HDKAL, HDKAQ, HDKAR, HDKAS

Generator Sets

Printed in U.S.A. 1-97 981-0148

Table of Contents
TITLE PAGE
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Feature and Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Controls and Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PRE-START CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exhaust Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STARTING AND STOPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WATTAGE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AC Wattage Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATING RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Break-In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
No-Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exercise Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Low Temperature/High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . 11
Extremely Dusty or Dirty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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.

i
TITLE PAGE
MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Generator Set Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Oil and Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
AC Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Muffler/Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cleaning the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
GENERATOR SET STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DC Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
AC Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INFORMATION FOR CALIFORNIA GENSET USERS . . . . . . . . . . . . . . . . 29
HOW TO OBTAIN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

ii
Safety Precautions
Thoroughly read the OPERATOR’S MANUAL or reproductive toxicity. Do not ingest, inhale, or
before operating the genset. Safe operation and contact used oil or its vapors.
top performance can be obtained only with
proper operation and maintenance. • Benzene and lead in some gasolines have
been identified by some state and federal
The following symbols in this Manual alert you to po- agencies as causing cancer or reproductive
tential hazards to the operator, service person and toxicity. Do not to ingest, inhale or contact gaso-
equipment. line or its vapors.

Alerts you to an immediate hazard • Do not work on the genset when mentally or
which will result in severe personal injury or physically fatigued or after consuming alcohol
death. or drugs.
WARNING Alerts you to a hazard or unsafe • Carefully follow all applicable local, state and
practice which can result in severe personal in- federal codes.
jury or death.
GENERATOR VOLTAGE IS DEADLY!
CAUTION Alerts you to a hazard or unsafe
practice which can result in personal injury or
equipment damage. • Generator output connections must be made
by a qualified electrician in accordance with ap-
plicable codes.
Electricity, fuel, exhaust, moving parts and batteries
present hazards which can result in severe personal
injury or death. • The genset must not be connected to the public
utility or any other source of electrical power.
GENERAL PRECAUTIONS Connection could lead to electrocution of utility
workers, damage to equipment and fire. An ap-
proved switching device must be used to pre-
• Keep ABC fire extinguishers handy.
vent interconnections.
• Make sure all fasteners are secure and torqued
properly. • Use caution when working on live electrical
equipment. Remove jewelry, make sure cloth-
• Keep the genset and its compartment clean. ing and shoes are dry and stand on a dry wood-
Excess oil and oily rags can catch fire. Dirt and en platform on the ground or floor.
gear stowed in the compartment can restrict
cooling air. FUEL IS FLAMMABLE AND EXPLOSIVE

• Before working on the genset, disconnect the • Keep flames, cigarettes, sparks, pilot lights,
negative (−) battery cable at the battery to pre- electrical arc-producing equipment and
vent starting. switches and all other sources of ignition well
away from areas where fuel fumes are present
• Use caution when making adjustments while and areas sharing ventilation.
the genset is running—hot, moving or electri-
cally live parts can cause severe personal inju- • Fuel lines must be secured, free of leaks and
ry or death. separated or shielded from electrical wiring.

• Used engine oil has been identified by some • Use approved non-conductive flexible fuel
state and federal agencies as causing cancer hose for fuel connections at the genset.

iii
 ENGINE EXHAUST IS DEADLY! BATTERY GAS IS EXPLOSIVE
• Learn the symptoms of carbon monoxide poi-
soning in this Manual. • Wear safety glasses and do not smoke while
servicing batteries.
• Never sleep in the vehicle while the genset is
running unless the vehicle has a working car- • When disconnecting or reconnecting battery
bon monoxide detector. cables, always disconnect the negative (−) bat-
tery cable first and reconnect it last to reduce
• The exhaust system must be installed in accor- arcing.
dance with the genset Installation Manual.
• Do not use engine cooling air to heat the vehicle DO NOT OPERATE IN FLAMMABLE AND
interior. EXPLOSIVE ENVIRONMENTS
• Make sure there is ample fresh air when operat-
ing the genset in a confined area. Flammable vapor can cause a diesel engine to
overspeed and become difficult to stop, resulting in
MOVING PARTS CAN CAUSE SEVERE possible fire, explosion, severe personal injury and
PERSONAL INJURY OR DEATH death. Do not operate a diesel-powered genset
where a flammable vapor environment can be
• Do not wear loose clothing or jewelry near mov- created by fuel spill, leak, etc., unless the genset
ing parts such as PTO shafts, fans, belts and is equipped with an automatic safety device to
pulleys. block the air intake and stop the engine. The
• Keep hands away from moving parts. owners and operators of the genset are the ones
solely responsible for operating the genset safely.
• Keep guards in place over fans, belts, pulleys, Contact your authorized Onan/Cummins dealer or
etc. distributor for more information.
Mobile-3

iv
Introduction

ABOUT THIS MANUAL MODEL IDENTIFICATION

This manual shows how to operate and maintain Have the following information ready when you call
the Onan® HDKAL, HDKAQ, HDKAR, and HDKAS a distributor:
generator set. Study the manual and heed all warn- • Model number
ings and cautions. Using the genset properly and • Serial number
maintaining it regularly will promote longer set life,
better performance, and safer operation. These are found on the nameplate (Figure 1).

The Operating Recommendations section covers Record these numbers from your generator set in
the break-in procedure and the effects of high alti- the area provided in Figure 1. Make sure that all
tude and variations in climate. The Wattage Re- numbers are recorded correctly.
quirements section describes the wattage capacity
of the set and lists the wattage use of common ap- FEATURE AND COMPONENT LOCATIONS
pliances and tools. Familiarize yourself and others
The standard control panel and the routine mainte-
who will operate this set with this information.
nance items are shown in Figure 2.
WARNING This genset is not a life support sys-
tem. It can stop without warning. Children, per-
sons with physical or mental limitations, and
pets could suffer personal injury or death. A
personal attendant, redundant power or a warn-
ing system must be used if genset operation is
critical.

RECORD COMPLETE
MODEL AND SERIAL
NUMBER HERE

MODEL NUMBER

SERIAL NUMBER
IMPORTANT ENGINE INFORMATION

Onan Onan
ONAN CORPORATION
R 1400 73rd Ave. NE R
Minneapolis, MN 55432
Made in USA

Model No. kvA kW:

S/N: Pf: RPM:
AC Volts Hz: Bat:
Amps:
Fuel:
Options: Wiring Diagram:

REFER TO OPERATOR’S MANUAL FOR MAINTENANCE

SPECIFICATIONS AND ADJUSTMENTS
THIS ENGINE MEETS 1995−1998 CALIFORNIA
EMISSION REGULATIONS FOR ULGE ENGINES.

ONAN NAMEPLATE

FIGURE 1. MODEL IDENTIFICATION

1
 FAULT SENSORS
START-STOP- (AT REAR OF SET)
PREHEAT FRONT
SWITCH AC OUTPUT DC ALTERNATOR OIL FILL
BOX AIR (AT REAR OF SET)
AC CIRCUIT CLEANER FRONT OIL
BREAKERS ASSY. STOP CHECK
SOLENOID
LIFTING
ASSY.
BRACKET
DC CONTROL SIDE
BREAKER OIL FILL

COOLANT FILL
(FLEXIBLE TUBE)

RADIATOR

DC
CONTROL
BOX

FAULT RESET
BREAKER COOLANT DRAIN
(AT LOWER
REAR EDGE OF
RADIATOR)
FUEL OIL FILTER
FUEL FILTER PUMP
VOLTAGE SIDE OIL
REGULATOR CHECK ASSY.

