(spec A-H) HDKAT HDKAU
Contents
1. 310H 9NIIN0ON S3QIS 11 401 HOLIMS dOLS LYYLS SNOISN3NIQ S81 02h 99 S 061 1H913M LINN L 107 69 8 310H WAWININ SM382S 9NINNOJ OV3UHI 91 98 803 S3SS3NUuVH ONIIVW 31319002 804 901V1VO AUOSS32OV 13S KINO 38108 39nV9 20 81 HLIM SZ 7 9 0351 38 01 03N91S30 JUV ONISNOH NV STYNIWYSL 3S3Hl OS 572 LOLI 2 1156 021 L S39V380S LNAWLYVdWOD WOYS JONVYVITD LINNA WAWINIW 8011 2 98087021 L 37872 Was EVLI EZE 99165021 ALIAV2 9fn 1d 318V1I VAV LIM 3108384 2 V OILI EZE 8088701 1 YOLIINNOD 1N3A313 383NV312 MOSHD 1113 LNV1009 23 2 2 ON LYVd NYNO ON Luvd QuYNovd ALO NOI1dI9U28S30 NV 7713 110 u3uv3ug 1102312 ISNI p E 40123NNOD WL W2vd Iu13N QuvyOVd HLIM S3lVN 9 SIN3NOdNOO 9NIMO1104 FHL OL SS3200V NV 8000 3ONVN3INIVN 30 9NISO10 NV 9NIN3dO MOTIV TIVHS SS322V LNAWLYVdWOd 55322 8000 321A493S NV AISA LIY SNIINDON jNngi 91 6 X2 HLIN S319VA ONY G2. EE 1 d busi Installation Manual HDKAJ HDKAK HDKAT HDKAU Printed in U S A 981 0623B 08 05 Supplement 981 1053 Date 08 05 Insert with Operator s Manual 981 0161 8 99 Installation Manual 981 0623 8 99 This Supplement adds Model HDKAU to the generator set models covered by the operator s and installation manuals in which it is inserted Page 2 of this Supplement is an updated Specifications page which includes the new generator set model Write a note in the manual under the heading ABOUT THIS MANUAL and also on the Specifications page to refer to the Supplement for Specifications on Model HDKAU Page 1 of 1 Specifications Mode HDKAJ HDKAT Model HDKAK HDKAU _ ENGINE 3 Cylinder In Line Water Cooled Indirect Injection 4 Stroke Cycle Diesel OPERATING SPEED RANGE 1800103200 RPM HDKAJ ORAT FUELGONSUWPTIOR O O aaaea No load 13 gph 49 I h 13 gph 49 I h Half load 4000 W 49 gph 1 85 49 gph 1 85 I h Full load 96 gph 3 63 I h 1 02 gph 3 86 1 DC SYSTEM Nominal Battery Voltage 12 volts 450 CCA down to 0 F 17 C 650 CCA down to 20 F 29 C cU e Weight wet 420 Ibs 191 kg Length x Width x Height 36 3 x 23 6 x 22 3 inch 922 x 599 x 566 mm See oil filling instructions Includes coolant recovery tank Cold Cranking
3. 22 Installation Review 22 Statup ecce hee erbe PEE ECKE HER w ME wei eae ERES 22 Temperature 5 cae vex EXE VEN ERR VA RA deu Yd qu NE 23 OUTLINE DRAWINGS AY 25 1 Redistribution or publication of this document by any means is strictly prohibited Safety Precautions Thoroughly read the OPERATOR S MANUAL before operating the genset Safe operation and top performance can only be obtained when equipment is operated and maintained properly The following symbols in this manual alert you to po tential hazards to the operator service person and equipment alerts you to an immediate hazard which will result in severe personal injury or death alerts you to a hazard or unsafe practice which can result in severe personal in jury or death alerts you to a hazard or unsafe practice which can result in personal injury or equipment damage Electricity fuel exhaust moving parts and batteries present hazards which can result in severe personal injury or death GENERAL PRECAUTIONS e Keep ABC fire extinguishers handy e Make sure all fasteners are secure and torqued properly e 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 e Let engine cool down before removing the coolant pressure cap or opening the coolant dr
4. 10 11 m J mam b E 7 LIFTING EYE ACCESS COVER REMOTE PLUG DETAIL SEE NOTE 6 FIGURE 20 OUTLINE DRAWING TOP 26 Redistribution or publication of this document by any means is strictly prohibited AINO TA0OW WIDHAWWOD NO HOOG 39IAH3S jONYUV310 4000 cp by any means is strictly prohibited Redistribution or publication of this document 27 ONVN31NITVN d Dn we Y 310N 335 310H ONT LNAON rl 12 27255 82 0211 1702 a g 1183 2 126 02 21270 606 81 i T SLE 8 g g A g 8 6 6061 d 052 V EBE X 1 CON 61111 22 97987 8955 d 91 911 9 917 sqvau SI 3925 068 J 80 1 u3A0 SEG 9222 6696 4 1 q ma 01140 113 Leet we 1 W3NV312 310838 19 S et 11 30 331N32 S Sl L161 06 6 997 9 99 776 8 69 SQV3H M3NOS YIAO 6 9 2 26
5. Note also that codes may require bonding conductors from the genset and the battery to the vehicle frame 19 TABLE 2 BATTERY CABLE SIZES FOR TEMPERATURES DOWN TO 20 F 29 C TOTAL CABLE LENGTH CABLE SIZE FEET METERS AWG 0 to 10 0 to 3 a 11 to 15 3 to 4 5 0 16 to 20 4 5 to 6 000 Add the negative battery cable lengths with the positive battery cable lengths for the total A total length of up to 20 feet 6 meters may be used in warmer climates or when battery capacity totals at least 1000 CCA Cold Cranking Amps Alternatively use rated cranking current as the ba sis for calculating battery cable size Rated cranking current for these gensets is 180 amperes at 0 F 18 C The cables should be sized so that voltage across the cranking motor terminals will be within 1 volt of the voltage across the battery terminals SIZE PER TABLE 2 VEHICLE FRAME FIGURE 15 FULL LENGTH CABLE FROM BATTERY NEGATIVE TERMINAL Redistribution or publication of this document by any means is strictly prohibited If a full length negative cable is not run from the battery Figure 16 all vehicle frame members in the path of battery cranking currents must have sub stantial crossections The electrical resistance of riveted or bolted frame joints must also be carefully considered especially if the joints will be exposed to corrosive conditions A cable must be used to con nect the fram
