 16).
ENGINE CRANKS WHEN BATTERY CONNECTED
(Faulty Start Switch or grounded wiring)
Corrective Action: See an authorized Onan dealer.
ENGINE WON’T CRANK—FUEL PUMP WON’T STOP
(Faulty Stop Switch or grounded wiring)
Corrective Action: See an authorized Onan dealer.
STATUS INDICATOR LIGHT DEAD
(Faulty connections, no battery voltage)
Corrective Action:
1. Try the genset Start Switch if the remote Start Switch does not work, and vice versa.
2. Replace Fuse F1 (B+) if blown (Page 6).
3. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery, vehicle
frame and genset (Page 16).
4. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
Page 27
23
TABLE 4. TROUBLESHOOTING (CONT.)
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.
WARNING
STARTING BATTERIES RUN DOWN
(Marginal battery, battery connections, or charging system; or parasitic loads)
Corrective Action:
1. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery, vehicle
frame and genset (Page 16).
2. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
ENGINE CRANKS BUT DOES NOT START
(Fuel delivery, glow plugs or engine are marginal)
Corrective Action:
1. Check fuel level. (Note: The genset fuel pickup is probably higher than the vehicle engine pickup.)
2. Prime the engine fuel system by holding the control switch down in its Stop position for at least 1 minute.
3. Check the engine air filter and remove any blockage (Page 16).
4. Replace Fuse F3 (glow plugs) if blown (Page 6).
STARTER ENGAGES-DISENGAGES
(Cranking voltage dips below 6 volts—low battery charge, poor connections, long cables)
Corrective Action:
1. Have the vehicle propulsion engine running while trying to start the genset—the battery charging
alternator may be able to maintain starting voltage high enough to get the genset started.
2. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery, vehicle
frame and genset (Page 16).
3. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
4. Increase battery cable size or run parallel cables.
NO POWER—GENSET RUNNING, RUN LIGHT ON
(Line circuit breaker OFF or tripped or faulty wiring)
Corrective Action: Reset or turn “On” the line circuit breaker on the genset operator’s console.
GENSET HUNTS UNDER FULL LOAD
(Fuel delivery marginal, governor misadjusted)
Corrective Action: Prime the engine fuel system by holding the control switch down in its Stop position for at least 1 minute.
Page 28
24
TABLE 4. TROUBLESHOOTING (CONT.)
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.
WARNING
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. 33 or No. 34.
LOW OIL PRESSURE—FAULT CODE NO. 2
(Low oil pressure cutoff switch did not open)
Corrective Action:
1. Check engine oil level and add oil as necessary (Page 14).
2. Drain excess oil (above dipstick Full mark).
SERVICE CHECK FAULT—CODE NO. 3
(A second-level fault occurred)
Corrective Action: Check the second-level fault code by touching Stop. The second-level fault will be
one of the following in this table.
OVERLOAD—CODE NO. 8
(Models HDKAH & HDKAV only: Load exceeded110 percent of genset rating for 2 minutes)
Corrective Action: Reduce load and restart
OVERCURRENT FAULT—CODE NO. 11
(AC output short)
Corrective Action:
1. Turn off the genset line circuit breaker. If the genset no longer shuts down, the genset is probably
okay—check for and repair a short circuit in the vehicle appliances, wiring or shorted battery charger
transformer.
2. Check whether the vehicle engine and genset share the same starting battery. If so, and this fault
occurs when cranking the vehicle engine, low battery voltage may be causing this shutdown. Increase battery capacity or install a separate battery and battery charging system for the genset.
Page 29
25
TABLE 4. TROUBLESHOOTING (CONT.)
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.
WARNING
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. If
so, and this fault occurs when cranking the vehicle engine, low battery voltage may be causing this
shutdown. Increase battery capacity or install a separate battery and battery charging system for the
genset.
INVERTER UNDERVOLTAGE FAULT—CODE NO. 13
(Controller not able to regulate to rated voltage)
Corrective Action: Check whether the vehicle engine and genset share the same starting battery. If
so, and this fault occurs when cranking the vehicle engine, low battery voltage may be causing this
shutdown. Increase battery capacity or install a separate battery and battery charging system for the
genset.
INVERTER OVERFREQUENCY FAULT—CODE NO. 14
(Controller not able to regulate to rated frequency)
Corrective Action: Reduce the number of connected appliances, especially when air conditioners and
battery chargers are running.
