Onan DKD Operator`s Manual - Reliable Diesel Truck and Trailer
Contents
1. see ok Oeo omo ee seme ee eens et es ae aren eel k i ma a ES orem ap nn oe ae A I A A a athe lt ene ee eane Er m DKD e e ih r Tae 3 Printed in U S A 981 0124 7 95 a PLE it J p 2 4 2 2 4 B e Redistribution or publication of this document PFa h F p 1 L LL 7 weneration by any means is strictly prohibited Safety Precautions Before operating the generator set read the Operator s Manual and become familiar with it and the op ment Safe and efficient operation can be achieved only if the unlit Is properly operated and malntalned Many accidents are caused by failure to follow fundamental rules and precautions The following symbols found throughout this manual alert you to panman dangerous conditions to the operator service per sonnel or the equipment MAs This symbol warns of immediate haz ards which will result in severe personal Injury or death This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death CAUTION This symbol refers to a hazard or unsafe practice which can result in personal injury or prod uct or property damage FUEL AND FUMES ARE FLAMMABLE Fire explosion and personal injury can result from improper practices DO NOT fill fuel tanks while engine is running Fuel contact with hot engine or exhaust is a potential fire hazard e DONOT SMOKE OR USE AN OPEN FLAME near the ge2. 4 It protects the generator from a short or overload in the circuit provided for operating an AC remote radiator cooling fan not used if a 12 VDC fan is used LINE CIRCUIT BREAKER SIDE OF CONTROL CONTROL START STOP BOX BREAKER PREHEAT SWITCH C 1525a TIME BREAKER BATTERY METER CHARGE BREAKER FIGURE 3 7 5 6 5 AND 6 0 DKD CONTROL BOX FRONT PANEL START STOP PREHEAT SWITCH DC CONTROL BREAKER DC CHARGING BREAKER FAULT RESET BREAKER FIGURE 4 DC CONTROL BOX FRONT PANEL REMOTE MOUNT VERSION Pr ek 2 Ove Sp eneration STARTING Starting at Control Panel The following steps outline the correct procedures for starting the generator set at the generator control panel The DC Control Breaker must be in the ON position 1 Press the Start Stop Preheat switch toward the Preheat Stop position for 10 to 30 seconds depend ing upon temperature as shown in Table 2 Do not exceed 30 seconds Preheat time longer than 30 A CAUTION seconds can damage glow plugs TABLE 2 PREHEAT TIME Ambient Temperature Preheating Time eg IEE Above 86 F 30 C Between 50 to 86 F 10 to 30 C About 10 sec About 15 sec About 20 sec About 30 sec Between 32 to 50 F 0 to 10 C Below 32 F 0 C 2 Release the switch from the Preheat position and push it toward the Start position This activates the engine control and starting system The starter will crank and after a few
3. 425 Cooling System Capacity Engine and Radiator 2 0 2 ccc eee eee 4 at 3 8 L Engine Oil Capacity with Filler 2 2 0 0 2 eee cc eee eee renee ene nees 4 qt 3 8 L Remote mount radiator systems may require additional coolant THE 6 5 7 5 AND 8 0 DKD ARE LISTED BY NATIONWIDE CONSUMER TESTING INSTITUTE INC te Power aa 2 Redistribution or publication of this document SS Generation by any means is strictly prohibited Operation 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 Nausea Headache Weakness and Sleepiness Throbbing in Temples Muscular Twitching Vomiting inability to Think Coherenitly IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist seek medical atten tion Shut down the unit and do not operate until it has been inspected and repaired Never sleep in vehicle with the generator set running unless the vehicle interior is equipped with an operating carbon monoxide detector Protection against carbon monoxide inhalation also includes proper exhaust system installation and visual and audible inspection of the complete exhaust system at the start of each generator set operation GENERAL This section covers starting and operatin
4. If this happens severe engine damage might result Operate the generator set under load at least one hour per week Exercising for one longer period each week is better than several shorter periods of operation Do NOT oper ate the set for extended periods at no load Low Temperature High Altitude Operation 1 Use correct SAE oil for temperature conditions Change oil only when warm See Table 4 2 Use No 1 diesel fuel for temperatures lower than 14 F 10 C or for all temperatures if altitudes are above 5000 feet 1500 m The fuel should have a cetane rating of at least 40 and have less than 0 5 percent sulfur if possible Decrease oil change interval by half if sulfur content is higher Extremely Dusty or Dirty Conditions Observe the following items during operation in extremely dusty or dirty environments Keep unit and radiator cooling surfaces clean Service air cleaner more frequently as necessary Change crankcase oil every 50 operating hours Clean generator as necessary See MAINTE NANCE Section Redistribution or publication of this document by any means is strictly prohibited Generation TROUBLESHOOTING DC Control The DC control has a number of sensors that continu ously monitor the engine for abnormal conditions such as low oil pressure and high coolant temperature If any one of these conditions occur the control stops the engine See Figure 5 The following sections describ
5. machine screws securing the breather baffle element plate and shield 3 Clean element in a suitable solvent Dry element then saturate with engine oil before replacing AWARNING Many cleaning solvents present a hazard of severe personal injury or death Follow the manufacturer s in structions and proceed with care lf necessary clean other breather components ina suitable solvent before reassembling Q r N CAP NUTS Sow if O RINGS ee A g CYLINDER AS HEAD COVER GASKET Sg BAFFLE ELEMENT PLATE SHIELD MACHINE SCREWS a C 1102 FIGURE 13 CRANKCASE BREATHER ASSEMBLY MUFFLER SPARK ARRESTER Exhaust spark arresters are necessary for SAFE OPER ATION All require periodic clean out to maintain maxi mum efficiency See the maintenance schedule for recommended cleaning intervals To clean the spark arrester remove the 1 8 inch pipe piug from the bottom of the muffler Run the generator set with load for five minutes Stop the generator set and allow the muffler to cool Replace the pipe piug in the muffler See Figure 14 ON PIPE PLUG FIGURE 14 EXHAUST MUFFLER EXS 1124 1 Cleaning the Generator Set The generator set should be cleaned every six months or sooner if severe road contamination or dusty condi tions are encountered Dust usuaily can be removed with a damp cloth Some road contaminants however may require steam for removal Do not steam clean the generat