6. might also be applicable Installation codes and rec ommendations can change from time to time and are different in different countries states and munic ipalities Obtain the standards in Table 1 for refer ence TABLE 1 REFERENCE CODES AND STANDARDS NFPA No 70 NFPA NO 501C ANSI A119 2 ANSI RVIA EGS 1 FMVSS 301 National Fire Protection Association 470 Atlantic Avenue Boston MA 02210 Recreational Vehicle Industry Association 14650 Lee Road Chantily VA 22021 State of California Documents Section P O Box 1015 North Highlands CA 95660 California Adminis trative Code Title 25 Chapter 3 CAN CSA Z240 Canadian Standards Association Recreational Ve Housing and Construction Materials Section hicles 178 Rexdale Blvd Bulletin 946 Rexdale Ontario Canada M9W 1R3 Redistribution or publication of this document by any means is strictly prohibited Location Mounting and Enclosure The location mounting and enclosure of a genset must be such that mounting is secure engine ex haust and fuel vapors are prevented from entering the vehicle cooling air flow is not restricted and ready access is afforded for operating the genset and performing periodic maintenance Figure 1 il lustrates typical genset installations Commercial Model HDKAT and HDKAU gensets are suitable for typical commercial vehicles applications as shown as well as RV style applications 1 Orient the genset so that the operator s conso
7. above ambi ent on adjacent combustible material must not exceed 117 F 65 C Do not route the tail pipe near fuel lines or fuel tanks Do not terminate the tailpipe such that it is clos er than 6 inches 153 mm to any opening into the vehicle interior door window vent See Figure 9 In high mount applications Model HDKAT and HDKAU the exhaust tailpipe must be routed down and underneath the vehicle and terminate at least 1 inch 25 4 mm beyond the perimeter of the vehicle Figure 8 The tail pipe may be routed inside the hot exhaust duct Page 10 but not through the interior of the ve hicle The tail pipe must be visible and accessi ble along its entire length for inspection and re placement 3 4 INCH 19 MM MAXIMUM SLOT BOTH SIDES FIGURE 7 EXHAUST TAILPIPE CONNECTIONS 1 INCH 25 mm MINIMUM LAST TAILPIPE HANGER CLOSE TO END FIGURE 8 TERMINATING THE EXHAUST TAILPIPE NO OPENING INTO THE VEHICLE INTERIOR MAY BE CLOSER THAN 6 INCHES 153 mm TO THE END OF THE TAIL PIPE WITHIN SHADED AREA 6in 153 mm TAILPIPE FIGURE 9 MINIMUM DISTANCES TO OPENINGS 13 Redistribution or publication of this document by any means is strictly prohibited 12 Route the tailpipe such that it will not likely be struck when the vehicle is moving At least keep it out of the approach and departure angles of the vehicle and above the axle clearance line Figure 10 DE
8. 10 but not through the interior of the vehicle The tail pipe must be visible and accessible along its entire length for inspection and replacement Redistribution or publication of this document by any means is strictly prohibited SEAMS WELD UP TYP FIGURE 3 ommercial Quiet Diesel 7500 10 GAUGE STEEL RISERS TO SUPPORT WEIGHT OF SET 4 REQ HIGH MOUNT INSTALLATION MODEL HDKAT AND HDKAU ONLY Redistribution or publication of this document by any means is strictly prohibited ial ommercia Guiet Diesel 7500 AIR INTAKE AREA MINIMUM DUCT SIZE 13 25 X 7 5 INCHES 336 6 TO 191 MM LENGTH AS NEEDED UP TO 60 INCHES 1524 MM HOT EXHAUST AREA NOTES e Keep exhausted air away from intake air e Test for recirculating air See Onan Installation Manual 981 0632 e Use foam gasketing material to seal duct to base of set FIGURE 4 INTAKE AIR EXHAUST AIR DUCTING MODEL HDKAT AND HDKAU ONLY 10 Redistribution or publication of this document by any means is strictly prohibited c lt I o H O H lt LL C 2 H 2 Lu FIGURE 5 EXHAUST AIR OUTLINE DRAWING 11 Redistribution or publication of this document by any means is strictl
9. 113 9 23 2 110 1102812 OV 1114 23H2 1NY 1002 YILIN NOI123NNOO LINGNOD wP E HOLIMS LUVLS dOLS WNO LLUN 8820297 100 JLONIY WNOILdO dV 3B0SS38d LNY1009 538513 20 FIGURE 21 OUTLINE DRAWING FRONT AND LEFT SIDES by any means is strictly prohibited Redistribution or publication of this document 0015 91 5 SON AU311V8 0115 91 5 le 61 504 AN311V8 88h 9011 7 56 v 310N 335 y 310N 335 y 310 335 NOI1V201 3414 ONT NAOH 6p 01 JTOH ONT LNNOW 1310H ONILNAON 1VNOILdO 992 69 6 PERS 91 iet L efl m 9 07 1168 02 916 9 0y L 001 G IS i j Z Stl p 9 8 al lt pre pi g g 991 t 817 1 d S 99 LdN 8 1 19 61 i mor Nun138 1304 2 81 o LdN 8 1 97 o NO11V201 3dld Aldd 13n4 TV 1YNOILdO 4 y D O 4 Li S y 8 a g ee J 66 2 WAON3H NOOQ 04 FONVYVITO NIN 17228 6672 90 7 9 09 698 1170 NOI123NNOO LINGNOD v gt M 61 LNO 2V 1VNOIIdO L0 v2 LNO FLOWN 1VNOIIdO e119 SQY3H 43825 43AO 2272 610 FIGURE 22 OUTLINE
10. Learn the symptoms of carbon monoxide poi soning in this manual and never sleep in the ve hicle while the genset is running unless the ve hicle is equipped with a working carbon monox ide detector The exhaust system must be installed in accor dance with the genset Installation Manual En gine cooling air must not be used for heating the working or living space or compartment Inspect for exhaust leaks at every startup and after every eight hours of running Make sure there is ample fresh air when operat ing the genset in a confined area Redistribution or publication of this document by any means is strictly prohibited FUEL IS FLAMMABLE AND EXPLOSIVE e Do not smoke or turn electrical switches ON or OFF where fuel fumes are present or in areas sharing ventilation with fuel tanks or equip ment Keep flame sparks pilot lights arc pro ducing equipment and all other sources of igni tion well away e Fuel lines must be secured free of leaks and separated or shielded from electrical wiring BATTERY GAS IS EXPLOSIVE e Wear safety glasses and do not smoke while servicing batteries e When disconnecting or reconnecting battery cables always disconnect the negative bat tery cable first and reconnect it last to reduce arcing MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH e Do not wear loose clothing or jewelry near mov Mobile 4 ing parts such as PTO shafts fans belts and pulleys e Keep