INVERTER UNDERFREQUENCY FAULT—CODE NO. 15
(Controller not able to regulate to rated frequency)
Corrective Action:
1. Reduce the number of connected appliances, especially when air conditioners and battery chargers
are running.
2. Have air conditioners and other appliances checked for proper operation. (A locked compressor rotor can cause very low power factor.)
GOVERNOR ACTUATOR FAULT—CODE NO. 19
(Controller sensed open or short circuit)
Corrective Action: See an authorized Onan dealer.
GOVERNOR ACTUATOR OVERLOAD FAULT—CODE NO. 22
(Duration of operation at or near full-duty cycle beyond design limit)
Corrective Action: Reduce the number of connected appliances, especially when air conditioners and
battery chargers are running.
Page 30
26
TABLE 4. TROUBLESHOOTING (CONT.)
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.
WARNING
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. 24
(Controller did not sense temperature change during first 5 minutes of operation)
Corrective Action: See an authorized Onan dealer.
ENGINE ABOVE SPEED TARGET FAULT—CODE NO. 25
(Governor unable to regulate to target speed)
Corrective Action: See an authorized Onan dealer.
ENGINE BELOW SPEED TARGET FAULT—CODE NO. 26
(Governor unable to regulate to target speed)
Corrective Action:
1. Reduce the number of connected appliances, especially when air conditioners and battery chargers
are running.
2. Prime the engine fuel system by holding the control switch down in its Stop position for at least 1 minute.
PMA SENSE LOST FAULT—CODE NO. 27
(Controller unable to sense PMA frequency)
Corrective Action: See an authorized Onan dealer.
DC SENSE LOST FAULT—CODE NO. 28
(Controller unable to sense DC bus voltage)
Corrective Action: Open the circuit breaker. If the fault does not persist, check for and disconnect excessive loads from the genset before starting.
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TABLE 4. TROUBLESHOOTING (CONT.)
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.
WARNING
HIGH BATTERY VOLTAGE FAULT—CODE NO. 29
(Voltage across battery system greater than 17.5 volts)
Corrective Action:
1. Check battery bank connections and reconnect if necessary so that the 12 volt batteries serving the
genset are connected in parallel (12 volt) rather than in series (24 volt).
2. Select a lower battery booster charge rate.
OVERSPEED FAULT—CODE NO. 31
(Engine speed greater than 3600 rpm)
Corrective Action: See an authorized Onan dealer.
LOW CRANKING SPEED FAULT—CODE NO. 32
(Cranking speed less than 180 rpm for more than 2 seconds)
Corrective Action:
1. Replace Fuse F2 (starter solenoid) if blown (Page 6).
2. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery and at
the genset (Page 16).
3. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
4. Replace the engine oil with oil of proper viscosity for the ambient temperature (Page 15). (High oil
viscosity can slow cranking speed.)
HIGH ENGINE COOLANT TEMPERATURE FAULT—CODE NO. 33
(Engine coolant temperature exceeded design limit)
Corrective Action:
1. Check the engine coolant level and add coolant and repair leaks as necessary (Page 19).
2. Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset.
3. Reduce the number of appliances connected at the same time. (Note that high altitude and high ambient temperature decrease engine cooling capacity.)
4. Clean and flush the cooling system to remove coolant passage fouling.
5. If the genset overheats only underway, see the coach manufacture regarding air baffles or other
means to direct cooling air into the genset.
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TABLE 4. TROUBLESHOOTING (CONT.)
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.
WARNING
HIGH INVERTER TEMPERATURE FAULT—CODE NO. 34
(Inverter heat sink temperature exceeded design limit*)
Corrective Action:
1. Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset.
2. Reduce the number of appliances connected at the same time. (Note that high altitude and high ambient temperature decrease cooling capacity.)
CONTROL CARD FAILURE FAULT—CODE NO. 35
(Microprocessor EEPROM error during self-test)
Corrective Action: See an authorized Onan dealer.