6. oom MAY VARY FROM Flushing After cleaning or before filling the system with new coolant drain the biock and radiator and fill with clean water Operate the set for 10 minutes and then drain the system completely Refill with the recom mended coolant Never pour hot water into a cold ACAUTION engine or cold water into a hot engine Doing so can crack the head or the cylinder block Do not operate the unit without water for even a few minutes Thermostat Replace thermostat when it is broken corraded or sticks in the open or closed position If engine overheats or does not reach and maintain a minimum operating temperature the thermostat should be removed and tested as a possible cause The thermostat can be removed for testing or replace ment using the following procedure 1 Drain cooling system 2 Remove capscrews and washers that secure ther mostat cover to water pump housing 3 Raise thermostat cover with radiator hose intact and position it fo one side 4 Remove thermostat cover gasket and thermostat 5 Clean inspect and remove any gasket material from the thermosiat cover and housing Use a new gasket when replacing thermostat Refill cooling system with the recommended antifreeze coolant Pressure Cap Closed cooling systems make use of a pressurized cap to increase the boiling point of the coolant and allow higher operating temperatures Pressure caps should be replaced every two years or sooner if
7. seconds the engine should start The starter will automatically disconnect when the generator AC voltage builds up 3 If engine does not start after cranking 30 seconds release Start switch Wait two minutes and then repeat Steps 1 and 2 Excessive cranking periods can ACAUTION overheat and damage the start er Do not engage starter for periods longer than 30 seconds without allowing two minutes for start er to cool 4 lf engine does not starton second try check the fuel supply and be sure system has been primed If the generator set runs out of fuel the fuel system may need priming before it will start See Fuel System in the MAINTENANCE section Remote Starting If generator set is started from a remote location the same procedures and cautions as for starting at the control panel should be followed Start up Checks Check gauges on the remote control panel if equipped after the engine is started Observe the oil pressure gauge immediately Redistribution or publication of this document by any means is strictly prohibited Oil Pressure Gauge The oil pressure should be in the range of 35 to 50 psi 241 to 345 kPa when the engineis at operating temperature but may vary below this range under various conditions DC Voltmeter Normal B battery voltage during opera tion should be 14 to 15 volts Water Temperature Gauge The water temperature should be in the range of 165 to 195 F 74 to 91 C depend
8. they mal function FAN BELT MODELS EQUIPPED WITH RADIATOR A loosened fan belt can cause the engine to overheat If this occurs loosen the adjusting nut and tighten the belt Be sure to retighten the adjusting nutafter the adjlstment Proper fan belt tension is such that the belt deflects about 0 4 in 10 mm at the middle when pressed with a finger at a force of 22 lbs 10 kq See Figure 8 The belt can be removed for inspection or replacement by loosening the adjustment nut and pushing alternator inward Inspect fan belt for excessive slickness oil soak wear tear cracks and overstretching Replace if needed Contact with rotating machinery can AWARNING cause severe personal injury or death Stay clear of rotating components and secure guards and shields in place before operating machinery Power 10 Generation Redistribution or publication of this document by any means is strictly prohibited ADJUST TENSION HERE PUMP FAN PULLEY CS 1239 FIGURE 8 BELT TENSION ADJUSTMENT FUEL SYSTEM Use only a good quality jue obtained from a reputable supplier The quality of fuel used is important in obtain ing dependable performance and satisfactory engine life Fuels must be clean completely distilled well refined and non corrosive to fuel system parts Fuel presents the hazard of fire or AWARNING explosion which can cause severe personal injury or death Do not permit any flame spark pilot
9. AUTION below the ADD mark or above the FULL mark Overfifling can cause foaming or aeration of the oil while operation below the ADD mark might cause loss of oil pressure r 2 AOAC i N OIL FILL DIPSTICK DRAIN VALVE M 1589 FIGURE 6 ENGINE OIL Oil and Filter Change Change the oil and filter at the intervals recommended in the maintenance table Use oil that meets the API classification and viscosity requirements as indicated in the previous section Engine Oil Change Run engine until thoroughly warm before draining oil Stop the engine place a pan under the drain outlet and open the drain valve After the oil is completely drained close the drain valve Refil with oil of the correct API classification and appropriate SAE viscosity for temperature conditions Hot crankcase oil can cause burns if AWARNING itis spilled or splashed on skin Keep fingers and hands clear when removing the oil drain plug and wear protective clothing Oil Filter Change Spin off oil filter and discard it Tho roughly clean filter mounting surface Apply a thin film of oil to filter gasket and install new element Spin element on by hand until gasket just touches mounting pad and then turn an additional 1 2 turn Do not overtighten With oil in crankcase start engine and check for leaks around filter element Retighten only as much as neces sary to eliminate leaks but do not overtighten Power COOLING SYSTEM _ The cooling
10. ICAL AiR CLEANER COMPONENTS Power 12 Generation Redistribution or publication of this document by any means is strictly prohibited BATTERY Check the condition ofthe starting battery at the interval specified in the Periodic Maintenance Schedule Always disconnect the negative ground strap from the battery before working on any part of the electrical sys tem or the engine Disregard the sections on Checking Specific Gravity and Checking Electrolyte Level if using a mainienance free type battery ignition of explosive battery gases AWARNING can cause severe personal injury Do not smoke while servicing batteries Cleaning Battery Keep the battery clean by wiping it with a damp cloth whenever dirt appears excessive lf corrosion is present around the terminal connections remove battery cables and wash the terminals with an ammonia solution or a solution consisting of 1 4 pound about 100 grams of baking soda added to 1 quart about 1 litre of water Be sure the vent plugs are tight to prevent cleaning solution from entering the cells After cleaning flush the outside of the battery and sur rounding areas with clean water Keep the battery terminals clean and tight After making connections coat the terminals with a light application of petroleum jelly or non conductive grease to retard corrosion Checking Specific Gravity Usea battery hydrometer to check the specific gravity of the electrolyte in each ba