11. butt connectors and heat shrink insulation tubing to connect to the wiring from the remote panel Use insulated 18 AWG copper conductors for The total load connected to P8 F Switched B should not exceed 2 amp The total load connected to P8 B Status Light should not exceed 2 amp Note To obtain genset status and diagnostics indication the remote panel status light must be the wiring from the remote panel connected to P8 B not to TYPICAL REMOTE CONTROL PANEL COOLANT TEMP VOLTMETER OIL PRESSURE SWITCHED B STOP GENSET CONNECTOR PLUG P8 OPTIONAL UNUSED GAUGE OIL PRESSURE HOURMETER UNUSED START STATUS LIGHT GND SWITCH amp LIGHT FIGURE 14 REMOTE CONTROL CONNECTOR PLUG AND TYPICAL CONNECTIONS 18 Redistribution or publication of this document by any means is strictly prohibited BATTERY CONNECTIONS Do not connect the battery cables to the battery until Installation Review and Startup Page 22 to pre vent accidental starting of the genset during installa tion Accidental starting of the genset can cause severe personal injury or death Do not
12. 0 6 0c 68 l FIGURE 2 FLOOR PLAN Redistribution or publication of this document by any means is strictly prohibited High Mount Installations If the genset is to be mounted high on the vehicle Model HDKAT and HDKAU only consider the fol lowing 1 The maximum fuel pump lift is 36 inches 914 4 mm An additional fuel pump must be used for generator sets mounted more than 36 inches 914 4 mm above the fuel source Auxiliary Fuel Pump Kit 541 0530 is available from Onan 2 Provide 2 5 inches 63 5 mm minimum clear ance to the sides and rear of the genset and 0 25 inch 6 35 mm clearance to the front of the genset This area provides the genset s intake air for cooling 3 Risers must be fabricated to raise and support the genset above the compartment floor This area provides the genset s intake air for cooling Figures 3 and 4 At these clearances mini mum compartment dimensions are Width 24 98 inches 634 5 mm Length 41 35 inches 1050 3 mm Ducting must be fabricated to exhaust hot air from the genset Foam or gasket material must be used between the duct and the base of the set to prevent recirculating of exhausted hot air See Figures 4 and 5 The exhaust tailpipe must be routed down and underneath the vehicle and terminate at least 1 inch 25 4 mm beyond the perimeter of the vehicle Page 13 The tail pipe may be routed inside the hot exhaust duct Page
13. 8 061966 X 301 1717721829 3HONI 38V X H9IH LLL 22 v16 SI 3715 NOI LVTTVISNI WAWINIW 8313NI TTIW 34V SNOISN3WIQO AUVMWI Yd 100 XIV 19 21 6 02 e 8 26 9 11 130 335 y 6821 Lng ayy 5 y 966 9681 5399 TWAONIY J 8113 9 310N 335 310H ONILNNOW Xy 110 NY312 LSNVHX3 110 LSMVHX3 v ut 66 12 t n E 9 899 mmm d 2v 61 916 B 9 8 39NYNV312 4000 I y22 196 alal 5 HA vl jd 612 i 66 16071 261 0 99 0 ee ET SR fe eT TT NIYNO 110 60102 3oNvuv312 wood 9 7 404 0S E pe _______ C85 Ly ez t 66 rl 0 9 2 s PONVEVI 1D HOOQ ELIS 53227 M3H2S LNAWHOVILY 20 pe 1304 028 X2 799 9 8000 3ONVN31NIVH 718 SALON FIGURE 19 OUTLINE DRAWING BOTTOM NOT A PLAN VIEW 25 document Redistribution or publication of this by any means is strictly prohibited NEUTRAL NEUTRAL L2 T GROUND Ji i Qo QUO 99 991 ETAIL A AC OUTPUT TERMINAL BLOCK 6 14 GAUGE WIRE 08 OPTIONAL AC OUT 4 25 3 4 CONDUIT CONNECTION SEE DETAIL AA abet GRAVITY T L ES q h OW 9 b 556 5 21 911 E E 251
14. Amps 0 F 179 Minimum Battery Capacity Page 2 of 2 California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm WARNING A Do not use this genset on a boat Such use may violate U S Coast Guard regulations and can result in severe personal injury or death from fire electrocution or carbon monoxide poisoning diesel warnings Redistribution or publication of this document by any means is strictly prohibited Table of Contents SAFETY PRECAUTIONS luu bl ever obi ete Bd es Bee ES 2 INTRODUCTION 35 4 53 1 960 ODORE QUE S CI Fedex Seca Hb iC B ap ee 4 About this Manual seeni ec i AEN teh Geen dee EN QU 4 Installation Codes and Standards for Safety 4 LOCATION MOUNTING AND ENCLOSURE EXHAUST nne 12 FUEL CONNECTIONS ERSNCRE TERR ERU HER Sees 15 ELECTRICAL CONNECTIONS 2 0 16 Generator Connections 2 2 celsa EE eee 16 Remote Control Connections 2 18 Battery Connections 19 SPECIFICATIONS z eere ho E We Y be dap en ae hc oos uid rt 21 INSTALLATION REVIEW AND STARTUP
15. DRAWING RIGHT AND BACK SIDES 28 Onon 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 Redistribution or publication of this document by any means is strictly prohibited
