Operator Manual RV Generator Set HDKCA HDKCB English 1−2009 981−0173 (Issue 5)
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 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii 1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Changing Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY PRECAUTIONS • Engine cooling air must not be used for heating the vehicle. 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. 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.
BATTERY GAS IS EXPLOSIVE • Keep the genset and its compartment clean. Excess oil and oily rags can catch fire. Dirt and gear stowed in the compartment can restrict cooling air. • Wear safety glasses. • Do not smoke. • Make sure all fasteners are secure and torqued properly. • To reduce arcing when disconnecting or reconnecting battery cables, always disconnect the negative (−) battery cable first and reconnect it last.
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 operating the genset and maintaining top performance.
HOW TO OBTAIN SERVICE RECREATIONAL VEHICLES − EQUIPMENT, PARTS AND SERVICE. 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.
ENGINE EMISSIONS COMPLIANCE The label that states compliance with applicable engine emissions regulations is located on the side of the Power Unit, 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. FIGURE 1-3.
TYPICAL GENSET cooling and ventilating air and the maintenance and service access panels of a typical genset. Not shown are the combustion air inlet and oil drain openings in the base. Figure 1-4 illustrates the fuel, battery, remote control and AC output connection points, the flow of AC OUTPUT AND REMOTE CONTROL CONNECTIONS MAINTENANCE ACCESS CONTROL PANEL FUEL CONNECTIONS EXHAUST CONNECTIONS BATTERY CONNECTIONS COOLING & VENTILATING AIR IN HOT AIR OUT FIGURE 1-4.
2. Operation FUEL RECOMMENDATIONS ENGINE OIL RECOMMENDATIONS Oil Performance Class 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 multiclass ABC fire extinguisher handy.
RECOMMENDED COOLANT the genset shuts down, it will blink a numerical code to indicate the nature of the fault shutdown (see Section 4. Troubleshooting). 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 recommendedfor all climates and is suitable for temperatures down to -34° F (-37° C).
LINE CIRCUIT BREAKER(S) COOLANT RECOVERY TANK FILL CAP COOLANT RECOVERY TANK FLUID LEVEL CONTROL SWITCH &STATUS LAMP HOUR METER FIGURE 2-2.
WARNING PRIMING THE FUEL SYSTEM EXHAUST GAS is deadly. All en- gine exhaust contains carbon monoxide; an odorless, colorless, poisonous gas that can cause unconsciousness and death. Symptoms of carbon monoxide poisoning include: • Dizziness • Nausea • Vomiting 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 half a minute. (Shutdown Code No.
AUTOMATIC STARTING AND STOPPING 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 vehicle may be equipped with an inverter-charger or other automatic genset starting device (AGS). Always follow the instructions and safety precautions provided by the manufacturer of the automatic starting device when enabling automatic genset starting.
RESETTING CIRCUIT BREAKERS OPERATING IN COLD WEATHER If a circuit breaker in the main power distribution panel of the vehicle or on the genset (Figure 2-2) trips, either a circuit shorted or too many appliances were running. Note that the genset will continue to run after a circuit breaker trips. Make sure the engine oil viscosity is appropriate for the cold weather temperatures. See ENGINE OIL RECOMMENDATIONS (Page 2-1). Be sure to change the oil if a sudden drop in temperature occurs.
BREAKING IN A NEW ENGINE CARBON MONOXIDE is deadly and can accumulate to dangerous levels in garages and other confined spaces. Disable the automatic genset starting feature of an inverter-charger or other automatic starting device before storing the vehicle. WARNING 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.
3. Periodic Maintenance Periodic maintenance is essential for top performance and long genset life. Use Table 3-1 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. any engine repair establishment or individual. However, warranty work must be completed by an authorized Cummins Onan dealer. WARNING Accidental or remote starting can cause severe personal injury or death.
GENERAL INSPECTION Inspect the genset before the first start of the day and after every eight hours of operation. Do not operate power ventilators or exhaust fans while the vehicle is standing with the genset running. The ventilator or fan can draw exhaust gases into the vehicle. Oil Level Fuel System Check engine oil level (Figure 3-1). Check for leaks at hose, tube and pipe fittings in the fuel supply system while the genset is running and while it is stopped.
2. Remove the front access door and the oil fill cap, unscrew the oil drain plug and drain all the oil from the engine. Reinstall the oil drain plug securely. 3. Add or drain oil as necessary. See RECOMMENDED ENGINE OIL (p. 2-1). 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.
MAINTAINING THE BATTERY AND BATTERY CONNECTIONS 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.