11. act used oil Remove all unnecessary grease and oil from the unit Accu mulated grease and oil can cause overheating and engine damage which presents a potential fire hazard DO NOT store anything in the generator compartment such as oil or gas cans oily rags chains wooden blocks portable propane cylinders ete A fire could result or the generator set operation cooling noise and vibration may be ad versely affected Keep the compartment floor clean and dry Do not work on this equipment when mentally or physically fatigued or after consuming any alcoho or drug that makes the operation of equipment unsafe Redistribution or publication Bis document by any means is strictly prohibited Table of Contents TITLE PAGE SAFETY PRECAUTIONS PEE sie uu qa E A O E E neues Inside Front Cover TABLE OF CONTENTS 20 cece eee eee eres EE A peek eee ee A aae 1 INTRODUCTION saihnte S ae oun enue a Cae EA pean EE EE E eeuee ce eee ecu 1 About this Manual 0ccceeeeeeee peur dwekdaa tease teed den se E E T erisa d How to Obtain Service 0 ccc ccc ccc eee e eens saosin esaewenteceuss EE eae 1 SPECIFICATIONS cece ees CERNANA P PE E E EA Torre Terr eT Tre Te ree 2 OPERATION sp ak dips wo Ane wee aes Gears bees TEE EE E eo eset pie nies cease Ceweeteaeacae 3 General csc ikcxduwindussdiveusesaveees ia Nie cuas saan T A Goadad tee aneetnnesaanes jeseeeecsussanes 3 Pre Start Che
12. as a reference to keep an accurate log of all service performed for warranty support Perform all service at the time period indicated or after the number of operating hours indi cated whichever comes first Use the table to determine the maintenance required and then refer to the sections that follow for the correct service procedures AWARNING Accidental starling of the set can cause severe personal injury or death Disconnect the negative battery cable when repairs are made to the engine controls or generator TABLE 3 PERIODIC MAINTENANCE SCHEDULE SERVICE TIME SERVICE THESE ITEMS Change Air Cleaner Element Clean Gooling System Monthly 6 Months Yearly or or or after atter after 100 hours 250 hours 500 hours 1 Check for oll fuel cooling and exhaust system leaks Check exhaust system audibly and visually with set running and repair any leaks immediately Replace corroded exhaust and fuel line components before leaks occur 2 Perform after first 35 hours of operation on new sets 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 Power Redistribution or publication of this document by any means is strictly prohibited Generation aa A Gua Ph Y kaem 2a GENERATOR SET INSPECTION During operation be alert for mechanical problems that could create unsafe or hazardous conditi
13. ature of the tank more rapidly than the temperature of the fuel If the fuel level is low the upper portion of the tank will cool more rapidly and tend to form condensation Condensation water can cause clogging of fuel filters as well as freezing problems in addition water mixing with the sulphur in the fuel forms acid which can cor rode and damage engine parts Priming the Fuel System The fuel system must be primed prior to initial start up or after the engine has run out of fuel Low Pressure Fuel System The electric fuel pump fuel filter and injection pump inlet comprise the low pressure fuel system To prime these components follow the same procedure as when the fuel filter is replaced fol lowing section Be sure to check fuel level in fuel tank and that shut off valve is open FUEL PUMP FUEL INLET FITTING Fai ti n AENA c i Ba f m sr i er m A EPDE r Pz a r KAAN A Daa Ss If NLT ll i N Poe NOTE GENSET APPEAR ANCE MAY VARY FROM W Z THIS ILLUSTRATION S EL lt f ae PUMP FIGURE 9 INJECTION PUMP FUEL SYSTEM 7 5 DKD SHOWN FOR REFERENCE ONLY FILTER FS 1615 Redistribution or publication of this document by any means is strictly prohibited Fuel Filter The filter replacement interval will vary according to the fuel quality and cleanliness Using the wrong fuel or dirty fuel will shorten the service life of the f
14. cks ccc ceec enn cctseeenenecees aww bevy bosresuen E A EEE 3 Control Panel s casicuviveiaeseaes phd eke ba E EE EEE E N EET TAT pens os nha eeearee 3 SLANG A E E PAEO E E E E E EEE E cus 4 SIODOING saienisi EN EEEE TE PE E OE P EEE EE E TT T T 5 Operating Recommendations sssesesesrererso E nce ceuee ede cscasaewenescsoe ues 5 THOUDIESHOOUNG snnc sac E N cee no ewave E E E T T 6 MAINTENANCE Se oc eT rere rr er eee a ee er ee PT T Periodic Maintenance Schedule cccvecvcccsvecnesrceeeenseeseeereseseccnssnaesanourecresenes 7 Generator Sot NSD ECUON cisheyguceandcsceerinedecesedewn EE ANENE EA N r 8 Lubrication System ssssssisisresrisrresrrisstnirpi neisi nran errari re kusti tard cathe ty askna wage ats 8 Can lling SUSI oe tvciscneveewsateiacrneis E eee enconectabdsaeniaudwensae ree iserweaes 9 A i SA E E E TE E EEE O E TTT TTET 10 Fua Syo irasas ari EEEE AAE E E EES EENE R EE TEER AEA 1 PA COAG ccc wie bactontecsceccaisundedscesaseassereeecusuanenencsseurerers onueessaaens esse eeecsoes 12 BANGIN AEE EE E core ni eene gh sands aera wusaebeverderenvesGesneueorencus 13 DC GORGIAION en 4 bas keane Senn eee weeds ciye be new eed noe ne by dae esas es eaten emcee saees 13 Crank ase Droalher ee eee er ee 14 UC er A er ere ee er ree er ee rrr 14 ut of Service Protection ac 5 cba o540s cen sie ceanea erie eine a se dekads dene ondeweeee ees 14 California Proposition 65 Warning Diesel engine exhaust and some of its const
15. ct exhaust system daily for leaks per the maintenance schedule Be sure that exhaust manifolds are secure and not warped Do not use exhaust gases to heat a compartment e Be sure the unit is well ventilated MOVING PARTS CAN CAUSE SEVERE PERSONAL IN JURY OR DEATH e Before starting work on the generator set disconnect batter aS This will prevent accidental arcing i ii Generation e Keep your hands away from moving parts e Make sure that fasteners on the generator set are secure Tighten supports and clamps keep guards in position over fans drive belts etc e Do not wear loose clothing or jewelry while working on gen erator sets Loose clothing and jewelry can become caughi in moving parts Jewelry can short out electrical contacts and cause shock or burning e if adjustment must be made while the unit is running use ex treme caution around hot manifolds moving parts etc ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Disconnect starting battery before removing protective shields or touching electrical equipment Use rubber insula five mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment Do not wear damp clothing particularly wet shoes or allow skin sur faces to be damp when handling electrical equipment e Use extreme caution when working on electrical compo nents High voliages can cause injury or death e Follow all state and loca
