CUMMINS HDKAW, Onan HDKAW Operator's Manual
Operator Manual
Generator Set
HDKAW (Spec A)
English 11−2009 A026M828 (Issue 3)
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
SECTION PAGE
Table of Contents i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY PRECAUTIONS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Obtain Service 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Emissions Compliance 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Genset 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. OPERATION 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Recommendations 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Recommendations 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Recommendations 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Batteries 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Panel 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Start Checks 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming the Fuel System 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Starting 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Stopping 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Starting and Stopping 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading the Genset 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting Circuit Breakers 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting to Utility Power 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Cold Weather 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Hot Weather 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating at High Altitude 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Dusty Environments 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Breaking In a New Engine 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercising the Genset 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storing the Genset 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
SECTION PAGE
3. PERIODIC MAINTENANCE 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Inspection 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Engine Oil Level 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Engine Oil and Oil Filter 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining the Battery and Battery Connections 3-4. . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Air Filter Element 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Spark Arrestor 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining/Replacing the Fuel Filter 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining the Engine Cooling System 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. TROUBLESHOOTING 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting With Table 4-1 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Code Blinking 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Restoring Fault Code Blinking 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. SPECIFICATIONS 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. MAINTENANCE RECORD 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
SAFETY PRECAUTIONS
Thoroughly read the OPERATOR’S MANUAL
before operating the genset. Safe operation and
top performance can only be obtained when
equipment is properly operated and maintained.
The following symbols in this manual alert you to
potential hazards to the operator, service person
and equipment.
DANGER
that will result in severe personal injury or
death.
WARNING
practice that can result in severe personal injury or death.
CAUTION
practice that 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.
When equipped with an integral or add-on Automatic Generator Starting System (AGS) control,
exhaust carbon monoxide (CO), electric shock, and
moving parts hazards are possible due to unexpected starting. Turn off AGS whenever performing
maintenance or service, when the vehicle is stored
between uses, is awaiting service, or is parked in a
garage or other confined area.
alerts you to an immediate hazard
alerts you to a hazard or unsafe
alerts you to a hazard or unsafe
• The exhaust system must be installed in accordance with the genset Installation Manual.
• Engine cooling air must not be used for heating
the vehicle.
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 shore
power (utility). Back-feed to shore power can
cause electrocution 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, arcproducing equipment and all other sources of
ignition well away.
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 genset 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
parked in a confined space, such as a garage.
• Disable the automatic genset starting feature
(AGS) of an inverter-charger or other automatic starting device before storing the vehicle or
parking it in a garage or other confined space.
• Fuel lines must be secured, free of leaks and
separated or shielded from electrical wiring.
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.
• Keep guards in place over fans, belts, pulleys,
and other moving parts.
iii
BATTERY GAS IS EXPLOSIVE
• Wear safety glasses.
• Do not smoke near the batteries or near the
generator set.
• To reduce arcing when disconnecting or reconnecting 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
operators of the genset are solely responsible for
operating the genset safely.
GENERAL PRECAUTIONS
• To prevent equipment damage or personal injury, do not store items in the clearance area
around the generator set, especially near the
belt guard end of the generator set.
• 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 readily at hand. Class A fires involve ordinary combustible materials such as wood and cloth.
Class B fires involve combustible and flammable liquids and gaseous fuels. Class C fires
involve live electrical equipment. See NFPA
No. 10 or equivalent—BS EN 3-7:2004 [Portable Fire Extinguishers].
• Genset installation and operation must comply
with all applicable local, state and federal
codes and regulations.
Mobile-8
iv
1. Introduction
ABOUT THIS MANUAL
This is the Operator’s Manual for the generator sets
(gensets) listed on the front cover. Read and carefully observe all of the instructions and precautions
in this manual. 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 top performance. The owner is responsible for performing
maintenance in accordance with the PERIODIC
MAINTENANCE SCHEDULE (p. 3-1).
[The engine family designation, engine displacement, statement
of compliance with the applicable EPA and / or California emissions regulations, including the compliance period or category,
appear in this block on the actual nameplate on the genset.]
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 alarm system must be used if genset operation is critical.
WARNING
Improper service or replacement of
parts can lead to severe personal injury or death
and to damage to equipment and property. Service personnel must be qualified to perform
electrical and mechanical service.
Unauthorized modifications or replacement of
fuel, exhaust, air intake or speed control system
components that affect engine emissions are
prohibited by law in the State of California.
NAMEPLATE
Be ready to provide the genset model and serial
numbers on the nameplate when contacting Cummins Onan for parts, service or information. Figure 1-1 illustrates the nameplate and its location.