CLEANING THE SPARK ARRESTOR 1. Remove the top enclosure panel. Refer to Table 3-1 for scheduled cleaning of the spark arrestor muffler (which meets U.S. Forest Service requirements). Cleaning is required for maximum genset performance. 2. Remove the cleanout plug from the muffler. Secure the top enclosure panel before running the genset. With the cover in place there will be enough air flow to cool the engine properly and carry the soot out of the compartment. A hot muffler can cause severe burns.
REPLACING THE FUEL FILTER hoses, use a flare nut wrench on the hose flare nuts, so as not to round the corners, and a second wrench on the filter fitting, so as not to stress the fitting. (Removing the bracket screws first will make the job easier.) See Table 3-1 for scheduled fuel filter replacement. A dirty fuel filter may be the cause of a failure to start. The fuel filter is accessible through the front access door (Figure 3-4). Dirt can damage the fuel system.
MAINTAINING THE ENGINE COOLING SYSTEM Flush and clean the cooling system 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. Refer to Table 3-1 for scheduled maintenance. The engine cooling system is filled at the factory with a 50/50 mixture of ethylene glycol anti-freeze and water, which is suitable for temperatures down to -34° F (-37° C).
COOLANT RECOVERY TANK RECOVERY TANK FILL CAP (BLUE) COOLANT LEVEL COOLANT DRAIN PLUG (1/4 INCH HEX SOCKET) FIGURE 3-5.
4. Troubleshooting TROUBLESHOOTING WITH TABLE 4-1 • Two blinks indicate shutdown due to a loss of engine oil pressure. To aid troubleshooting the genset controller causes the status indicator light to blink the numeric code assigned to the fault that caused shutdown. For a brief description of the fault and step-by-step corrective action, refer to TABLE 4-1. TROUBLESHOOTING, which lists the fault codes in numerical order. • Three blinks indicate a service fault.
TABLE 4-1. TROUBLESHOOTING Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. WARNING NO RESPONSE AT CONTROL SWITCH (Faulty switch, poor or missing connections, dead battery) Corrective Action: 1.
TABLE 4-1. TROUBLESHOOTING Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. WARNING ENGINE OVER TEMPERATURE—CODE NO. 1 (During normal operation engine coolant temperature exceeded 239° F [115° C] for 10 seconds) Corrective Action: 1.
TABLE 4-1. TROUBLESHOOTING Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. WARNING UNDER VOLTAGE—CODE NO. 13 (After voltage regulation was enabled Output Voltage fell to less than 90% of rated for 5 seconds) Corrective Action: Turn OFF the line circuit breaker on the operator’s console.
TABLE 4-1. TROUBLESHOOTING Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. WARNING FAULTY ENGINE TEMPERATURE SENDER—CODE NO. 24 (After 10 minutes of normal operation the Controller checked for and sensed an open temperature sender/harness) Corrective Action: See an authorized Onan dealer.
TABLE 4-1. TROUBLESHOOTING Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. WARNING MECHANICAL FAULT—CODE NO. 36 (The Controller declared this fault because engine speed fell below 1000 RPM for 0.5 seconds, though not by Controller action) Corrective Action: 1.
TABLE 4-1. TROUBLESHOOTING Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. WARNING LOSS OF FIELD SENSE—CODE NO. 48 (The field sense circuit on the Controller circuit board failed during normal voltage regulation) Corrective Action: See an authorized Onan dealer. OVERPRIME—CODE NO.
5. Specifications MODEL: HDKCA HDKCB GENSET CONTROL: Integrated Microprocessor-Based Engine and Generator Controller GENERATOR: Single-Bearing, 4-Pole Rotating Field, 1800 RPM Power (@1.0 power factor) 10,000 W Voltage 120 / 240 Frequency 60 Hz Number of Phases 1 Current 41.7 amps per leg Line Circuit Breaker 2-pole, 45 amp 12,500 W 120 / 240 60 Hz 1 52.1 amps per leg 2-pole, 50 amp FUEL CONSUMPTION: No-load Half-load Full-load 0.11 gph (0.4 lph) 0.48 gph (1.8 lph) 1.01 gph (3.8 lph) 0.11 gph (0.
6. Maintenance Record Record all periodic and unscheduled maintenance and service. See Section 3. Periodic Maintenance. DATE HOUR METER READING MAINTENANCE OR SERVICE PERFORMED Record the name, address, and phone number of your authorized Onan service center.
Cummins Power Generation 1400 73rd 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. E2008 Cummins Power Generation, Inc. All rights reserved.