16. e eoc eee gt Redistribution or publication of this document by any means is strictly prohibited Onon Onan Corporation 1400 73rd Avenue N E Minneapolis MN 55432 1 800 888 ONAN 612 574 5000 International Use Telex 275477 Fax 612 574 8087 Onan is a registered trademark of Onan Corporation Power Redistribution or publication of this document osam Generation by any means is strictly prohibited
17. e entire unit Coat parts susceptible to rust with a light coat of grease or oil Returning a Unit to Service Refer to preceding paragraphs in this Maintenance sec tion for specific service procedures 1 Remove plug from exhaust outlet 2 Check tag on oil base and verify that oil viscosity is still correct for existing ambient temperature 3 JOO S Clean and check battery Measure specific gravity 1 260 at 80 F 27 C and verify level to be at split ring if specific gravity is low charge until correct value is obtained If leve is low add distilled water and charge until specific gravity is correct DO NOT OVERCHARGE Battery electrolyte can cause AWARNING severe eye damage and burns to the skin Wear goggles rubber gloves and a pro tective apron when working with battery Prime the fuel system Connect starting battery ground terminal last Remove all loads before starting the engine After start apply load to at least 50 percent of rated capacity Check gauges for normal readings Set is ready for service Power sad l3 Redistribution or publication of this document Generation by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited nm mer
18. e the operation of the fault systems and suggested items the operator can check If a major problem is indicated contact an Onan dealer or distributor for help or service Fault Reset Breaker The control panel Fault Reset breaker will trip for any one of the fault conditions de scribed separately below The white breaker reset but ton pops out about 1 4 inch 6 mm when a fault occurs Locate the problem and make the necessary correc tions before resetting breaker and starting the generator set All fault shutdowns except overspeed are delayed 5 seconds to avoid nuisance tripping NOTE GENSET APPEAR ANCE MAY VARY FROM THIS ILLUSTRATION LOW OIL PRESSURE SWITCH SENDER COOLANT HIGH TEMP SWITCH SENDER LINE CIRCUIT BREAKERS tae Oe zs t 3 FAULT RESET FIGURE 5 FAULT SENSOR LOCATION 7 5 DKD SHOWN FOR REFERENCE ONLY Low Oil Pressure Remove dipstick and check oil level lf low add oil to bring level up to full mark Inspect engine exterior for leaks and repair as necessary The oil pressure switch actuates the fault circuit if pressure drops below 9 psi 62 kPa Crankease pressure can blow out hot AWARNING oi and cause SEVERE burns Do NOT check oil while the generator set is operating High Coolant Temperature f fault occurred during operation observe Coolant Temperature Gauge option for indication of temperature over 250 F 127 C The coolant thermostat switch closes at this temp
19. ead and hand tighten 5 Disconnect starter solenoid lead at terminal con nector This allows fuel pump operation without cranking engine 6 Depress Start Switch until fuel purges at bleed plug opening 7 Replace bleed plug and close bleed screw Recon nect starter lead 7 5 DKD 6 5 DKD 6 0 DKD BLEED PLUG BLEED 8 0 DKD N GASKET ween ELEMENT FS 1696 FIGURE 10 FUEL FILTER ASSEMBLY High Pressure Fuel System The injection pump fuel injection lines and fuel injectors comprise the high pressure fuel system This part of the system is usually self priming since any trapped air is usually forced out through the injection nozzies AIR CLEANER The air cleaner is not Onan supplied on the 8 0 DKD and may vary from the air cleaner described here The air cleaner element is a dry type and should never have oil applied to it Avoid touching the element except when cleaning it Figure 11 Instructions for cleaning the element are on a label attached to the element The dust cup should be cleaned once a week or every day in extremely dusty conditions Be sure the dust cup TOP or arrow on the rear of cup is in the upright position if the dust cup is mounted incor ACAUTION rectly dust does not collect in the cup and can shorten life of the filter element Change the element yearly or more often in extremely dusty conditions DUST CUP ELEMENT AIR CLEAN ER BODY FS 1592 FIGURE 11 TYP
20. erature and actuates the fault circuit Check coolant ievel in radiator after allowing engine to cool down Ensure pump belt is OK and has proper tension Also check cooling system cleanliness free dom from contaminants rust sludge build up etc Contact with hot coolant can result in AWARNING SEVERE burns Allow cooling system to cool before releasing pressure and removing radia tor cap or release of hot coolant can result AC Control The AC contro consists of the line circuit breakers connected between the generator output and the load Breakers are required to protect the generator from shorts or overload When supplied by Onan they mount on the side of the control box on the 7 5 6 5 and 6 0 DKD See Figure 5 The 8 0 DKD has a fan circuit breaker mounted on the side of the AC control box as shown in Figure 4 Line circuit breakers are customer supplied on the 8 0 DKD and their location may vary Ed Power _ ori Generation Redistribution or publication of this document by any means is strictly prohibited Maintenance Establish and adhere to a definite schedule for mainte nance and service If the set will be subjected to extreme operating conditions the service intervals should be reduced accordingly Consult with an authorized Onan dealer or distributor if the generator set will be subjected to any extreme oper ating conditions and determine a suitable schedule of maintenance Use the running time meter