FIGURE 2. HDKAL/HDKAQ/HDKAR/HDKAS GENERATOR SET

2
Control Panel

This section describes the features of the standard DC Control Breaker: A 15 ampere DC breaker that
control panel. The set controls and breakers are lo- protects the control box and remote wiring from
cated on the front of the DC control box. The line short circuits or overload. Also serves as an emer-
circuit breaker is located on the front of the AC con- gency stop switch.
trol box. See Figure 3.. In some installations the DC
control box and line circuit breaker is remotely Fault Reset Breaker: A manual reset breaker that
mounted. The commercial HDKAL/HDKAS gener- shuts down the engine for:
ator set has environmental covers over the • Low oil pressure
switches and circuit breakers, and rubber boots • High coolant temperature
over the electrical connectors. • Overspeed
Controls and Breakers Line Circuit Breaker(s): A circuit breaker or break-
Start/Stop/Preheat Switch: Starts and stops the ers that protect customer wiring from a short circuit
generator set. Operates the engine cylinder or other overload. They are mounted on the front of
preheaters. the AC control box. Different sizes and configura-
tions are supplied depending on the model.

AC OUTPUT BOX (PARTIALLY

HIDDEN BEHIND AIR
START-STOP- CLEANER ASSEMBLY) LINE CIRCUIT
PREHEAT BREAKER(S) (SIZE
SWITCH AND CONFIGURATION
VARY)

Stop Start
DC CONTROL
Push stop to preheat 20 sec max
BREAKER See manual for preheat instructions

DC
HOURMETER Control
Breaker

FAULT RESET
BREAKER

Fault Breaker

NOTE: IN SOME APPLICATIONS, THE

CONTROL BOX AND BREAKER BOX
ARE REMOTELY MOUNTED

FIGURE 3.. GENERATOR SET CONTROLS AND BREAKERS

3
Pre-Start Checks

ENGINE OIL Checking Engine Oil Level

Check the engine oil level (with the coach on level Do not operate the engine with the
ground) before each start. When the generator set oil below the ADD mark or above the FULL mark.
is new, the engine must be filled with oil before the Overfilling can cause foaming or aeration of the
initial start. The engine oil capacity is 4.26 liters (4.5 oil, while operation below the ADD mark might
quarts). cause loss of oil pressure.
If adding oil between changes, use the same brand Check the engine oil level at the intervals shown in
because different brands might not be compatible Table 4. The oil dipstick and fill are located as
when mixed. Be careful not to overfill the crankcase shown in Figure 4. The dipsticks are stamped with
because the oil may foam or overflow through the FULL and ADD to indicate the oil level in the crank-
breather, resulting in engine shutdown. case. For an accurate reading, shut off the engine
and wait 10 minutes before checking the level. This
Oil Recommendations lets oil in the upper part of the engine drain into the
Use oils with the American Petroleum Institute (API) crankcase.
classification CC and later in viscosities shown be-
low in Table 1. Keep the oil level near as possible to the FULL mark
on the dipstick. Remove the oil fill cap and add the
Select the oil viscosity that is right for the lowest same type of oil when necessary.
temperature expected. Oil that is too thick may not
lubricate when the engine is started. Use a lower Do not operate the engine with the
viscosity oil as the ambient temperature gets colder. oil level below the ADD mark or above the FULL
mark. Overfilling can cause foaming or aeration
Do not use synthetic oil or non-detergent oil. Do not of the oil, while operation below the ADD mark
mix different brands of oil. can cause loss of oil pressure.

TABLE 1. OIL VISCOSITY VS. TEMPERATURE

Anticipated Ambient Temperature

4
 TOP OIL FILL SIDE OIL FILL FRONT
OIL FILL

FRONT OIL
DIPSTICK

SIDE OIL
DIPSTICK

ADDITIONAL OIL DRAIN OIL FILTER

PLUG UNDER SET; ACCESS DRAIN
THROUGH DRIP PAN HOLE VALVE

FIGURE 4. ENGINE OIL

EXHAUST CHECK Do not start the set if exhaust gases will not effec-
tively expel away from the vehicle. Be aware that
any vent, window or opening that is not permanently
Thoroughly inspect the exhaust system for leaks or sealed from the vehicle living space can be an ave-
corrosion. Make certain that the tailpipe extends an nue for carbon monoxide.
inch beyond the perimeter of the vehicle. Have any
problems repaired before operating the generator Exhaust gases can cause severe
set. personal injury or death. Never operate the gen-
erator set unless the exhaust outlet is clear of
walls, snow banks, or any obstructions that can
Exhaust gas presents the hazard of prevent exhaust gases from dissipating. Never
severe personal injury or death. Make certain operate any exhaust fan in the vehicle when the
that all exhaust components are operational generator set is running: an exhaust fan can
and that there are no exhaust leaks. draw exhaust gas into the vehicle.

5
 FUEL CHECK diesel fuel when ambient temperatures are below
32° F (0° C), and during long periods of light engine
Carefully inspect the fuel system for leaks or corro- load.
sion. Have any problems repaired immediately.
Use low sulfur content fuel which has a cloud point
Fuel presents the hazard of fire or at least 10 degrees below the lowest expected fuel
explosion which can cause severe personal in- temperature. (Cloud point is the temperature at
jury or death. Do not permit any flame, spark, pi- which wax crystals begin to form in diesel fuel.)
lot light, cigarette, or other ignition source near
the fuel system. GENERAL INSPECTION
Use the best fuel available. Fuel quality is important Check the generator set for damaged or loose
for dependable performance and satisfactory en- parts. Make sure the air inlet and outlet areas are
gine life. not blocked. Investigate any abnormal operating
noises. Make sure that the generator set is securely
Ignition of fuel can cause serious
mounted in its compartment or under-floor housing.
personal injury or death by fire or explosion. Do
not permit any flame, cigarette, pilot light, spark
Check to see that the vehicle is not parked in high
or other igniter near the fuel system.
grass or brush.
Fuel Recommendation
Do not operate the generator set
Use ASTM 2-D (No. 2 Diesel) or ASTM 1-D (No. 1 when the vehicle is parked in high grass or
Diesel) fuel with a minimum Cetane number of 45. brush. Engine exhaust could ignite the grass,
Number 2 diesel fuel gives the best economy and and the resulting fire could cause severe per-
performance under most conditions. Use number 1 sonal injury or death, and/or property damage.

6
Starting and Stopping

EXHAUST GAS IS DEADLY!

Exhaust gases contain carbon monoxide, an odorless and colorless gas.

Carbon monoxide is poisonous and can cause unconsciousness and
death. Symptoms of carbon monoxide poisoning can include:
• Dizziness • Throbbing in Temples
• Nausea • Muscular Twitching
• Headache • Vomiting
• Weakness and Sleepiness • Inability to Think Coherently

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS,

GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek
medical attention. Shut down the unit and do not operate until it has been
inspected and repaired.

Never sleep in the vehicle with the generator set running unless the vehi-
cle interior is equipped with an operating carbon monoxide detector. Pro-
tection against carbon monoxide inhalation also includes proper exhaust
system installation and visual and audible inspection of the complete ex-
haust system at the start of each generator set operation.