16. PARTURE ANGLE 13 The exhaust back pressure under full load must not exceed 2 inches 51 mm water column WC as measured within 6 inches 153 mm of the muffler outlet flange ACAUTION Excessive back pressure can cause loss of performance and engine dam age APPROACH AXLE CLEARANCE LINE FIGURE 10 APPROACH AND DEPARTURE ANGLES AND AXLE CLEARANCE LINE 14 Redistribution or publication of this document by any means is strictly prohibited Fuel Connections Diesel fuel is a combustible and can cause severe personal injury or death Do not smoke or allow any flame spark pilot light arc producing equipment electrical switch or other ignition source around fuel or fuel components or in areas sharing ventilation Keep a type ABC fire extinguisher handy Do not interconnect genset and vehicle engine fuel lines Follow the vehicle chassis manufacturer s in structions when making connections to the vehicle engine fuel tank Either or both engines could starve for fuel if the genset and vehicle engine fuel lines are interconnected Always use separate fuel lines or a separate fuel tank for the genset To prevent the genset from running the vehicle out of fuel do not extend the genset fuel pickup tube down into the fuel tank as far as the pickup tube for the vehicle engine Fuel lines supply and return must have at least a 1 4 inch 6 4 mm ID See Figure 11 for connections at the genset Run the fuel li
17. ain Hot coolant under pressure can spray out and cause severe burns e Before working on the genset disconnect the negative battery cable at the battery to pre vent starting e Use caution when making adjustments while the genset is running hot moving or electri cally live parts can cause severe personal inju ry or death Used engine oil has been identified by some state and federal agencies as causing cancer or reproductive toxicity Do not ingest inhale or contact used oil or its vapors Benzene and lead in some gasolines have been identified by some state and federal agencies as causing cancer or reproductive toxicity Do not to ingest inhale or contact gaso line or its vapors Do not work on the genset when mentally or physically fatigued or after consuming alcohol or drugs Carefully follow all applicable local state and federal codes GENERATOR VOLTAGE IS DEADLY Generator output connections must be made by a qualified electrician in accordance with ap plicable codes The genset must not be connected to the public utility or any other source of electrical power Connection could lead to electrocution of utility personnel and damage to equipment An ap proved switching device must be used to pre vent interconnections Use caution when working on live electrical equipment Remove jewelry make sure cloth ing and shoes are dry and stand on a dry wood en platform ENGINE EXHAUST IS DEADLY
18. connect the starting battery until Installa tion Review and Startup Page 22 The genset has a 12 VDC negative ground engine control and cranking system See Specifications for the requirements for cranking batteries Battery Recharging The genset is equipped with a 10 amp regulated voltage battery charger if electrical option B183 was ordered If the option was not ordered other means will have to be provided for recharging the genset battery or batteries Battery Compartment Batteries must be mounted in a separate compart ment from that of the genset and away from spark producing equipment A compartment must have openings of at least 1 7 square inches 11 square centimetres at the top and bottom for ventilation of battery gasses It should be mounted such that spills and leaks will not drip acid on fuel lines wiring and other equipment that could be damaged Arcing can ignite the explosive hy drogen gas given off by the battery causing se vere personal injury The battery compartment must be ventilated and must isolate the battery from spark producing equipment Battery Cables Size battery cables according to Table 2 The cur rent path between the genset and the negative battery terminal must also be able to carry full crank ing current without causing excessive voltage drop It is highly recommended that a full length cable be used to connect the genset to the negative bat tery terminal Figure 15
19. d Startup INSTALLATION REVIEW Before starting the genset inspect the installation and check V each of the following questions if it can be answered YES If an item cannot be checked provision must be made to satisfy the requirement Is the operator s console easily accessible for starting and stopping the genset resetting cir cuit breakers checking and adding engine coolant and oil Is the genset securely bolted in place Are all specified clearances provided Are the air inlet and outlet openings free of ob structions Does the maintenance access door in the bot tom of the genset swing all the way open for fuel and oil filter replacement Is there easy access for draining engine oil Is there easy access for draining engine cool ant Are all tailpipe connections tight and all hang ers and support straps secure Does the tailpipe terminate at least 1 inch 25 mm beyond the perimeter of the vehicle and at least 6 inches 153 mm away from any opening into the vehicle Is the genset located outside the vehicle interior or separated by approved vapor tight and fire resistive materials Are all openings into the vehicle such as for AC wiring sealed to keep out engine exhaust Are AC conduit connectors sealed inside and out side Have all AC connections been inspected and approved Hasa properly sized battery ies been installed in a ventilated compartment isola