21. g the generator set It is recommended that the operator read through this entire section before attempting to start the set Itis essential that the operator be completely familiar with the set for safe operation PRE START CHECKS Before starting be sure the following checks have been made and the unit is ready for operation Refer to the MAINTENANCE section for the proper procedures Lubrication Check the engine oil level Keep oil level near as possi ble to the dipstick full mark Do not overfill Coolant The coolant level should be near the top of the fill cap Do not check while the coolant is hot The sudden release of pressure from AWARNING a heated cooling system can resultin possible severe personal injury from the hot coolant Remove the expansion tank pressure cap slowly after the engine has coofed Fuel Make sure the fuel tanks are full and the fuel system primed for operation see MAINTENANCE section AWARNING Fuel presents the hazard of fire or s explosion which can cause severe personal injury or death Do not permit any flame spark pilot light cigarette or other ignition source CONTROL PANEL The following describes the function and operation of the generator set controls Control switches and circuit breakers are located on the face of the control panel as shown in Figures 3 and 4 The 8 0 DKD DC control box is designed for remote mounting applications Gauges Meters and Switches S
22. he cooling efficiency Be sure the antifreeze solution will protect the cooling system during the coldest weather A 50 50 solution of ethylene glycol and water is applicable for most applica tions This solution will protect the cooling system to 35 F 37 C temperature Filling the Cooling System Verify that all drain cocks are closed and all hose clamps secure Remove the radiator pressure cap and slowly add coolant until level is near the top of radiator Exceeding the recommended fill rate ACAUTION can cause incomplete filling of the engine block which can result in possible engine dam age during warm up Always follow the recommended fill pracedure Add coolantto the recovery tank or separate expansion tank if equipped to the full cold level When the engine is first started remove the pressure cap and monitor the coolant level As trapped air is expelled from the system the coolant level will drop and additional coolant should be added Replace the pres sure cap when the coolant level is stable Redistribution or publication of this document by any means is strictly prohibited Generation Coolant Level Check the coolant level during shutdown periods at the intervals specified in the Periodic Maintenance Sche dule Check by observing the coolant level in the recov ery tank or separate expansion tank if equipped when the system is cold See Figure 7 for typical cooling system Engine coolant is at prope
23. ilter Dirt or water in the system will cause ACAUTION severe damage to both the injection pump and the injection nozzies ft is extremely impor tant the fuel be kept clean and free of water Refer to the Periodic Maintenance Schedule for the recommended filter change interval However if the engine shows signs of fuel starvation reduced power or surging change the fuel filter To Service 7 5 DKD 6 5 DKD and 6 0 DKD 1 Loosen drain and bleed screws Collect fuel in suit able container Remove bleed plug See Figure 10 2 Remove filter element from head with the bowl connected 3 Clean bowl O ring gland and O ring 4 Lubricate O ring with clean diesel fuel and place in bowl gland 5 Spin bowl onto new element DO NOT OVER TIGHTEN 6 Lubricate element and gasket and fill bow and ele ment with clean diesel fuel 7 Spin bowl and element assembly onto head and hand tighten 8 Disconnect starter solenoid lead at terminal con nector This allows fuel pump operation without cranking engine 9 Depress Start switch until fuel purges at bleed screw and bleed plug opening Replace bleed plug and close bleed screw Recon nect starter lead 10 To Service 8 0 DKD 1 Loosen drain and bleed screws Collect fuel in suit able container Remove bleed plug See Figure 10 2 Remove filter element from head 3 Lubricate new element and gasket and fill element with clean diesel fuel 4 Spin element onto h
24. ing on the load and ambient temperature STOPPING Before Stopping Run the generator set at no load for three to five minutes before stopping This allows the lubricating oil and engine coolant to carry heat away from the combustion chamber and bearings Failure to allow running time for A CAUTION engine cooling without load can resultin engine damage Make sure generator set runs unloaded for at feast three minutes To Stop Place the Start Stop switch or the remote start ing switch to the Stop position OPERATING RECOMMENDATIONS Break In Drain and replace the crankcase oil after the first 35 hours of operation on new generator sets Refer to the MAINTENANCE section of this manual for the recom mended procedures No Load Operation Hold periods of no load operation to a minimum and avoid if possible No load operation allows combustion chamber temperatures to drop so low that the fuel does not burn completely This results in carbon deposits which can clog injectors cause piston rings and valves to stick and can cause cylinder glazing If itis necessary to run the engine for long periods at no load connect a dummy electrical load to the generator Power Exercise Period Infrequent use can result in difficult starting and mois ture condensation problems This moisture is a result of the engine not being run long enough to reach normal operating temperature and might show up as water in ihe oil in extreme causes
25. ituents are known to the State of California to cause cancer birth defects and other reproductive harm Power oi l Redistribution or publication of this document Generation by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited Introduction ABOUT THIS MANUAL This manual provides information for operating and maintaining the Onan DKD generator set Study this manual carefully and observe all warnings and cau tions Using the generator set properly and following a regular maintenance schedule will result in longer unit life better performance and safer operation HOW TO OBTAIN SERVICE When the generator set requires servicing contact an Onan dealer or distributor for assistance Onan factory trained parts and service representatives are ready to handle ali service needs A copy of the warranty form AB355 and a parts catalog is in the literature package included with the unit A service manual is available on special order through the Onan dealer or distributor When contacting an Onan dealer or distributor always supply the complete Model number and Serial number as shown on the Onan nameplate See Figure 1 The Onan nameplate is located on the side of the gener ator control box on the 7 5 DKD 6 5 DKD and 6 0 DKD and is located on the side of the belt guard on the 8 0 DKD Onon Mode ant Spec No Always give above no s l Impo