STARTING 3. If the engine does not start after cranking 30

seconds, release the switch. Wait two minutes,
Starting at Set then repeat Step 1 (preheat).
1. Press the Start/Stop/Preheat switch to Stop/
Preheat. Hold for up to 20 seconds, depending Excessive cranking can over-
on the temperature (see Table 2). heat the starter, damaging it. Do not engage
the starter longer than 30 seconds without
Preheat time longer than 20 sec- allowing two minutes for cooling.
onds may damage glow plugs.
4. If the engine does not start on the second try:
TABLE 2. PREHEAT TIME vs. TEMPERATURE
• Check the fuel supply.
Ambient Temperature Preheat Time
• Make sure the fuel system has been primed.
Above 50° F (10° C) 10 seconds
With an empty tank, the fuel system may need
Between 0° to 50° F 15 seconds priming before the set can start. See Fuel Sys-
(-17° to 10° C) tem in the Maintenance Section.
Below 0° F (-17° C) 20 seconds Starting at Remote Panel
The same procedures and cautions for normal
starting apply to remote starting.
2. Press the Start/Stop/Preheat switch to Start.
Release the switch when the engine starts.

7
Start-up Checks (Optional Remote Panel)
Check the gauges (if equipped) on the control box
after the engine starts. Check the oil pressure
gauge immediately.

Oil Pressure Gauge: Oil pressure should be 40 to

60 psi (276 to 414 kPa) when the engine is at oper-
ating temperature.

DC Voltmeter: Battery voltage during operation

should be 14 to 15 volts, depending on the state of
battery charge.

Water Temperature Gauge: Water temperature

should be 165° to 195° F (74° to 91° C) depending
on load and ambient temperature.

STOPPING
Before Stopping
Run the genset at no load three to five minutes be-
fore stopping. This lets the lubricating oil and en-
gine coolant carry heat away from the combustion
chamber and bearings.

Failure to allow running time for en-

gine cooling without load can cause engine
damage. Make sure the generator set runs un-
loaded at least three minutes.

To Stop: Press the Start/Stop/Preheat switch to the

stop position.

8
Wattage Requirements

AC WATTAGE CAPACITY Electrical shock can cause severe

personal injury or death. Appliances should be
The AC power output from the generator will power in good working condition and be properly
appliances and other equipment. (The wattage re- grounded to provide additional protection from
quirement of appliances and electrical equipment electrical shock.
may be referred to as “electrical load”.)
TABLE 3. APPROXIMATE POWER DRAW OF
Connecting a Load COMMON APPLIANCES
To determine the maximum amount of electrical Appliance or Tool Approximate
load that can be applied, follow these steps: Running Wattage
1. Determine the maximum load which your gen- Air Conditioner . . . . . . . . . . . . . . . 1400-2000
erator can operate. In most cases this will be Battery Charger . . . . . . . . . . . . . . Up to 800
determined by the rating which is listed on the Coffee Percolator . . . . . . . . . . . . 550-750
nameplate. There are a few cases where the Converter . . . . . . . . . . . . . . . . . . . 300-500
circuit breaker rating is the limiting factor. Electric Blanket . . . . . . . . . . . . . . 50-200
Choose the lower of the circuit breaker rating Electric Broom . . . . . . . . . . . . . . . 200-500
or name plate rating. Electric Drill . . . . . . . . . . . . . . . . . 250-750
Electric Frying Pan or Wok . . . . 1000-1500
2. Check the wattage requirement of each device Electric Iron . . . . . . . . . . . . . . . . . 500-1200
to be connected (See Table 3.). The appliance Electric Stove (Per Element) . . . 350-1000
nameplate should list the wattage or current Electric Water Heater . . . . . . . . . 1000-1500
rating. Hair Dryer . . . . . . . . . . . . . . . . . . . 800-1500
Microwave Oven . . . . . . . . . . . . . 1000-1500
3. Add the wattages of all items to be powered at Radio . . . . . . . . . . . . . . . . . . . . . . . 50-200
the same time. Make sure that the total watt- Refrigerator . . . . . . . . . . . . . . . . . 600-1000
age (or current) does not exceed the rating of Space Heater . . . . . . . . . . . . . . . . 1000-1500
the generator set or circuit breaker, whichever Television . . . . . . . . . . . . . . . . . . . 200-600
is smaller.

Motorized Devices
Example:
Motorized devices (such as air conditioners) con-
Air Conditioner 1800 watts sume more power during startup than they do when
Converter 500 watts running at normal speed (Some motors draw as
Coffee Percolator 600 watts much as three times their operating power during
Television 300 watts startup). If you plan to use a motorized device, turn
Total 3200 watts it on before starting other appliances. When the
motor is running at normal speed, more devices
4. Start the generator set and let it warm up a few may be added.
minutes before applying electrical load.

Make sure that each appliance or tool is properly

grounded and in good working condition before us-
ing it.

9
Circuit Breakers outlet) only through an approved device, to protect
against the possibility of generator power and utility
Circuit breakers on the electrical distribution panel power being connected. Consult the Installation
or on the genset will open if their current ratings are Manual (publication 981-0605) for information on
exceeded. This may be caused either by running isolating the genset from utility-supplied power.
too many appliances at once, or by a short circuit.
Connecting the generator set direct-
The genset will continue to run after a breaker trips. ly to the public utility or any other power system
Turn off all loads, then reset the breaker. If it trips can cause electrocution, damage to equipment,
again, a short circuit is indicated. Turn off the set or fire. Hazardous voltages can flow from the
and contact a qualified technician for assistance. generator set into the utility line. An approved
If the breaker does not trip, turn on only as many de- switching device must be used to prevent inter-
vices as the breaker size allows (see Connecting A connections.
Load in this section). If the breaker trips again, this
DC POWER
may indicate a defective load or circuit breaker.
Contact a qualified technician to measure the exact A 30-amp belt-driven alternator on the engine sup-
current requirements of your specific loads to deter- plies DC power to recharge the starting battery for
mine if the breaker or the load is defective. the set.
Connection to Utility Power
Connect the RV or commercial vehicle to utility pow-
er (power from an outside source such as a plug-in

10
Operating Recommendations

BREAK-IN PROCEDURE LOW TEMPERATURE/HIGH ALTITUDE

OPERATION
Change the crankcase oil after the first 50 hours of
operation. See the Maintenance section of this 1. Use the correct SAE oil rating for the current
manual for the procedure. temperature conditions. Change the oil only
when it is warm. See Table 1.
NO-LOAD OPERATION
2. Use No. 1 diesel fuel for temperatures lower
Hold no-load operation to a minimum. With no than 14° F (-10° C) or for all temperatures if alti-
load, combustion chamber temperatures can drop tude is above 5000 feet (1500 m). The fuel
so low that fuel does not burn completely. This can should have a cetane rating of at least 40.
create carbon deposits which clog injectors, glaze Shorten the oil change interval by half if the sul-
cylinders and cause piston rings and valves to stick. fur content of the fuel is higher than 0.5%.
If it is necessary to run the engine for long periods,
connect an electrical load to the generator out- EXTREMELY DUSTY OR DIRTY
put. CONDITIONS
EXERCISE PERIOD If running the genset in extremely dusty or dirty en-
vironments, do the following:
Infrequent use can result in difficult starting and
moisture condensation problems. This moisture is • Keep genset and radiator cooling surfaces
a result of the engine not being run long enough to clean.
reach normal operating temperature. In extreme
cases, water may be deposited in the oil. If this hap- • Service the air cleaner more frequently (as nec-
pens, severe engine damage can result. To prevent essary).
this possibility, run the generator set under load at
least one hour per week. • Change crankcase oil every 50 operating
hours.
Exercising for one long period each week is better
than several shorter periods of operation. Do NOT • Clean the generator as necessary. See Mainte-
operate the set for long periods at no load. nance section.