ENGINE STOPPED FAULT—CODE NO. 36
(Engine stopped without command by controller)
Corrective Action:
1. Check fuel level. (Note: The genset fuel pickup is probably higher than the vehicle engine pickup.)
2. Prime the engine fuel system by holding the control switch down in its Stop position for at least 1 minute.
3. Check the engine air filter and remove any blockage (Page 16).
4. Check for mechanical damage.
INVALID GENSET CONFIGURATION FAULT—CODE NO. 37
(Genset configuration is preprogrammed at the factory)
Corrective Action: See an authorized Onan dealer.
OVERCURRENT FAULT—CODE NO. 38
(Too many loads connected)
Corrective Action: Reduce the number of appliances running at the same time, especially those with
high motor starting loads such as air conditioners. Start up with no load and let the genset run for five
minutes to cool down the inverter.
PROCESSOR FAULT—CODE NO. 42
(Microprocessor ROM error during self-test)
Corrective Action: See an authorized Onan dealer.
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29
TABLE 4. TROUBLESHOOTING (CONT.)
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.
WARNING
PROCESSOR FAULT—CODE NO. 43
((Microprocessor RAM error during self-test)
Corrective Action: See an authorized Onan dealer.
INVERTER POWER SUPPLY FAULT—CODE NO. 46
(Low battery voltage or power supply device failure)
Corrective Action:
1. Avoid running the genset while cranking the vehicle engine in installations where the genset batteries
are used to supplement the vehicle engine batteries.
2. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery, vehicle
frame and genset (Page 16).
3. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
4. Install or service a battery charging system in the vehicle if the genset is not so equipped.
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30
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
Frequency 60 Hz 60 Hz 60 Hz
Number of Phases 1 1 1
Current 50.0 ampere 62.5 ampere 66.7 ampere
Line Circuit Breaker(s) 2-pole, 30 amp 2-pole, 30 or 35 amp 2-pole, 30 or 35 amp
ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection, 4-Stroke Cycle Diesel
Bore 2.64 inch (67 mm)
Stroke 2.68 inch (68 mm)
Displacement 44 inch3 (719 cc)
Compression Ratio 23 : 1
Oil Capacity (with filter)*
3 quart (2.6 l)
Cooling System Capacity**
4.2 quart (4 l)
Intake and Exhaust Valve Lash (Cold)
0.0065 inch (0.165 mm)
OPERATING SPEED RANGE:
1600 to 2900 RPM 1600 to 3200 RPM 1600 to 3300 RPM
FUEL CONSUMPTION:
No-load
Half-load (4000 W)
Full-load
.13 gph (.49 l/h)
.49 gph (1.85 l/h)
.80 gph (3.03 l/h)
.13 gph (.49 l/h)
.49 gph (1.85 l/h)
.96 gph (3.63 l/h)
.13 gph (.49 l/h)
.49 gph (1.85 l/h)
1.02 gph (3.86 l/h)
DC SYSTEM:
Nominal Battery Voltage
12 volts
Minimum Battery Capacity
450 CCA*** down to 0° F (−17° C)
650 CCA*** down to −20° F (−29° C)
Maximum Regulated-Voltage Battery
Charging Current (Optional)
10 ampere
Fuse F1 (control circuit)
10 ampere mini-bayonet
Fuse F2 (starter solenoid circuit)
10 ampere mini-bayonet
Fuse F3 (glow plug circuit)
25 ampere
WEIGHT AND SIZE:
Weight (wet)
Length x Width x Height
420 lbs (191 kg)
36.3 x 23.6 x 22.3 inch (922 x 599 x 566 mm)
* See oil filling instructions.