26. itute API classification SF CD in viscosities per temperature as shown in Table 4 TABLE 4 OIL SELECTION OIL VISCOSITY VS TEMPERATURE 32 OF 30 20 10 0 10 20 30 40 50 60 70 80 90 100110120 C9429 23 18 12 7 1 4 10 18 21 27 32 38 43 48 Anticipated Ambient Temperature When selecting the oil viscosity pick the viscosity that is right for the lowest temperature expected Oil that is too thick may result in a lack of lubrication when the engine is started Use a lower viscosity oil as the ambient temperature reaches the lower end of the scale Do not use synthetic oil non detergent oil and do not mix different brands of oil Engine Oil Level Check the engine oil level during engine shut down periods at the intervals specified in the Maintenance Table The oil dipstick and oil fill are located on the side of the engine see Figure 6 The dipstick is stamped with FULL and ADD to indicate the level of oil in the crank case For accurate readings shut off the engine and wait approximately 10 minutes before checking the oil level This allows oil in the upper portion of the engine to drain back into the crankcase Power _ 8 Generation Redistribution or publication of this document by any means is strictly prohibited Keep the oil level as near as possible to the FULL mark on the dipstick Remove the oil fill cap and add oil of the same quality and brand when necessary Do not operate the engine with the oil AC
27. l electrical codes Have all electrical installations performed by a qualified licensed electrician Tag open switches to avoid accidental closure e DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM Hazardous volt ages can flow from the generator set into the utility line This creates a potential for electrocution or property damage Connect only through an approved device and after building main switch is open Consult an electrician in regard to emergency power use GENERAL SAFETY PRECAUTIONS Have afire extinguisher nearby Maintain extinguisher prop erly and become familiar with its use Extinguishers rated ABC by the NFPA are appropriate for all applications Con sult the local fire department for the correct type of extin guisher for various applications Hot coolants under pressure can cause severe personal in jury DO NOT open a radiator pressure cap while the engine is running Stop the engine and carefully bleed the system pressure Benzene and lead found in some gasoline have been iden tified by some state and federal agencies as causing cancer or reproductive toxicity When checking draining or adding gasoline take care nat to ingest breathe the fumes or con tact gasoline e Used engine oils have been identified by some state or fed eral agencies as causing cancer or reproductive toxicity When checking or changing engine oil take care not to in gest breathe the fumes or cont
28. lighi cigarette or other ignition source near the fuel system Fuel Recommendations Use ASTM 2 D No 2 Diesel or ASTM 1 D No 1 Diesel fuel with a minimum Cetane number of 45 Number 2 diese fuel gives the best economy and performance under most operating conditions Use number 1 diesel fuel when ambient temperatures are below 32 F 0 C and during long periods of light engine load Use low sulfur content fuel having a cloud point of at least 10 F 6 C below the lowest expected fuel temperature Cloud point is the temperature at which wax crystals begin to form in diesel fuel Fuel Handling Precautions Take appropriate precautions io prevent the entrance of dirt water or other contaminants into the fuel system Filter or strain the fuel as the tank is filled Due to the precise tolerances of die ACAUTION sel injection systems dirt or water in the fuel can cause severe damage to both the injection pump and injector nozzles Take special precautions to keep the fuel clean and free of water Power _ Generation To avoid condensation problems keep fuel supply tanks as full as possible by filling up each time the engine is used In cold weather warm fuel returning from the injectors heats the fuel in the supply tank If the fuel level is low the upper portion of the tank tends to form condensation In warm weather both the fuel and the tank will be warm during the daytime At night cool air tends to lower the temper
29. n erator set or fuel tank e Fuel lines must be adequately secured and free of leaks Fuel connection at the engine should be made with an ap roved flexible nan conductive line Do not use copper pip hiat flexible lines as copper will work harden and become rittle e Be sure all fuel supplies have a positive shutoff valve GASOLINE AND LPG FUEL MAY BE ACCIDENTALLY IG NITED BY ELECTRICAL SPARKS poeng the hazardof fire or explosion which can result in severe personal In jury or death When installing the generator set e Do not tie electrical wiring to fuel lines e Do not run electrical lines and fuel lines through the same compartment openings Keep electrical and fuel lines as far apart as possible e Place a physical barrier between fuel lines and electrical lines wherever possible If electrical and fuel lines must pass through the same com partment opening make certain that they are physically separated by running them through individual channels or by passing each line through a separate piece of tubing e DO NOT SMOKE while servicing batteries Lead acid bat teries emit a highly explosive hydrogen gas that can be ig nited by electrical arcing or by smoking EXHAUST GASES ARE DEADLY e Never sleep in the vehicle with the generator set running un less vehicle is equipped with an operating carbon monoxide detector e Provide an adequate exhaust system to properly expel dis charged gases Inspe
30. nasystseneuesess 8 0 KW 8 0 KVA 1 0 PF Includes fan load if required 50 Hertz ot Dt ee ee ee ee ee ee ee ee ee ee 6 0 kW 6 5 kVA 1 0 PF Frequency regulation under varying load GO 2s asa pac E nese ea owen reste anaes eres Genes eae 4 eee een 440 ee ues s 5 percent Voltage regulation under varying load 2 0 0 0 ccc ee cee rete en eee e ee eenes 3 Hz maximum Random voltage variation 0 0 een eee e eee k ee ena nen n ene eeneee 2 percent GENERATOR SET DETAILS Air requirements COGN EEE decease ws ecoanes sae teeeantweuness vase es 1200 ft8 min 34 m min SO HOMA seig ce adbaeecus hee ANEREN ANEAN 1000 ft3 min 28 3 m3 min Engine Speed DOPO serere ainara Eii E E EREE en 1800 r min S0 MOME arrin na EEE A A E AAE EEA EE e Ee 1500 r min FUG EOE E E E EE E E E E ae bade nes nee No 2 Diesel Fuel Pump Inlet Thread Size nnnnuuaarannnsnnssrsespnsssenarrensaarenanne 1 8 NPTF Fuel Return Outlet Thread Size cee ee eee eens 1 8 NPTF Fuel Pump Maximum Lift 2 0 0 0 cece ee eee te eee teeter neta eerteeterseees 3 ft 0 9 m Exhaust Outlet i ees ocb cow cateseeesdee dd ttoseuseessaetede ss Flange or 1 1 4 in NPT External Starting Systemi VONAGG 6222 dda sons ec dees ee ra seswecde td uvdess ERREK EEES EA EERE EEEE 12 Battery Requirements Battery Voltage ee Cree ee ee re wee ee eee re ee ee eee ee eS E 12 CUANIRY FIGQUINGG cscs Ea at oe esa shane ONE house EAE EEEE 1 Cold Cranking Amps 0 F 17 8 C