20. device to keep the genset and utility from being interconnected See Figure 13 for typical connections Interconnecting the genset and the public utility or any other power source can lead to the electrocution of personnel working on the utility lines damage to equipment and fire An approved switching device must be used to prevent interconnections 50 AMP SHORE POWER AND TRANSFER SWITCH GENSET TERMINALS TO VEHICLE AC DISTRIBUTION PANEL GND L1 N 12 AE TE CR eaae 50 AMP SHORE POWER 120V 240V TRANSFER SWITCH NOT SECURE MORE THAN ONE CONDUCTOR AT ANY TERMINAL TB2 Because L1 and L2 from the genset are in phase current in the Neutral conductors is the sum of the currents in L1 and L2 Wiring and equipment must be sized accordingly 30 AMP SHORE POWER AND TRANSFER SWITCH AND SEPARATE AIR CONDITIONER CIRCUIT TO VEHICLE AC TO REAR AIR CONDITIONER DISTRIBUTION PANEL GND N L2 GENSET TERMINALS GND Li N pom x RCM NN TB2 30 AMP SHORE POWER TRANSFER SWITCH DO NOT SECURE MORE THAN ONE CONDUCTOR AT ANY TERMINAL ON TB2 This circuit has a 30 or 35 amp circuit breaker Wiring and equipment must be sized and protected accordingly FIGURE 13 TYPICAL CONNECTIONS 17 Redistribution or publication of this documen
21. e to the designated negative termi nal on the genset Figure 17 The cable must be sized according to Table 2 The genset mounting bolts are not considered adequate means for bonding the genset to the vehicle frame either for the purpose of carrying cranking currents or for complying with requirements for genset system grounding Route battery cables away from fuel lines and hot engine exhaust components Battery cables should be accessible for inspection and replacement pro tected from damage and secured to prevent chafing due to vibration Routing battery cables with fuel lines can lead to fire and severe personal injury or death Keep battery cables away from fuel lines Genset Bonding Terminal The negative battery cable terminal shown in Figure 17 is also the bonding terminal for grounding the genset to the vehicle chassis If the grounding cable is also going to carry starter motor current it must be sized the same as the battery cables Connecting Battery and Bonding Cables Before connecting the battery and genset clearly and permanently mark the polarity of the battery cables Mark one cable positive on both ends and the other cable negative on both ends Mark bonding cables negative on both ends Making sure the battery cables are NOT yet con nected at the battery connect the positive cable to the POS terminal on the genset Figure 17 and the negative cable and bonding cable
22. h that conden sate from air conditioners will not drip on it Provide protection from direct road splash if the genset is located behind a road wheel Redistribution or publication of this document by any means is strictly prohibited TYPICAL RV INSTALLATIONS FIGURE 1 TYPICAL GENSET INSTALLATIONS Redistribution or publication of this document by any means is strictly prohibited r J2NV43gV312 8000 JINVUVIATD 3000 0 310H 9NI1INAON 69 0 3 ONT LNNOW 60 322V MAYS v S3HONI 3HY SNOISN3INIG JoNY3V312 0 vt yooq NIVUd 110 4 _____ J29NV3V412 4000 AE 9 601 08 4000 JONVNALNI VW 9 DJ LNAWLYVdWOd S40 LNAWLYEVdWOd S470 7 55 MAYS ONILNNOW 31OH HONI dWNd 1915 S31OH HONI 620 110 41 NAWINIW LN3NLdVdNOO 568 9t X JAIM EL Y2 JIOH ONT LNNOW JIOH ON LNAOW 110 pe JIOH ONILNMOW Xv lt 10
23. hands away from moving parts e Keep guards in place over fans belts pulleys etc DO NOT OPERATE IN FLAMMABLE AND EXPLOSIVE ENVIRONMENTS Flammable vapor can cause a diesel engine to overspeed and become difficult to stop resulting in possible fire explosion severe personal injury and death Do not operate a diesel powered genset where a flammable vapor environment can be created by fuel spill leak etc unless the genset is equipped with an automatic safety device to block the air intake and stop the engine The owners and operators of the genset are solely re sponsible for operating the genset safely Contact your authorized Onan Cummins dealer or distribu tor for more information Redistribution or publication of this document by any means is strictly prohibited Introduction ABOUT THIS MANUAL This manual is a guide for the installation of the HDKAJ HDKAK HDKAT and HDKAU Series of generator sets gensets Proper installation is es sential for safe reliable and quite operation Read through this manual before starting the installation Keep this manual and the Operator s Manual with the other vehicle manuals This manual addresses the following aspects of the installation e Location Mounting and Enclosure e Exhaust Connections e Fuel Connections e Electrical Connections e Startup Improper installation can result in severe personal injury death and equipment damage The installer must be qualif
24. ied to per form the installation of electrical and mechani cal equipment Unauthorized modifications or re placement of fuel exhaust air intake or speed control system components that affect engine emissions are prohibited by law in the State of California See the Operator s Manual for operation and main tenance and the Service Manual for service Note Manuals are updated from time to time to re flect changes in the equipment and its specifica tions For this reason only the copy of the installa tion manual supplied with the genset should be used as a guide for the installation INSTALLATION CODES AND STANDARDS FOR SAFETY The builder of the RV or work vehicle bears sole re sponsibility for the selection of the appropriate gen set for its proper installation and for obtaining ap provals from the authorities if any having jurisdic tion over the installation These sets meet the basic requirements of the Standard for Safety for Engine Generator Sets for Recreational Vehicles ANSI RVIA EGS 1 They are suitable for installation in ac cordance with e NFPA No 70 Article 551 Recreational Ve hicles and RV Parks e ANSI A119 2 NFPA No 501C Recreational Vehicles e CSA Electrical Bulletin 946 Requirements for Internal Combustion Engine Driven Electric Generators for Use in Recreational Vehicles Federal State and local codes such as the Califor nia Administrative Code Title 25 RV installation