11
Maintenance Schedule
Following the maintenance schedule and using the Consult an Onan service center if the generator set
generator set properly will result in longer genset will be subjected to extremely hot or dusty condi-
life, better performance, and safer operation. Per- tions; a more frequent maintenance schedule may
form each maintenance procedure at the time peri- be necessary. Log all service and maintenance for
od indicated or after the number of operating hours warranty support (see the Maintenance Record
indicated, whichever comes first. Refer to the Main- section).
tenance Procedures section for instructions.
Accidental starting of the generator
NOTE: Many of these procedures are best performed set during maintenance can cause severe per-
by an authorized Onan service center. If you are at all sonal injury or death. Disconnect both genera-
in doubt about your ability to perform genset mainte- tor set starting battery cables before perform-
nance, have the Onan service center nearest you
ing maintenance. Remove the negative (-) cable
perform these tasks.
first to reduce the risk of arcing.

TABLE 4. PERIODIC MAINTENANCE SCHEDULE

SERVICE TIME
Every Every Every Every Every
SERVICE THESE ITEMS 8 hours 50 hours 100 hours 250 hours 500 hours
Inspect set x1
Check oil level x
Check coolant level x
Check fuel level x
Clean out spark arrester x
Check air cleaner dust cap (clean if required) x3 x
Check battery charging system x
Check drive belt tension x4
Clean air cleaner element x
Check battery specific gravity x
Change crankcase oil and filter x 2,7
Drain water/sediment from fuel filter x5
Check anti-freeze x
Clean generator assembly x
Check fuel shut-off linkage x
Change fuel filter element x
Check generator brushes x6
Change air cleaner element x3
Clean cooling system x
Check valve clearance x6
1 - Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually
with genset running and repair any leaks immediately.
2 - Perform after first 50 hours of operation on new genset.
3 - Perform more often in extremely dusty conditions.
4 - Visually check belts for evidence of slippage.
5 - Drain one cup of fuel to remove water and sediment.
6 - To be performed by authorized service technician.
7 - Perform every 200 hours.

12
 Maintenance Procedures

GENERATOR SET INSPECTION WARNING Fuel leakage will create a fire hazard
which can result in severe personal injury or
Inspect the generator set daily or after every eight death if ignited. While checking for leaks, do
hours of operation, whichever comes first. Check not smoke or allow any spark, flame, pilot light
the exhaust, fuel, and DC electrical systems as de- or other ignition source in the area. If any leaks
scribed below. Also check the mechanical condi- are detected, have them corrected immediately.
tion of the set.
DC Electrical System
Engine Gauges (Remote Installation) With the genset off, check the battery terminals for
clean and tight connections. Loose or corroded
Check these gauges while the set is running. connections create resistance which can impede
starting. Clean and reconnect loose battery cables.
Oil Pressure Gauge: Oil pressure should be 40 to Always disconnect the negative battery cable first
60 psi (276 to 414 kPa) when the engine is at oper- and connect it last, to reduce the possibility of arc-
ating temperature. ing.

WARNING Ignition of explosive battery gases

Coolant Temperature Gauge: Coolant tempera-
can cause severe personal injury. Do not
ture should be 165° to 195° F (74° to 91° C), de-
smoke. Wear goggles, protective rubber gloves
pending on load and ambient temperature. and apron when servicing batteries.

DC Voltmeter: Battery voltage during operation Mechanical

should be 14 to 15 volts. Check for any signs of mechanical damage. Start
the set and listen for any unusual noises that may
Exhaust System indicate mechanical problems. Have any problems
corrected immediately.
With the set running, inspect the entire exhaust sys-
tem including the exhaust manifold, exhaust elbow, Check the mounting fasteners to make sure the set
muffler and exhaust pipe. Visually and audibly is secure in its compartment. If an under-floor hous-
check for leaks at all connections, welds, gaskets, ing is used, make sure that the set is secured to the
and joints. If any leaks are detected, shut down housing. Check the condition of the housing com-
the genset and do not operate until corrected. ponents and make sure they are secure to the vehi-
Replace corroded exhaust components before cle.
leaks occur. Make sure that the generator set air inlet and outlet
areas are not blocked.
WARNING Inhalation of exhaust gases can re-
Clean the generator set whenever dust and dirt be-
sult in severe personal injury or death. Inspect gin to accumulate. Dust and dirt can usually be re-
exhaust system audibly and visually for leaks moved with a damp cloth. Steam cleaning may be
daily. Repair all leaks immediately. needed to remove road contaminants. Do not clean
the genset while the engine is running. Protect the
Fuel System generator, air cleaner, control panel, and electrical
connections from cleaning solvents. Cleaning sol-
With the set running, inspect the fuel supply lines, vents can damage electrical connectors.
return lines, filters, and fittings for leaks. Check flex-
ible sections for cuts, cracks and abrasions. See OIL AND FILTER CHANGE
that the fuel lines do not rub against anything that
could break them. Replace worn fuel line compo- The generator set was shipped with oil installed.
nents before leaks occur. See the Specifications section for oil capacity.

13
Change the oil and filter at the intervals listed in Ta- WARNING State or federal agencies have de-
ble 4. Use oil that meets the API classification and termined that used engine oil can cause cancer
SAE viscosity grade indicated in the previous sec- or reproductive toxicity. When adding, chang-
tion. ing or working with used oil, take care not to
breathe, ingest or come into excessive contact
Engine Oil Change with these substances. Wash hands after use.
Run the engine until thoroughly warm (but not hot). Wear protective clothing and equipment. Pro-
Stop the engine, open the drain valve or remove the vide adequate ventilation.
drain plug (Figure 5) and drain the oil into a con-
tainer. When completely drained, close the valve or Oil Filter Change
reinstall the plug and refill the crankcase with new
oil.
Spin off the oil filter and discard it. Thoroughly clean
On side compartment mount applications, the front the filter mounting surface. Apply a thin film of oil to
oil drain valve may be rotated to the side and a hose the filter gasket, and spin the filter on until the gasket
attached and extended through the radiator mount- just touches the mounting pad. Then turn an addi-
ing bracket, or in any available direction. tional 3/4 turn. Do not over-tighten the filter.
WARNING Hot crankcase oil can cause burns if
it is spilled or splashed on skin. Keep fingers With oil in the crankcase, start the set and check for
and hands clear when removing the oil drain leakage around the filter gasket. Tighten the filter
plug and wear protective clothing. only enough to eliminate leaks.

14
 TOP OIL FILL SIDE OIL FILL FRONT
OIL FILL

FRONT OIL
DIPSTICK

SIDE OIL
DIPSTICK

ADDITIONAL OIL DRAIN OIL FILTER

PLUG UNDER SET; ACCESS DRAIN
THROUGH DRIP PAN HOLE VALVE

FIGURE 5. ENGINE OIL

COOLING SYSTEM Do not exceed a 50/50 mixture of ethylene glycol

and water. A higher proportion of ethylene glycol
The generator set is shipped with coolant installed.
Cooling system capacity is listed in the Specifica- will alter the heat transfer properties of the coolant.
tions section. A 50/50 mixture will provide freeze protection to
-34° F (-37° C).
Coolant Requirements
Engine coolant must inhibit corrosion and protect
against freezing. A 50/50 mixture of ethylene glycol Water used for engine coolant should be clean, low
antifreeze and water is recommended for normal in minerals, and free of corrosive chemicals. Use
operation and storage. Use only a reliable brand of distilled or soft water if available. Avoid the use of
antifreeze that contains a rust and corrosion inhibi- well water, which may contain minerals that can
tor. The antifreeze must not contain a stop-leak clog the heat exchanger core and reduce cooling ef-
additive. ficiency.