The gray boxes illustrate where to look for the model
and serial numbers.
FIGURE 1-1. TYPICAL NAMEPLATE
Record these numbers in Figure 1-2 so that they are
easy to find when needed. Each 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. Genuine Cummins Onan replacement parts are recommended
for best results. Refer to the genset Parts Catalog.
MODEL NUMBER: ___________________________
SERIAL NUMBER: ___________________________
FIGURE 1-2. RECORD NUMBERS HERE
1-1
HOW TO OBTAIN SERVICE
Information to Have Ready
When you call for service, parts, or product literature
(such as the Service Manual or Parts Catalog) for
your genset, contact the nearest authorized Cummins Onan distributor. Cummins Onan has factorytrained representatives to handle your requests for
genset parts and service. For information for contacting our distributors worldwide, go to internet site
www.cumminsonan.com.
In North America
Call 1-800-888-ONAN to contact the nearest Cummins Onan distributor in the United States or Canada. (This automated service utilizes touch-tone
phones only). Select OPTION 1 (press 1) to be automatically connected to the distributor nearest to
you.
If you are unable to contact a distributor using the
automated service, consult the Yellow Pages. Typically, our distributors are listed under:
GENERATORS − ELECTRIC,
ENGINES − GASOLINE OR DIESEL, or
RECREATIONAL VEHICLES − EQUIPMENT,
PARTS AND SERVICE.
Before calling for service, have the following information available:
1. The complete genset model number and serial
number. See the nameplate..
2. The date of purchase.
3. The nature of the problem. See Section 4. Trou-
bleshooting.
ENGINE EMISSIONS COMPLIANCE
The label that states compliance with applicable engine emissions regulations is located on the side
wall of the base pan, as shown circled in Figure 1-3.
Refer also to the FEDERAL EMISSION DESIGN
AND DEFECT LIMITED WARRANTY FOR C. I. ENGINES (DIESELS) that was shipped in the same
package as the Operator’s Manual.
If you have difficulty in arranging service or resolving a problem, please contact the Service Manager
at the nearest Cummins Onan distributor for assistance.
Outside North America
If you are outside North America, call Cummins
Power Generation at 1−763−574−5000 from
7:30 AM to 4:00 PM, Central Standard Time,
Monday through Friday, or fax 1−763−528−7229.
EMISSIONS LABEL
FIGURE 1-3. EMISSIONS LABEL LOCATION
1-2
TYPICAL GENSET
Figures 1-4 and 1-5 illustrate the location of key operating features such as the fuel and battery con-
nection points, control panel switches, hour meter,
the coolant and oil fill locations, and other operating
component locations.
COOLANT AIR BLEED VALVE
REAR CONTROL PANEL CONNECTIONS
WITH COVER AND GENERATOR SET
CONTROL REMOVED FOR CLARITY -
SEE DETAIL
COMPARTMENT AIR
TEMPERATURE
SWITCH
SPARK ARRESTOR PLUG
LINE 1
LINE 2
FIGURE 1-4. TYPICAL GENSET
1-3
LOAD 1
LOAD 2
GROUND STUD
CIRCUIT BREAKER
COOLING/
VENT AIR
IN
HOUR METER
START/STOP/
PRIME
AIR FILTER
COOLANT FILL
OIL
FILL
OIL DIP-
STICK
OIL FILTER
OPTIONAL
BATTERY
AND FUEL CON-
NECTIONS
ON THIS END
COMPARTMENT
COOLING FAN
LIFTING EYE
COOLANT
RECOVERY
TANK
HOT AIR OUT
OIL
DRAIN
HOSE
FUEL
CONNECTIONS
FUEL FILTER
BATTERY
CONNECTIONS
HOT
AIR OUT
COOLING FAN
FIGURE 1-5. GENSET COMPONENT LOCATIONS
1-4
ENGINE COMBUSTION
AIR
2. Operation
FUEL RECOMMENDATIONS
WARNING
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 multiclass ABC fire extinguisher handy.
High quality diesel fuel is necessary for good performance and long engine life.
• The specifications for the type and sulfur content (ppm, % weight) of the diesel fuel used
must comply with all emissions regulations applicable in the areas where the genset is to be
operated.
• Diesel fuels meeting ASTM D975 or EN 590
specifications are recommended. Use Grade
1-D diesel fuel where ambient temperatures
are below 14° F (−10° C). A minimum Fuel Cetane Rating of 45 is recommended. Where ambient temperatures are below −4° F (−20° C), or
the elevation is above 5000 ft (1500 m), a minimum Cetane Rating of 50 is recommended.