25. is indoors or where exhaust can accumulate Check for fuel coolant and exhaust leaks and un usual noises while the genset is running under full and intermediate loads Do not place the genset in service until all fuel and exhaust leaks have been fixed and operation is satisfactory 22 Redistribution or publication of this document by any means is strictly prohibited TEMPERATURE TEST Conducted this test on the first installation represen tative of a new application of a genset Do not con tinue production until the temperature specifica tions are met Thermocouples Measure temperatures with thermocouples not heavier than 24 AWG 0 21 mm at the loca tions shown in Figure 18 When called for shield the thermocouple with a 2 inch diameter by 6 inch long white PVC pipe or equivalent 1 Locate a shielded thermocouple in the center of the air inlet opening of the genset to measure in let air temperature 2 Locate a shielded thermocouple within 48 inch es 1 2 meters of the inlet air opening and at the same height to measure ambient air tempera ture Make sure it is not affected by warm air dis charged from the genset 3 Locate a thermocouple on the oil dip stick to measure oil temperature The thermocouple should not extend past the ball on the end of the dip stick To prevent severe scalding al ways let the engine cool down before remov ing the coolant pressure cap Turn the cap slowly and do no
26. le will be outboard and accessible There should be easy access for starting and stopping the genset resetting the circuit breaker s check ing and replenishing engine oil and coolant re placing the fuses on the back of the access panel on the console and withdrawing the cool ant system pressure cap and fill hose For el HDKAT and HDKAU provide access to the side service door Figure 21 and air filter A Remote Air Cleaner Kit 541 0531 is available from Onan for Models HDKAT and HDKAU 2 Locate the genset so that there is sufficient ac cess for battery fuel exhaust remote control and AC connections The exhaust tailpipe must not terminate underneath the vehicle and must be visible and accessible along its whole length for inspection and replacement 3 Support the genset on a structure able to resist the dynamic weight of the genset 420 lbs 191 kg 3 g force 1260 Ibf vertical and 1 g force 420 Ibf horizontal The genset is shipped with four 3 8 16 by 1 1 2 inch thread forming screws to secure it to the supporting frame or floor Design the genset support structure carefully to prevent the genset from falling from the vehicle and possibly causing a serious road accident 4 Provide at least 0 5 inch 12 7 mm clearance to the top and 0 25 inch 6 4 mm clearance to the sides of the genset See Figure 2 At these 10 clearances minimum compartment dimen sions are Height 22 78 inches 578 6
27. mm Width 24 73 inches 628 1 mm Length 36 85 inches 936 mm If the genset is mounted on the floor of the coach in a compartment inside the envelope of the living space or cab provide a vapor tight fire resistive compartment of 26 gauge galva nized steel or equivalent to isolate the genset from the vehicle interior Do not duct genset cooling air which can include exhaust gases into the vehicle for heating EXHAUST GAS AND FIRE ARE DEADLY Install a vapor tight and fire re sistive barrier of approved materials be tween the genset and the vehicle interior Do not duct genset cooling air into the ve hicle for heating Provide cutout openings in a compartment floor that are at least as large as the cooling air inlet and outlet openings in the bottom of the genset shaded areas in Figure 2 Frame cross members must NOT cut across the open ings Make sure that vehicle components located be low the genset including the genset exhaust tailpipe will not interfere with draining coolant engine oil and removing the oil and fuel filters The maintenance door in the base of the genset must be able to swing open a full 90 degrees without interference Models HDKAJ and HDKAK See shaded area in Figure 2 for cut out area Provide access for removing the two fuel pump mounting screws so that the genset does not have to be removed to replace a fuel pump See Figure 2 Locate or shield the genset suc
28. ne at or above the top of the fuel tank to reduce the risk of siphoning fuel out of the tank if the line should break The maximum fuel pump lift is 36 inches 914 mm An auxiliary fuel pump kit Kit 541 0530 is available from Onan for generator sets mounted more than 36 inches 914 mm above fuel source Route fuel lines away from electrical wiring and hot engine exhaust components Fuel lines should be accessible for inspection and replacement pro tected from damage and secured to prevent kinking contact with sharp edges and chafing due to vibra tion 15 FUEL SUPPLY 1 8 INCH NPT FUEL RETURN 1 8 INCH NPT FIGURE 11 FUEL CONNECTIONS Redistribution or publication of this document by any means is strictly prohibited Electrical Connection Do not connect the battery cables to the battery until Installation Review and Startup Page 22 to pre vent accidental starting of the genset during installa tion Accidental starting of the genset can cause severe personal injury or death Do not connect the starting battery until Installa tion Review and Startup Page 22 GENERATOR CONNECTIONS The genset is equipped with a terminal block and conduit connector knockouts for AC power output connections Figure 12 See Figure 13 for typical connections Wiring Methods Follow the National Electrical Code especially not ing the following 1 Have a qualified elec