15
Flushing and Cleaning CAUTION Exceeding the recommended fill
Once a year, drain, flush and refill the cooling sys- rate can cause incomplete filling of the engine
tem with new coolant. To drain the system, open the block, leading to engine damage during warm-
radiator coolant drain (located on the service side up. Always follow the recommended fill proce-
and has a hose) and the cylinder block drain on the dure.
the rear (non-service access) side of engine. See
Start the engine, then remove the pressure cap and
Figure 6.
monitor the coolant level. As trapped air is expelled
WARNING Contact with hot coolant can cause from the system, the coolant level will drop. Add
severe burns. Do not bleed hot, pressurized coolant to replace it. Replace the pressure cap
coolant from a closed cooling system. when the coolant level is stable.

Chemical Cleaning: Rust and scale slow heat ab- Add coolant to the recovery tank or separate expan-
sorption and can block coolant flow. Clean the cool- sion tank (if equipped) to the full-cold level.
ing system if rust and scale have collected on the
engine water jacket or in the heat exchanger. Use a Coolant Level
good cleaning compound and follow its instructions. Check the coolant level at the intervals specified in
the Periodic Maintenance Schedule. Check by ob-
Flushing: After cleaning, or before filling the sys-
serving the coolant level in the recovery tank or sep-
tem with new coolant, drain the system and fill with
arate expansion tank (if equipped), or at the fill loca-
clean water. Run the genset for 10 minutes, then
tion, when the system is cold. See Figure 6 for a typ-
drain the system completely. Refill with the coolant
ical cooling system. Engine coolant is at the proper
mixture.
level when the recovery tank level is between FULL
CAUTION Never pour hot water into a cold en- and LOW marks, or the coolant can be seen in the
gine or cold water into a hot engine. Doing so fill hose.
can crack the head or the cylinder block. Do not WARNING Coolant in a warm engine is under
operate the unit without water for even a few pressure and can flash to steam causing severe
minutes. burns if the radiator cap or drain cock are
opened. Let the engine cool down before open-
Filling the Cooling System ing the radiator cap or drain cock.
Verify that all drain cocks are closed and all hose
CAUTION The high engine temperature cutoff
clamps are secure. Remove the fill neck hose from
will shut down the engine in an overheat condi-
the clamp, then remove the cooling system pres-
tion only if the coolant level is sufficiently high
sure cap and slowly fill the cooling system with the
to physically contact the shutdown switch.
coolant mixture. Replace the cap and reclamp the
Loss of coolant will allow engine to overheat
hose.
without protection of shutdown device, thereby
WARNING Coolant in a warm engine is under causing severe damage to the engine. Ade-
pressure and can flash to steam causing severe quate engine coolant levels must be maintained
burns if the radiator cap or drain cock are for operational integrity of the cooling system
opened. Let the engine cool down before open- and engine coolant overheat shutdown protec-
ing the radiator cap or drain cock. tion.

16
 TUBE TO RECOVERY
TANK CONNECTS NEXT
TO RADIATOR CAP

RAISE FLEXIBLE TUBE TO

VERTICAL AND REMOVE CAP
TO CHECK COOLANT LEVEL

RADIATOR COOLANT DRAIN LOCATED

UNDER THIS CORNER OF RADIATOR
BRACKET

RECOVERY TANK LOCATED IN/

NEAR GENSET COMPARTMENT

OVERFLOW
HOSE
CYLINDER BLOCK COOLANT DRAIN

(REAR OF GENSET ENGINE BLOCK

SHOWN WITHOUT SHEET METAL,
EXHAUST PARTS)

FIGURE 6. COOLING SYSTEM COMPONENTS

Thermostat higher operating temperatures. Replace the pres-

sure cap every two years, or sooner if it malfunc-
If the engine overheats or does not reach and main- tions.
tain a minimum operating temperature, have the
thermostat removed and tested. Replace the ther- FAN BELT
mostat with its gasket if necessary. See the Service
Manual for instructions. A loose fan belt can cause the engine to overheat.
The belt tension must be correct for the set to run
Pressure Cap well.

Closed cooling systems use a pressure cap to in- First, remove the generator set’s starting battery ca-
crease the boiling point of the coolant and allow bles (negative [-] cable first).

17
 WARNING Accidental starting of the set can WARNING Ignition of fuel can cause serious
cause severe personal injury or death. Stop the personal injury or death by fire or explosion. Do
generator set and disable it by disconnecting not permit any flame, cigarette, pilot light, spark
the starting battery cables (negative [-] cable or other igniter near the fuel system.
first) when maintaining or repairing the engine,
controls, or generator.
Fuel Recommendation
To reach the fan belt, remove the belt guard from the
Use ASTM 2-D (no. 2 Diesel) or ASTM 1-D (No. 1
front of the set. Do not operate the genset with-
Diesel) fuel with a minimum Cetane number of 45.
out the belt guard in place.
Number 2 diesel fuel gives the best economy and
performance under most conditions. Use number 1
To adjust the belt, loosen the bolt that passes
diesel fuel when ambient temperatures are below
through the long slot in the alternator mounting
32° F (0° C), and during long periods of light engine
bracket and slide the alternator until the tension is
load.
right. See Figure 7.

Belt tension is correct when a finger pressure of 22 Use low sulfur content fuel which has a cloud point
pounds (10 kg) at the middle of the belt deflects it at least 10 degrees below the lowest expected fuel
about 0.4 inch (10 mm). temperature. (Cloud point is the temperature at
which wax crystals begin to form in diesel fuel.)

Fuel Handling Precautions

ADJUST
PUMP TENSION
Prevent dirt, water or other contaminants from en-
HERE tering the fuel system. Filter or strain the fuel as the
tank is filled.

CAUTION Due to the precise tolerances of die-

sel injection systems, dirt or water in the system
will cause severe damage to both the injection
pump and the injection nozzles. It is extremely
important the fuel be kept clean and water free.
ALTERNATOR
Condensation (water) can cause clogging of fuel fil-
ters as well as freezing problems. Water mixing
CRANKSHAFT/ with the sulfur in the fuel forms acid which can cor-
FAN PULLEY rode and damage engine parts.

CS-1239 Low fuel in the tank promotes condensation. In

warm weather, the fuel tank cools at night quicker
FIGURE 7. FAN BELT ADJUSTMENT than the fuel. If the fuel level is low, the upper por-
tion of the tank will cool more rapidly, forming con-
FUEL SYSTEM densation. In cold weather, the warm fuel returning
from the injectors heats the fuel in the supply tank. If
Use the best fuel available. Fuel quality is important the fuel is low, condensation may form on the upper
for dependable performance and satisfactory en- part of the tank. To avoid condensation, fill the
gine life. fuel tank every time the genset is used.