• Current US EPA regulations for Non-Road engines limit diesel fuel sulfur content to a maximum of 500 ppm (0.05% weight). Therefore,
use Grade 2-D S500 or 2-D S15 diesel fuel.
Where ambient temperatures are below 14° F
(−10° C), use Grade 1-D S500 or 1-D S15 diesel fuel. Note that beginning in year 2010, US
EPA regulations for Non-Road engines will limit
diesel fuel sulfur content to a maximum of 15
ppm (0.0015% weight).
Diesel fuel is combustible and can
• Do not use diesel fuel having a sulfur content
greater than 10,000 ppm (1.0% weight).
• Diesel fuel must meet the ASTM D975 standard for lubricity and pass a minimum load level
of 3100 grams as measured by ASTM D6078,
or maximum scar diameter of 0.45 mm as measured by ASTM D6079 or ISO 12156−1.
• B20 Bio-Diesel fuel that meets industry specifications and quality is suitable for use with this
genset.
ENGINE OIL RECOMMENDATIONS
Oil Performance Class
Use API (American Petroleum Institute) classified
engine oils according to the following guidelines:
• Emissions-Regulated Areas: It is mandatory
to use CF, CF−4, CG−4, CH−4 or CI−4 class oil
with low sulfur fuel (sulfur content less than 500
ppm, 0.05% weight) or ultra low sulfur fuel (sulfur content less than 15 ppm, 0.0015% weight).
• Non-Regulated Areas: CF class oil is recommended when using high sulfur fuel—sulfur
content between 500 ppm (0.05% weight) and
5000 ppm (0.5%weight). If CF−4, CG−4, CH−4
or CI−4 class oil is used, the oil and oil filter
must be changed twice as often as specified in
the PERIODIC MAINTENANCE SCHEDULE
(Page 3-1).
• Non-Regulated Areas: Use CF, CF−4, CG−4,
CH−4 or CI−4 class oil when using high sulfur
fuel—sulfur content between 5000 ppm (0.5%
weight) and 10,000 ppm (1.0% weight). The oil
and oil filter must be changed twice as often as
specified in the PERIODIC MAINTENANCE
SCHEDULE (Page 3-1).
2-1
Oil Viscosity
Look for the SAE (Society of Automotive Engineers)
viscosity grade. Referring to Figure 2-1, choose the
viscosity grade appropriate for the ambient temperatures expected until the next scheduled oil change.
Multi-grade oils such as SAE 15W-40 are recommended for year-round use.
30
15w40
10w30, 10w40
5w30
0w40
FIGURE 2-1. OIL VISCOSITY VS. TEMPERATURE
COOLANT RECOMMENDATIONS
Use the best quality ethylene glycol antifreeze solution available. It should be fully formulated with rust
inhibitors and coolant stabilizers and mixed with
fresh (distilled) water that is low in minerals and corrosive chemicals. A 50/50 mixture is recommended
for all climates and is suitable for temperatures
down to -34
See Section 5. Specifications for coolant capacity.
Coolant Recovery Tank Fill Cap − The recovery
tank provides for coolant expansion. Replenish the
normal loss of coolant by filling here.
° F (-37° C).
STARTING 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 MAINTAINING THE BATTERY AND BATTERY
CONNECTIONS (p. 3-4) and Section 5. Specifi-
cations for minimum required battery ratings.
CONTROL PANEL
The control panel (Figure 2-2) 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 Lamp − This is a lamp in the control switch
that blinks rapidly during preheat and cranking. It
stays on continuously while the genset is running. If
the genset shuts down, it will blink a numerical code
to indicate the nature of the fault shutdown (see
Section 4. Troubleshooting).
(Rapid blinking before cranking starts indicates that
the glow plugs are preheating the combustion
chambers. The genset controller automatically varies the time based on engine temperature.)
Line Circuit Breaker(s) − The line circuit breakers
protect the AC power leads connected to the genset.
Hour Meter − The hour meter records the total run-
ning time of the genset. It cannot be reset.
REMOTE CONTROL PANEL
A remote genset control panel can be installed inside the vehicle. Three control panel kits are available:
• Remote switch / status lamp
• Remote switch / status lamp and hour meter
• Remote switch / status lamp and DC voltmeter
The DC voltmeter indicates whether voltage across
the 12 VDC control system and battery is normal. If
the indicator consistently stays above or below the
normal zone, see MAINTAINING THE BATTERY
AND BATTERY CONNECTIONS (p. 3-4).
2-2
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