31. ons The fol lowing sections cover several areas that should be fre quently inspected to provide continued safe operation Engine Gauges Optional Check gauges on the remote contro panel if equipped while the generator set is operating Oil Pressure Gauge The oil pressure should be in the range of 35 to 50 psi 241 to 345 kPa when the engineis at operating temperature but may vary below this range under various conditions Coolant Temperature Gauge The water temperature should be in the range of 165 to 195 F 74 to 91 C depending on the load and ambient temperature DC Voltmeter Normal B voltage during operating should be 14 to 75 volts Exhaust System With the generator set operating inspect the entire exhaust system including the exhaust manifold exhaust elbow muffler and exhaust pipe Visually and audibly check for leaks at all connections welds gaskets and joints If any leaks are detected shut down the generator set and do not operate until corrected Replace cor roded exhaust components before leaks occur Exhaust gas presents the hazard of AWARNING severe personal injury or death inspect exhaust system audibly and visually for leaks daily Repair any leaks immediately Fuel System With the generator set operating inspect the fuel supply line return line filter and fittings for leaks Check any flexible sections for cuts cracks and abrasions and make sure they are not rubbing against any
32. or set while the engine is running When clean ing provide cover or protection so spray is not directed into the generator air cleaner contro box fuel sole noid or electrical connectors Do not clean with sol vents they can damage electrical connectors OUT OF SERVICE PROTECTION The inherent lubricating qualities of No 2 diesel fuel should protect the cylinders of a diesel engine for at least 30 days when the unit is not in service To protect an engine that will be out of service for more than 30 days proceed as follows 1 Exercise the generator set as described in the OPERATION section until the engine is up to operat ing temperature 2 Shut down engine and disconnect the battery Store battery in a cool dry place and connectto a charger every 30 days to maintain full charge Redistribution or publication of this document by any means is strictly prohibited eg ral Power 14 ori Generation Battery electrolyte can cause AWARNING severe eye damage and burns to the skin Wear goggles rubber gloves and a pro fective apron when working with batteries 3 Drain the oil base while still warm Replace oil filter Refill crankcase and attach a tag indicating viscos ity of oil used 4 Check the coolant level and add more coolantifthe level is low If freezing temperatures are possible test strength of coolant mixture 5 Plug exhaust outlets to prevent entrance of mois ture bugs dirt ect 6 Clean and wip
33. r level when the rec overy tank level is between Full and Low marks Contact with hot coolant can cause A WARNING severe burns Allow cooling system to cool before releasing pressure and removing radia tor cap or release of hot coolant can result The High Engine Temperature Cutoff ACAUTION will shut down engine in an overheat condition only if coolant level is sufficiently high to physically contact shutdown switch Loss of coolant will allow engine to overheat without protection of shutdown device causing severe damage to engine It is therefore imperative that adequate engine coolant levels be maintained for operational integrity of the cooling system and overheat shutdown protection Flushing and Cleaning For efficient operation the cooling system should be drained flushed and refilled once a year To drain the system completely the radiator drain and the cylinder block drain located on the left side of engine must be opened See Figure 7 Chemical Cleaning Thoroughly clean the cooling sys tem if rust and scale have collected on the engine water jacket or in the radiator Rust and scale slow down heat absorption and can block the coolani flow Use a good radiator cleaning compound in accordance with in structions furnished by the supplier RADIATOR CAP RECOVERY TANK THERMOSTAT e A ILLUSTRATION he ts DRAIN COCK M 1598 FIGURE 7 TYPICAL COOLING SYSTEM COMPONENTS ewan oom GENSET APPEAR ewan
34. rtant when orderiny putts Insulation For Flee lati al png ssid a Equipmin I Gly Onan Cano fel 1400 73rd Avenue N E Minneapolss Minnesota 55437 1 S A FIGURE 1 ONAN NAMEPLATE AWARNING INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN SEVERE PERSONAL INJURY DEATH AND OR EQUIPMENT DAMAGE SERVICE PER SONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND OR MECHAN ICAL SERVICE REMOTE CONNECTOR CLEANER START STOP LINE FITTING _ NOTE OPTIONAL SIDE FILL AC CIRCUIT PREHEAT SHOWN alla ih Sa BREAKERS DC CONTROL SWITCH POINTS UPWARD o ie ut MSs Ws ne es z k ve ii ENE il OIL FILL RUNNING TIME 4 HATI Nie ii 5 DIPSTICK MET A Bie eee 2 Tn l OIL PRESSURE gf A COOLANT TEMP COOLANT FAULT RESET DRAIN BREAKER a VALVE OIL FILTER OIL A FUELINLET DRAIN PIGER FITTING YALVE BATTERY CHARGE EL M1598 1s BREAKER PUMP FIGURE 2 6 5 7 5 DKD GENERATOR SET FOR RECREATIONAL VEHICLE Power _ 1 Generation Redistribution or publication of this document by any means is strictly prohibited Specifications GENERATOR DETAILS TODE e4ace wi ou nee beak ee eet oh ee ae aes Onan YD Revolving Field 4 Pole Brushless PROSS prea see pe ee eew neds es be we E one eee Reeve ee tenee eae eee E Single Standby ratings 60 Hertz OID E E E ee aadee see bebe E E PTE E 6 5 kW 6 5 KVA 1 0 PF PSD oc oes ers eae as eee ae oes E E 7 5 KW 7 5 KVA 1 0 PF SAGAD dE ies checanete