18
Fuel Filter
MOUNTING HOLE (2) CENTER BOLT
ASSEMBLY
The wrong fuel or dirty fuel will shorten the life of the
SEPARATOR HEAD
fuel filter. See the Periodic Maintenance Schedule
Table 4 for the filter change interval.
VENT
PLUG
CAUTION Dirt or water in the system will cause
severe damage to both the injection pump and
the injection nozzles. It is extremely important FUEL FUEL
that the fuel be kept clean and free of water. PORT PORT
(out) (in)

The commercial HDKAL/HDKAS generator set of-

fers an optional Racor fuel filter/water separator unit
in place of the fuel filter. Periodically check the con-
tamination bowl and drain if water is present. (Wa- FUEL/WATER
ter settles to the bottom of the bowl and is a distinc- ELEMENT
tive lighter color.) Refer to Figure 8.
CONTAMINATION
BOWL
To drain the Racor fuel filter/water separator: CONTAMINATION DRAIN HOSE
DRAIN VALVE NIPPLE
1. Attach a rubber hose to the drain hose nipple to
drain the water away from the generator set FIGURE 8. FUEL/WATER SEPARATOR
and into a container.
The degree of contamination of the fuel determines
the frequency of fuel filter/water separator element
2. Loosen the vent plug. replacement. Difficult starting and loss of full power
usually signify an immediate need to change the
3. Loosen the contamination drain valve until the element.
water begins to exit. To replace the Racor fuel filter/water separator ele-
ment:
4. When all the water has drained, tighten both 1. Follow steps 1 through 3 for draining unit.
the contamination drain valve and the vent
plug. 2. When the entire contents of the fuel/water ele-
ment and contamination bowl has drained,
5. Remove the rubber hose. tighten both the contamination drain valve and
the vent plug.

6. Clean up any fuel that may have spilled during 3. Unscrew the center bolt assembly until you can
the draining procedure. remove the element and bowl as a unit.
4. Unscrew the bowl from the filter and properly
WARNING Leakage of fuel presents the hazard of discard the filter.
fire or explosion that can cause severe personal inju-
ry or death. Make certain all spilled fuel is properly 5. Clean the bowl, the O-ring, and the O-ring
cleaned up. Be certain there are no ignition sources channel.
such as flame, spark, pilot light, arcing switch or
equipment, cigarette, etc., near the generator set. 6. Lubricate the O-ring with a light oil and place in
Keep an ABC type fire extinguisher nearby. the O-ring channel.

19
 7. Screw the bowl onto the new element (Onan check the fuel level in the tank and that the shutoff
Part Number 149-2577). Do not overtighten. valve is open.

8. Lubricate the element gasket with a light oil. NOTE: Priming the fuel system and replacing the fuel
filter are procedures that are best performed by an
9. Thread the element and bowl as a unit onto the Onan service technician. If you are at all in doubt
center bolt assembly until the element makes about these procedures, consult an authorized Onan
contact with the separator head. service center.

10. Tighten the center bolt assembly with a torque Refer to the Periodic Maintenance Schedule for the
wrench to 65 inch-pounds. recommended filter change interval. However, if
the engine shows signs of fuel starvation (reduced
11. Clean up any fuel that may have spilled during
power or surging), the fuel filter must be changed.
the element replacement procedure.
This involves bleeding the fuel system of trapped
WARNING Leakage of fuel presents the hazard of
air.
fire or explosion that can cause severe personal inju-
ry or death. Make certain all spilled fuel is properly Bleeding the system means loosening the fittings of
cleaned up. Be certain there are no ignition sources the low-pressure fuel lines one by one, and crank-
such as flame, spark, pilot light, arcing switch or ing the electric fuel pump to drive out trapped air.
equipment, cigarette, etc., near the generator set. This procedure must be done by an Onan serv-
Keep an ABC type fire extinguisher nearby. ice center or a professional diesel technician.
Low Pressure Fuel System
High Pressure Fuel System: The injection pump,
The electric fuel pump, fuel filter and injection pump fuel injection lines and fuel injectors are the high
inlet comprise the low pressure fuel system. See pressure fuel system. See Figure 9. The high-pres-
Figure 9. These components are normally primed sure system is self-priming; trapped air is forced out
(purged of trapped air) at set installation. Be sure to through the injection nozzles.

20
 FUEL FILTER FUEL
HOSE FUEL HOSE FUEL PUMP
RETURN INLET

FIGURE 9. FUEL SYSTEM

21
 UNCLIP AIR CLEANER COVER TO
REMOVE: AIR CLEANER ELEMENT
PRESS-FITS INTO HOUSING

SQUEEZE BOOT TO RELEASE

DUST AND DIRT BEFORE
INSTALLING NEW ELEMENT

FIGURE 10. AIR CLEANER ASSEMBLY

AIR CLEANER the sealing surface; correct the situation if nec-

essary.
The air cleaner element is a dry type, and should
never have oil applied to it. Avoid touching the ele- 17. Inspect the new filter for damage. Do not install
ment except when cleaning it. Before beginning a damaged filter.
installation, squeeze the dust boot to release any 18. Insert the filter into the housing. Apply pres-
trapped dust or dirt. Install the new filter as follows: sure at the outer rim of the filter, not its flexible
center.
12. Unclip the cover.
19. Check all connections for tight fit.
13. Pull the filter out gently to reduce the amount of
dust dislodged. Gently move the filter side to Change the element yearly or after 500 hours, or
side or twist to disengage the seal. more often in extremely dusty conditions.
14. Pull the filter off the outlet tube and out of the
housing. Avoid dislodging dirt inside the hous-
ing, which can enter the engine. BATTERY CARE
15. Clean the sealing surface and the inside of the Service the battery at the intervals shown in the
outlet tube. Remove all dust and dirt from in- maintenance schedule. Check the electrolyte level
side the housing. more frequently during hot weather. Consult the
16. Examine the old filter for dust on the clean air battery manufacturer’s maintenance instructions. If
side of the filter. This could indicate leakage on the battery is not the sealed type, service as follows:

22
 WARNING Batteries present the hazard of ex-
plosion that can result in severe personal inju-
ry. Do not smoke or allow any fire, flame, spark,
pilot light, arc-producing equipment or other
ignition sources around the battery area. Do
not disconnect battery cables while the genera- SPECIFIC GRAVITY
tor set is cranking or running because explo- READING SHOULD BE
sive battery gases could be ignited. 1.260 AT 80° F (27° C)

WARNING Battery electrolyte can cause se-

vere eye damage and burns to the skin. Wear
goggles, rubber gloves and a protective apron
when working with batteries.
1. Keep the battery case clean and dry.
2. Make certain that the battery cable connec-
tions are clean and tight. Use a terminal puller B45
tool to remove the battery cables.
Remove corrosion from the battery terminal
FIGURE 11. BATTERY CHECK
connections. Wash the terminals with an am-
monia solution or a solution consisting of 1/4
pound (about 100 grams) of baking soda in 1 AC GENERATOR
quart (about 1 liter) of water. Be sure the vent
Generator Brushes
plugs are tight to prevent cleaning solution from
entering the cells. After cleaning, flush the out- The generator should be inspected for brush wear
side of the battery and the surrounding areas and cleaning as required per the Periodic Mainte-
with clean water. nance Schedule. This procedure should be per-
3. Identify the cable as positive (+) or negative (-) formed by an authorized Onan service technician.
before making the battery connections. Al-
ways connect the negative (-) cable last, to re- WARNING Accidental starting of the generator
duce the risk of arcing. set can cause severe personal injury or death.
4. Maintain the electrolyte level by adding distilled Stop the generator set and disable by discon-
water. Fill each cell to the split-level marker in necting the starting battery cables (negative [-]
the battery. The water component of the elec- cable first before inspecting the generator.
trolyte evaporates, but the sulfuric acid compo-
nent remains. For this reason, add water, not Generator Bearing
electrolyte to the battery. Inspect the bearing for evidence of outer case rota-
5. Use a battery hydrometer to check the specific tion every 1000 hours of use. The bearing should
gravity of the electrolyte in each battery cell be replaced every five years, because the bearing
(Figure 11). Charge the battery if the specific grease gradually deteriorates due to oxidation. See
gravity measures less than 1.215. Do not over- the Service Manual (publication 981-0516) for the
charge the battery. Stop charging the battery bearing replacement procedure. If the generator
when the electrolyte specific gravity reaches requires major repair or service, contact an author-
1.260, at approximately 80° F (27° C). ized Onan dealer or distributor.