** Includes coolant recovery tank.
*** Cold Cranking Amps @ 0° F (−17° C)
Page 35
31
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) 6000 W 7500 W 8000 W
Voltage 120 volts 120 volts 120 volts
Frequency 60 Hz 60 Hz 60 Hz
Number of Phases 1 1 1
Current 50.0 ampere 62.5 ampere 66.7 ampere
Line Circuit Breaker(s) 2-pole, 30 amp 2-pole, 30 or 35 amp 2-pole, 30 or 35 amp
ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection, 4-Stroke Cycle Diesel
Bore 2.64 inch (67 mm)
Stroke 2.68 inch (68 mm)
Displacement 44 inch3 (719 cc)
Compression Ratio 23 : 1
Oil Capacity (with filter)*
3 quart (2.6 l)
Cooling System Capacity**
4.2 quart (4 l)
Intake and Exhaust Valve Lash (Cold)
0.0065 inch (0.165 mm)
OPERATING SPEED RANGE:
1600 to 2900 RPM 1600 to 3200 RPM 1600 to 3300 RPM
FUEL CONSUMPTION:
No-load
Half-load (4000 W)
Full-load
.13 gph (.49 l/h)
.49 gph (1.85 l/h)
.80 gph (3.03 l/h)
.13 gph (.49 l/h)
.49 gph (1.85 l/h)
.96 gph (3.63 l/h)
.13 gph (.49 l/h)
.49 gph (1.85 l/h)
1.02 gph (3.86 l/h)
DC SYSTEM:
Nominal Battery Voltage
12 volts
Minimum Battery Capacity
450 CCA*** down to 0° F (−17° C)
650 CCA*** down to −20° F (−29° C)
Maximum Regulated-Voltage Battery
Charging Current (Optional)
10 ampere
Fuse F1 (control circuit)
10 ampere mini-bayonet
Fuse F2 (starter solenoid circuit)
10 ampere mini-bayonet
Fuse F3 (glow plug circuit)
25 ampere
WEIGHT AND SIZE:
Weight (wet)
Length x Width x Height
420 lbs (191 kg)
36.3 x 23.6 x 22.3 inch (922 x 599 x 566 mm)
* See oil filling instructions.
** Includes coolant recovery tank.
*** Cold Cranking Amps @ 0° F (−17° C)
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Information for California Genset Users
These gensets meet the requirements of California’s Exhaust Emissions Standards as stated on the
nameplate (Page 3).
As a California user of these gensets, please be
aware that unauthorized modifications or replacement of fuel, exhaust, air intake, or speed control
system components that affect engine emissions
are prohibited. Unauthorized modification, removal
or replacement of the genset label is prohibited.
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.
California genset users may use Table 5 as an aid in
locating information related to the California Air Resources Board requirements for emissions control.
TABLE 5. EMISSIONS CONTROL INFORMATION
Genset Warranty Information
The California emissions control warranty statement is located in
the same packet of information as this manual when the genset is
shipped from the factory.
Engine Valve Clearance (Lash) See Specifications (Page 30).
Engine Fuel Requirements
The engine is certified to operate on diesel fuel. See FUEL RECOMMENDATIONS (Page 5).
Engine Lubricating Oil Requirements See ENGINE OIL RECOMMENDATIONS (Page 5).
Engine Adjustments
High Idle Speed. This is a service procedure requiring trained
personnel and proper tools. See the Service Manual.
Engine Emission Control System
The engine emission control system consists of engine design
and precision manufacture. (IFI)
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33
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:
1. Check the North American Sales and Service
Directory (F-118) and the International Sales
and Service Directory (IN-1013) supplied with
your Onan genset. These directories list authorized distributors who will assist you in locating
the nearest authorized dealer.
2. Consult the Yellow Pages. Typically, our distributors are listed under:
GENERATORS − ELECTRIC,
ENGINES − GASOLINE OR DIESEL, or
RECREATIONAL VEHICLES − EQUIPMENT,
PARTS AND SERVICE.
3. Call 1-800-888-ONAN for the name and telephone number of the nearest Onan dealer in
the United States or Canada. (This automated
service utilizes touch-tone phones only). By
calling this number you can also request a di-
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. If you have difficulty in arranging
for service or resolving a problem, please contact
the dealer coordinator or service manager at the
nearest Onan dealer for assistance.
Before calling for service, have the following information available:
1. The complete genset model number and serial
number. See Model Identification (Page 4).
2. The date of purchase
3. The nature of the problem. See Troubleshoot-
ing (Page 21).
WARNING
Improper service or replacement of
parts can result in severe personal injury, death,
and/or equipment damage. Service personnel
must be qualified to perform electrical and/or
mechanical service.
Page 38
34
Maintenance Record
Record all periodic and unscheduled maintenance and service. See Periodic Maintenance (Page 12).
DATE
HOUR
METER
READING
MAINTENANCE OR SERVICE PERFORMED
Record the name, address, and phone number of your authorized Onan service center.
Page 39
Page 40
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email www.cumminsonan.com/contact
www.cumminsonan.com
CumminsR, OnanR, the “C” logo, and “Performance you rely on.”
are trademarks of Cummins Inc.
E2010 Cummins Power Generation, Inc. All rights reserved.
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