29. nto the engine that is idle causing engine damage 2 Use 1 3 8 inch ID 18 gauge aluminized steel tubing or equivalent for the tailpipe Do not use flexible pipe Flexible pipe is not gas tight or du rable 3 Secure the tailpipe or adapter flange to the muf fler flange with a gasket and two 5 16 18 bolts MUFFLER OUTLET FLANGE TAILPIPE CLEARANCE HOLES USE AN ELBOW ADAPTER FIGURE 6 EXHAUST CONNECTION AT GENSET 12 Redistribution or publication of this document by any means is strictly prohibited 10 11 Use U bolt muffler clamps to connect sections of tailpipe It is recommended that the overlap ping pipe be slotted as shown in Figure 7 Use automotive type tailpipe hangers every 2 to 3 feet 610 to 914 mm Attach the hangers to steel framework not to wood or other com bustible material Do not terminate the tailpipe underneath the vehicle Extend it a minimum of 1 inch 25 mm beyond the perimeter of the vehicle Figure 8 Support the end of the tailpipe such that it can not be pushed inward and up under the skirt of the vehicle Do not route the tailpipe such that it will interfere with opening the maintenance door or draining engine oil or coolant or restrict the air inlet Do not route the tailpipe closer than 3 inches 76 mm to combustible material wood felt cotton organic fibers etc unless it is insulated or shielded The temperature rise
30. s to the NEG terminal on the genset Connect the battery cables to the battery only at STARTUP Page 22 Reversing battery connections can lead to battery charger failure if so equipped 20 SIZE PER TABLE 2 GENSET c2 Ii VEHICLE FRAME FIGURE 16 VEHICLE FRAME AS PATH FROM BATTERY NEGATIVE TERMINAL GENSET BONDING GENSET BATTERY TERMINAL CABLE TERMI NALS FIGURE 17 BATTERY CABLE CONNECTIONS Redistribution or publication of this document by any means is strictly prohibited Specifications Ted HOKASTHDKAT Mode HDKAKT HOKAU_ Frequency Line Circuit Breaker s One 2 pole 30 or 35 amp One 2 pole 30 or 35 amp ENGINE 3 Cylinder In Line Water Cooled Indirect Injection 4 Stroke Cycle Diesel 2500 10 3200 RPM 20010 3200 RPM HDKAU PFUELCONSUMPTION I No load 13 gph 49 1 13 gph 49 I h Half load 4000 W 49 gph 1 85 I h 49 gph 1 85 I h Full load 96 gph 3 63 I h 1 02 gph 3 86 1 DC SYSTEM 12 volts 450 CCA down to 0 F 17 C 650 CCA down to 20 F 29 C ciem Du Weight wet 420 Ibs 191 kg Length x Width x Height 36 3 x 23 6 x 22 3 inch 922 x 599 x 566 mm See oil filling instructions Includes coolant recovery tank Cold Cranking Amps 0 F 17 Minimum Battery Capacity 21 Redistribution or publication of this document by any means is strictly prohibited Installation Review an
31. set will shut down and fault code No 33 High Engine Coolant Temperature will be displayed by the status indicator light High temperatures and temperature rises indicate that warm discharge air is recirculating back into the genset compartment or that the inlet or outlet air opening is restricted Find out why and correct as necessary to meet the temperature specifications TABLE 3 TEMPERATURE DATA TEMPERATURE RG THERMOCOUPLE LOCATION Time Of Reading eame cooaNT enaincou _ Power Output Ratings Maximum genset power nameplate rating is 7500 watts in an ambient of 85 F 29 C but only 6000 watts in an ambient of 120 F 50 C the maximum operating temperature Also continuous operation at up to 80 percent of maximum power 6000 watts is acceptable Redistribution or publication of this document by any means is strictly prohibited THERMOCOUPLE SECURED IN CENTER OF THERMOSTAT OUTLET SHIELDED THERMOCOUPLE AT AIR INLET THERMOCOUPLE SECURED TO END OF OIL DIP STICK SHIELDED THERMOCOUPLE LOCATED 48 INCHES 1 2 METERS MAXIMUM FROM AIR INLET AND AT SAME HEIGHT FIGURE 18 THERMOCOUPLE LOCATIONS 24 Redistribution or publication of this document by any means is strictly prohibited 11 13
32. t by any means is strictly prohibited REMOTE CONTROL 5 Keep control leads away from AC power leads to reduce the possibility of erratic operation due Figure 14 shows the 10 pin plug on the end of the to induced signals remote control leads and typical connections to a re 6 mote control panel The plug and leads are stowed inside the AC terminal enclosure when the genset is shipped from the factory Harnesses of various lengths with mating receptacles are available sepa rately Seal the hole where the leads enter the interior of the vehicle to keep out exhaust gas Use sili cone rubber or an equivalent type of sealant EXHAUST GAS IS DEADLY Seal all wiring openings into the vehicle in terior to keep out exhaust gas Wiring Methods Remote Control Panels 1 Remove the AC terminal access cover and re 1 The control switch should be two pole move one of the control wiring knockouts mentary contact center return center off type 2 Pull out the remote control connector plug fit of switch with an indicator light the bushing around the connector leads into 2 the knockout slot and secure the access cover The engine oil pressure and water temperature gauges should be compatible with the genset See your Onan dealer for makes and models 3 Snap the connector plug and harness recep tacle together If the harness does not have a plug for connec tions at the control panel use solder type