23
 MUFFLER/SPARK ARRESTER CLEANING THE GENERATOR SET
The exhaust spark arrester mounted inside the muf-
Clean the generator set at least every six months.
fler is necessary for safe operation. It must be peri-
Dust usually can be removed with a damp cloth.
odically cleaned out for maximum efficiency, and to
Some road contaminants may require steam clean-
meet Forest Service requirements (RV use). See
ing. Do not steam clean the generator set while the
the maintenance schedule for cleaning intervals.
engine is running. When cleaning, protect the area
To clean the spark arrester, remove the 1/8 inch so spray is not directed into the generator, air clean-
pipe plug from the bottom of the muffler. Run the er, control box, fuel solenoid, or electrical con-
generator set with a full load for five minutes. Stop nections. Do not clean with solvents; they can dam-
the generator set and allow the muffler to cool. Re- age electrical connectors.
place the pipe plug in the muffler. See Figure 12.

PIPE EXS-1190s

PLUG

FIGURE 12. EXHAUST MUFFLER

24
Generator Set Storage

OUT-OF-SERVICE PROTECTION Returning the Genset to Service

The lubricating qualities of No. 2 diesel fuel should Refer to the preceding paragraphs in this Mainte-
protect the cylinders of a diesel engine at least 30 nance section for specific service procedures.
days when the set is not being run. For storage lon-
ger than 30 days, proceed as follows: 1. Remove plug from the exhaust outlet.

1. Exercise the genset (see Operation section) 2. Check tag on oil base and verify that oil viscosity
until the engine is at operating temperature. is still correct for existing ambient temperature.

2. Shut down the genset and disconnect the bat- 3. Clean and check the battery. Measure the elec-
tery cables (negative [-] cable first). Store the trolyte specific gravity with a hydrometer (1.260
battery in a cool, dry place and connect to a @ 80° F [27° C]) and verify the proper level. If
trickle charger once every 30 days to maintain the specific gravity is low, charge the battery un-
full charge. til the value is correct. If the level is low, add dis-
tilled water and charge until the specific gravity
Battery electrolyte can cause se- reading is correct. DO NOT OVERCHARGE.
vere eye damage and burns to the skin.
Wear goggles, rubber gloves and a protec- Battery electrolyte can cause se-
tive apron when working with batteries. vere eye damage and burns to the skin.
Wear goggles, rubber gloves and a protec-
3. Drain the crankcase oil while still warm. Re- tive apron when working with batteries.
place oil filter. Refill crankcase and attach a tag
indicating oil viscosity. 4. Prime the fuel system.

4. Check the coolant level. Add more coolant if 5. Connect the starting battery, negative (-) cable
low. If freezing temperatures are possible, test last.
the coolant mixture.
6. Remove all loads before starting the genset.
5. Plug exhaust outlets to prevent entrance of
moisture, bugs, dirt, etc. 7. After starting, apply load of at least 50 percent
rated capacity.
6. Clean and wipe the entire genset. Lightly coat
parts that may rust with grease or oil. 8. Check all gauges for normal readings. Genset
is ready for operation.

25
 Troubleshooting

DC CONTROL AC CONTROL
The DC control has a number of sensors that con- The AC control consists of the line circuit breakers
tinuously monitor the engine for abnormal condi- connected between the generator output and the
tions such as low oil pressure and high coolant tem- load.
perature. If any one of these conditions occur, the If the breaker trips, the electrical load is too great for
control stops the engine. See Figure 13.. If a major the generator set. This may be caused either by
problem is indicated, contact an Onan dealer or dis- running too many appliances at once, or by a short
tributor for help or service. circuit.
Consult the Wattage Requirements section of this
Fault Reset Breaker
manual to determine the wattage needed by typical
The control panel fault reset breaker will trip for any appliances.
one of the fault conditions described separately be-
low. The red breaker reset button pops out about FAULT CODE BLINKING
1/4 inch (6 mm) when a fault occurs. Locate the At fault shutdown, the status indicator light will re-
problem and make the necessary corrections be- peatedly blink sets of 1, 2, 3 or 4 blinks.
fore resetting breaker and starting the generator
set. All fault shutdowns except overspeed are S One blink indicates shutdown due to high en-
delayed five seconds to avoid nuisance tripping. gine coolant temperature.
S Two blinks indicate shutdown due to a loss of
Low Oil Pressure engine oil pressure.
Remove dipstick and check oil level. If low, add oil S Three blinks indicate a service fault. Press
to bring level up to the Full mark. Inspect engine ex- Stop once to cause the two-digit, second-level
terior for leaks and repair as necessary. The oil shutdown code to blink. (Pressing Stop again
pressure switch actuates the fault circuit if pressure will stop the blinking.) The two-digit code con-
drops below 7 psi (49 kPa). sists of 1, 2, 3, 4 or 5 blinks, a brief pause, and
then 1 to 9 blinks. The first set of blinks repre-
Crankcase pressure can blow out sents the tens digit and the second set of blinks
hot oil and cause SEVERE burns. Do NOT the units digit of the shutdown code number.
check oil while the generator set is operating. For example, shutdown code No. 36 appears
as:
High Coolant Temperature blink-blink-blink—pause—blink-blink-blink-blink-blink-blink—long
pause—repeat
If fault occurred during operation, observe Coolant
Temperature Gauge (option) for indication of tem- S Four blinks indicate that cranking time ex-
perature over 230° F (110° C). The coolant thermo- ceeded 35 seconds.
stat switch closes at this temperature and actuates • Fault Code Nos. 1, 2, 3, and 4 are first level faults.
the fault circuit. Pay close attention to the pause sequence to avoid
interpreting first level faults as second-level Fault
Check coolant level in radiator after allowing engine
Codes Nos. 11, 22, 33, or 44.
to cool down. See that the pump belt is OK and has
proper tension. Also check cooling system cleanli- • To avoid the possibility of anyone misinterpreting
ness (freedom from contaminants, rust, sludge Code Nos. 3 and 4 as Code Nos. 33 and 44, the lat-
buildup, etc.). ter have not been assigned faults.

Contact with hot coolant can result RESTORING FAULT CODE BLINKING
in SEVERE burns. Allow cooling system to cool The fault code stops blinking after five minutes.
before releasing pressure and removing radia- Press Stop three times within three seconds to re-
tor cap or release of hot coolant can result. store fault code blinking.