35. system on each set is drained prior to shipping and must be refilled before being operated The cooling system capacity of the standard unit with set mounted radiator is shown in the SPECIFICATIONS section The 8 0 DKD does not have an Onan supplied radiator This unit is provided for custom installations and may have a vertical or horizontal mount remote radiator Horizontai mounted radiator systems require an expan sion tank that must be mounted at the highest point of the cooling system improper operation can result in A CAUTION overheating and equipment damage With custom installations that use a common radiator for both vehicle engine and generator set cooling do NOT operate the vehicle engine and the generator sei atthe same time or equipment damage can result due to overheating Coolant Requirements Asatsifactory engine coolant inhibits corrosion and pro tects against freezing A solution of ethylene glycol anti freeze permanent type and water is recommended for normal operation and storage periods Choose only a reliable brand of antifreeze that contains a rust and corrosion inhibitor but does not contain a stop leak additive The water used for engine coolant should be clean low in mineral content and free of any corrosive chemicals such as chloride sulphate or acid Use soft water when ever available Well water often contains lime and other minerals which eventually may clog the radiator core and reduce t
36. tart Stop Switch Starts and stops the unit locally The unit may also be operated from a remote switch wired to the control panel Running Time Meter Registers the total number of hours that the unit has run Use it to keep a record for periodic servicing Time is cumulative meter cannot be reset lf equipped the running time meter on the 8 0 DKD will be remotely located Circuit Breakers Fault Breaker A manual reset breaker that shuts down the engine for low oil pressure high coolant tempera ture high exhaust temperature and overspeed Battery Charge Breaker A 15 ampere breaker protect ing the DC voltage regulator alternator and wiring from short circuits or overload Control Breaker A 15 ampere DC breaker providing protection to the control box wiring and remote wiring from short circuits or overload Also serves as an emer Gd neardhe duel system q gency stop switch Generation Redistribution or publication of this document by any means is strictly prohibited Line Circuit Breaker The AC output line circuit break er s is mounted on the side of the control box on the 7 5 DKD 6 5 DKD and 6 0 DKD See Figure 3 The line circuit breaker is customer supplied on the 8 0 DKD and location may vary The line circuit breaker protects the generator from a short circuit or other overload Fan Circuit Breaker The 8 0 DKD has a 15 ampere circuit breaker mounted on the side of the AC control box see Figure
37. thing that could cause breakage Replace worn fuel line compo nents before leaks occur Fuel presents the hazard of fire or AWARNING explosion which can result in severe personal injury or death if ignited If any leaks are detected have them corrected immediately DC Electrical System With the generator set off check the terminals on the battery for clean and tight connections Loose or cor roded connections create resistance which can hinder starting Clean and reconnect the battery cables if loose Always connect the negative battery cable last to reduce the possibility of arcing AWARNING ignition of explosive batiery gases can cause severe personal injury Do not smoke while servicing batteries Mechanical With the generator set stopped check for loose belt fittings leaking gaskets and hoses or any signs of mechanical damage If any problems are found have them corrected immediately With the set running listen for any unusual noises that may indicate mechanical problems and check the oil pressure frequently Investi gate anything that indicates possible mechanical problems LUBRICATION SYSTEM The engine oil was drained from the crankcase prior to shipment Before the initial start the lubrication system must be filled with oil of the recommended classification and viscosity Refer to the Specifications section for the lubricating oil capacity Oil Recommendations Use oils with the American Petroleum Inst
38. tifier assembly to make sure the diodes see Figure 12 are free of dust dirt and grease Excessive foreign matter on these diodes and heatsinks will cause the diodes to overheat and will result in their failure Blow out the assembly periodically with filtered low pressure air Accidental starting of the set can AWARNING cause severe personal injury or death Move the Operation Selector swiich to STOP and disconnect the starting battery before inspecting rotating rectifier assembly Excessive foreign maiter on diodes ACAUTION and heat sinks will cause overheat ing and possible failure ROTATING RECTIFIER ASSEMBLY it _ wt nt tt O ES 1223 FIGURE 12 GENERATOR END VIEW Generator Bearing inspect the bearing for evidence of outer case rotation every 1000 hours of operation Replace the bearings every five years Deterioration of the bearing grease due to oxidation makes this replacement necessary If generator requires major repair or servicing contact an authorized Onan dealer or distrib tor Redistribution or publication of this document by any means is strictly prohibited Generation CRANKCASE BREATHER Clean the crankcase breather element ai the scheduled intervals Service using the following procedure Refer to Figure 13 1 Remove three cap nuts and O rings from the top of cylinder head cover Carefully remove the cover trying not to damage gasket 2 From inside the cover remove two
39. ttery cell Battery electrolyte can cause severe AWARNING eye damage and burns to the skin Wear goggles rubber gloves and a protective apron when working with batteries Hold the hydrometer vertical and take the reading Cor rect the reading by adding four gravity points 0 004 for every five degrees the electrolyte temperature is above 80 F 27 C or subtracting four gravity points for every five degrees below 80 F 27 C A fully charged battery will have a corrected specific gravity of 1 260 Charge the battery if the reading is below 71 215 Checking Electrolyte Level Check the level of the electrolyte acid and water solu tion in the battery at least every 100 hours of operation If the cells are low on water fill cells to the bottom of the filler neck with distilled water and recharge lf one cell is low check case for leaks or for a bad cell Keep the battery case clean and dry An accumulation of moisture will lead to a more rapid discharge and battery failure Power Do not add water in freezing weather ACAUTION unless the engine will run long enough two to three hours to assure a thorough mix ing of water and electrolyte AC GENERATOR There are no brushes brush springs or collector rings on these generators therefore they require very little servicing Periodic inspections to coincide with engine oil changes will provide good performance Remove the generator end bell cover and inspect the rotating rec
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