33. t open it fully until the pres sure has been relieved 4 First relieve coolant system pressure by loosen ing the coolant pressure cap Then secure the cap and remove the coolant hose from the ther mostat outlet Secure a thermocouple so that the bead is in the center of the thermostat outlet fitting Run the leads out between the fitting and hose and secure the hose with a new hose clamp Method 1 Conduct the test at a location where the ambient air temperature will remain between 60 F and 100 F 16 C and 38 C during the test 2 Connect the genset to a load bank that can be adjusted to apply full rated load 23 3 Run the genset under full load with all service and compartment doors closed and record temperatures every 15 minutes until they stabi lize Temperature is considered stable when there is no change in three consecutive read ings See Table 3 for an example of how the data can be recorded Temperature Specifications To determine temperature rises subtract the ambi ent air temperature from the other temperatures in the same column in Table 3 Inlet Air Temperature Rise The rise in inlet air temperature over ambient air temperature must not exceed 8 F 4 4 C Oil Temperature Rise The rise in engine oil tem perature over ambient air temperature must not ex ceed 190 F 106 C Maximum Coolant Temperature Maximum cool ant temperature is 230 F 110 C at which point the gen
34. ted from the genset Have properly sized battery cables been installed and secured at sufficient intervals to prevent chaffing and contact with sharp edges fuel lines and hot exhaust parts 15 the genset bonding terminal negative battery cable terminal properly grounded to the vehicle chassis Are all fuel connections tight Hasthe fuel lines been secured at sufficient in tervals to prevent chaffing and contact with sharp edges electrical wiring and hot exhaust parts 15 the genset protected from direct road splash Is the genset located or shielded such that con densate from air conditioners will not drip on it STARTUP When all the items on the Installation Review check list have been checked connect the battery cables to the battery positive cable first Batteries give off explosive gases that can cause severe personal injury Do not smoke near batteries Keep flames sparks pilot lights electrical arcs and arc producing equip ment and all other ignition sources well away Read the Operator s Manual and perform the main tenance and pre start checks instructed The gen set is shipped from the factory with the proper level of engine oil which should nevertheless be checked before the genset is started Start and operate the genset following all the instructions and safety pre cautions in the Operator s Manual EXHAUST GAS IS DEADLY Do not operate the genset when the vehicle
35. trician supervise and in spect the installation of all AC wiring 2 Secure only one lead at each AC output termi nal The terminals are suitable for wire sizes up to No 6 AWG 3 Install vibration proof switches and controls that won t open and close circuits when the ve hicle is in motion 4 Provide ground fault circuit interrupters GFCls for all convenience power receptacles 5 Route AC wiring remote control wiring and fuel lines separately 6 Seal all conduit openings into the vehicle interi or to keep out exhaust gas Apply silicone rub ber or an equivalent type of sealant inside and outside each conduit connector Flexible con duit is not vapor tight and will allow exhaust gas to enter along the wires if not sealed EXHAUST GAS IS DEADLY Seal all wiring openings into the vehicle in terior to keep out exhaust gas S 16 AC WIRING KNOCKOUTS FIGURE 12 AC OUTPUT BOX CONTROL WIRING KNOCKOUTS Redistribution or publication of this document by any means is strictly prohibited 7 Bond the genset and all connected and DC equipment and controls to a common ground ing point in accordance with applicable codes Faulty grounding can lead to fire and electrocution resulting in severe personal injury or death Grounding must be in accordance with applicable codes Connecting the Vehicle to Utility Power When the vehicle has provision for connecting utility power it must have an approved
36. y prohibited Exhaust Connections The exhaust system must be gas tight and de signed to limit entry of exhaust gases into the ve hicle EXHAUST GAS IS DEADLY Keep exhaust gases from entering the vehicle Do not terminate the exhaust tailpipe underneath the vehicle or closer than specified to openings into the vehicle Figure 9 or route it such that it is likely to be damaged Figure10 Use approved materials and parts only The muffler is mounted inside the genset housing and has a flanged outlet opening Figure 6 The muffler is approved by the U S Forest Service as a spark arrest muffler Failure to provide and main tain a spark arrester can be a violation of the law Liability for damage injury and warranty expense due to the modification of the exhaust system or due to the use of unapproved parts becomes the re sponsibility of the person performing the modifica tion or installing the unapproved parts Contact an Onan distributor for approved exhaust system parts Tailpipe adapter kits are separately available Use a straight adapter for a tailpipe routed up from below the genset Use an elbow adapter for a tailpipe routed through the clearance hole in the right or back side of the base of the genset When connect ing and routing the tailpipe 1 Do not connect the genset to the vehicle engine exhaust system Interconnecting the engine ex haust systems will allow exhaust conden sates and soot to migrate i
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