26
 COOLANT TEMPERATURE
SWITCH (SHUTDOWN)

OIL PRESSURE SENDER

(OPTIONAL METER)
REAR OF GENERATOR
OIL PRESSURE SET (OPPOSITE FROM
SWITCH (LATCH) SERVICE ACCESS SIDE)

OIL PRESSURE SWITCH

(SHUTDOWN)

OPTIONAL COOLANT NOTE: GUARDS,

TEMPERATURE SENDER BRACKETS, SHEET
(METER) METAL PARTS NOT
SHOWN

SERVICE ACCESS
SIDE (FRONT) OF
GENERATOR SET

FIGURE 13. OIL AND COOLANT SENSOR LOCATIONS

27
Specifications

Control • Unit Mounted, Drip-Proof, Vibration Isolated • AC Controls

Console • Voltage Regulator (See Generator Detail)
System • DC Controls - 12-Volt System • One or Two Circuit Breakers
• Start/Stop/Preheat Switch
• Sealed Remote Connector for
Start/Stop/Preheat
Switch Gauge Package
• Manual Reset Fault Relay Indicating
Engine Shutdown for High Coolant
Temperature, Low Oil Pressure

Engine Design: 4-Cycle, Liquid-cooled Diesel Engine

Cylinders: Inline Vertical - 3
Fuel Injection Pump: Bosch K mini
Combustion Chamber: Spherical
Detail Bore: Fuel Consumption: No. 2 Diesel Fuel, gph/lph
HDKAL/HDKAQ 2.99-in (76 mm) No Load Half Load Full Load
HDKAR/HDKAS 2.83 IN (72 MM) HDKAL 0.24 gph 0.49 gph 0.85 gph
Stroke: 2.90-in (73.6 mm) 0.90 lph 1.85 lph 3.2 lph
Displacement
HDKAL/HDKAQ 61.08in3 (1001 cm3) HDKAQ 0.25 gph 0.56 gph 0.9 gph
HDKAR/HDKAS 54.8 in3 (898 cm3) 0.95 lph 1.93 lph 3.41 lph
Compression Ratio: 23 to 1
Lube Oil Capacity: 4.5 qt (4.25 L) Including Filter HDKAR 0.23 gph 0.46 gph 0.8 gph
Cooling System Capacity:1.25 gal (4.73 L) 0.87 lph 1.74 lph 3.03 lph
Engine Power (max) at 1800 r/min:
HDKAL/HDKAQ 13.1 bhp HDKAS 0.23 gph 0.46 gph 0.8 gph
HDKAR/HDKAS 11.9 bhp 0.87 lph 1.74 lph 3.03 lph
Starting System: Remote, 12-volt

Generator Design: Onan, Brush type, Drip-proof Construction.

Insulation System Rise: Class F per NEMA
Bearing: Double Sealed Prelubricated Ball Bearing
Cooling: Direct Drive Centrifugal Blower
Detail MGI-1.65 and BS 2757 Insulating Varnish Conforms Damper Bar: Improves Harmonics and Voltage
to MIL-1-24092, Grade CB, Class 155 C. Waveforms (Comm HDKAL/HDKAS Only)
Exciter System: Electronic Voltage Regulator

GenSet Regulation, No Load to Rated Load

Voltage: ±2.5°%
from No Load to Full Load is ±1%

Performance Frequency: ±2.5%

Random Voltage Variation: Under These
Conditions is ±1%
Battery Charging: 12-Volt Battery Charging
DC Alternator (30 amp output) Maximum Operating Ambient Temperature:
Sound Level: 78 dB(a) @ 3 m rated load Efficient Radiator Cooling System Permits Operation
Random Frequency Variation for Constant Loads at Ambient Temperatures up to 120°F (49°C).

Accessories Required Accessory

• (USDA Forest Service Approved Spark
• Remote Circuit Breaker Kits
• Remote Wiring Harness, 15 or 25 ft.
Arrester Muffler. • Coolant Recovery Kit
• Exhaust Resonator • Engine Block Heater (Comm HDKAL/HDKAS
Optional Accessories Only)
• Battery - 12 volt, 475 Cold Cranking Amps at • RACOR Fuel/Water/Separator
0°F (-17.8°C) (Comm HDKAL/HDKAS Only)
• Remote Gauge Package with Start/Stop/- • Remote DC Gauge Kit (Comm
Preheat Switch, Voltage Meter, Water HDKAL/HDKAS Only)
Temperature Gauge, Oil Pressure Gauge,
Hour Meter (Standard on Comm
HDKAL/HDKAS)

28
Information for California Genset Users
These gensets meet the requirements of California’s Exhaust Emissions Standards for 1995 and
later for Utility and Lawn and Garden Equipment Engines.
As a California user of these gensets, please be aware that unauthorized modifications or replace-
ment 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 prohib-
ited.
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 authorized 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

The California emissions control warranty statement is lo-

Genset Warranty Information cated in the same packet of information as this manual
when the engine is shipped from the factory.
The engine is certified to operate on diesel fuel. See FUEL
Engine Fuel Requirements
RECOMMENDATIONS in Pre-start Section.
Engine Lubricating Oil Require- See ENGINE OIL RECOMMENDATIONS in Pre-start
ments Section.
High Idle Speed. This is a service procedure requiring
Engine Adjustments trained personnel and proper tools. See the Service
Manual.
The engine emission control system consists of engine
Engine Emission Control System
design and precision manufacture. (IFI)

29
How to Obtain Service
LOCATING SERVICE ASSISTANCE If you need additional assistance, please call Onan
Corporation, 1-612-574-5000, 7:30 AM to 4:00 PM,
When your generator set needs parts or service, Central Standard Time, Monday through Friday.
contact the nearest authorized dealer or distributor.
Onan Parts and Service representatives are facto- You can obtain an individual directory of authorized
ry-trained to handle all of your service needs. Lo- RV servicing dealers by calling Onan at
cate the nearest authorized distributor as follows: 1-800-888-ONAN or by writing to Onan (“Attn: Mar-
keting”) at the address listed on the rear cover.
1. Check the North American Sales and Service Please ask for: RV Sales and Service Directory
Directory (F-118) supplied with your Onan gen- F-919.
set. This directory lists authorized distributors
who will assist you in locating the nearest au-
SCHEDULING SERVICE
thorized dealer.
-or- 1. Before calling for service, have the following in-
formation available:
2. Consult the Yellow Pages. Typically, our dis-
tributors are listed under: The complete Onan product model number
and serial number (see Model Identification on
GENERATORS-ELECTRIC, page 1)
ENGINES-GASOLINE OR DIESEL, OR Date of purchase
RECREATIONAL VEHICLES-EQUIPMENT,
PARTS AND SERVICE. Nature of the problem
Approximate hours in service
-or-
3. For the name of your local Cummins/Onan or 2. Contact the authorized dealer or distributor
Onan-only distributor in the United States or nearest you to explain the problem and make
Canada, call 1-800-888-ONAN (this auto- an appointment.
mated service utilizes touch-tone phones 3. If you have difficulty in arranging for service or
only). By entering your area code and the first resolving a problem, please contact the dealer
three digits of your local telephone number, coordinator or service manager at the nearest
you will receive the name and telephone num- Cummins/Onan distributor for assistance.
ber of the distributor nearest you.

INCORRECT SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE PERSONAL INJURY,

DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE QUALIFIED TO PERFORM
ELECTRICAL AND/OR MECHANICAL SERVICE.

30
Maintenance Record
Keep a record of all periodic and unscheduled number of operating hours from the optional hour
maintenance. Record the service date and the meter (if equipped).

DATE HOUR METER READING SERVICE PERFORMED / NOTES

Record the name, address, and phone number of

your authorized Onan service center.

31
Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
763-574-5000
Fax: 763-528-7229

Cummins and Onan are registered trademarks of Cummins Inc.