Onan DKHA Series, Installation Manual

Page 1: ...Caution This document contains mixed page sizes 8 5 x 11 or 11 x 17 which may affect printing Please adjust your printer settings according to the size of each page you wish to print ...

Page 2: ... Installation Manual 01 07 981 0644 Model DKHA ...

Page 3: ...California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm diesel warnings ...

Page 4: ...ONS 3 1 General 3 1 Standard Tailpipe 3 1 Customer Fabricated Tailpipe 3 2 4 COOLANT CONNECTIONS 4 1 5 FUEL CONNECTIONS 5 1 6 ELECTRICAL CONNECTIONS 6 1 AC Power Output 6 1 Remote Control 6 3 Battery Connections 6 5 7 INSTALLATION REVIEW AND STARTUP 7 1 8 SPECIFICATIONS 8 1 CONTROL SCHEMATIC SHEET 1 A 1 CONTROL SCHEMATIC SHEET 2 A 2 OUTLINE DRAWING SHEET 1 A 3 OUTLINE DRAWING SHEET 2 A 4 OUTLINE D...

Page 5: ... 911 Do not operate the APU again until it has been repaired and inspected To reduce the risk of CO poisoning Inspect for exhaust leaks at every startup and after every eight hours of running Never sleep in the vehicle while the APU is running unless the vehicle is equipped with a working carbon monoxide detector Do not operate the APU when the vehicle is parked in a confined space such as a ga ra...

Page 6: ...em can cause the engine to over speed which can result in fire explosion and equipment damage The owners and opera tors of the APU are solely responsible for safe operation GENERAL PRECAUTIONS Keep children away from the APU Do not use evaporative starting fluids They are highly explosive Let the engine cool down before removing the coolant pressure cap or opening the cool ant drain Hot coolant un...

Page 7: ...s if any having jurisdiction over the installation WARNING This genset is not a life support sys tem It can stop without warning Children per sons with physical or mental limitations and pets could suffer personal injury or death A per sonal attendant redundant power or an alarm system must be used if genset operation is criti cal OUTLINE DRAWINGS See the Outline Drawings beginning on Page A 3 for...

Page 8: ...TING Use both lifting eyes on the engine head or a forklift under the shipping pallet to raise the APU to its mounting position Raise the elevation of the APU so that the mounting bolts pull straight across the top and bottom of the frame rail flanges Figure 2 1 After all four bolts have been snugged up even and straight torque the nuts to 260 ft lb 352 N m Offset spacers two with hardware are ava...

Page 9: ...te of California The APU must be installed with the standard tailpipe or with a customer fabricated tailpipe using tailpipe adapter PN 155 2610 Figure 3 1 STANDARD TAILPIPE The standard tailpipe can be installed on the muffler outlet flange after mounting the APU and removing the shipping pallet The flange gasket and screws are packaged with the tailpipe Torque the flange and bracket screws to 19 ...

Page 10: ...Figure 3 2 3 Support the tailpipe every 2 to 3 feet 60 to 90 cm 4 Do not terminate the tailpipe underneath the vehicle cab or living space 5 Do not route the tail pipe near fuel lines or fuel tanks or terminate it below or near a fuel fill opening 6 Route the tailpipe such that it is visible along its entire length and accessible for replacement 7 Route the tailpipe such that it will not likely be...

Page 11: ...lass D2 coolant hose Route and secure the hoses to keep them away from hot engine exhaust components They 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 There must be enough slack in the hoses at the ve hicle engine to take up engine movement without stretching or compressing the hoses...

Page 12: ...ate 541 1425 for mounting the pickup tube as sembly In a 24 inch diameter fuel tank the pickup tube ex tends down to approximately 3 inches from the bot tom To prevent the APU from running the vehicle out of fuel it is recommended that the pickup tube be cut if necessary so that it is shorter than the ve hicle engine pickup tube If it is necessary to extend the fuel pickup tube use 5 16 inch SAE J...

Page 13: ...tlet boxes and wiring har nesses are available for connection to the load cen ter breaker box Seal all wiring openings into the vehicle interior to keep out exhaust gas Apply silicone rubber or equivalent sealant WARNING EXHAUST GAS IS DEADLY Seal all wiring openings into the vehicle interior to keep out exhaust gas Route or protect AC wiring so that it will not be cut or abraded exposed to hot su...

Page 14: ...6 2 30 AMP LOAD CENTER BREAKER BOX 319 6604 HVAC UNIT APU AC HARNESS 335 0257 OUTLET BOX 323 2458 FIGURE 6 1 AC CONNECTIONS ...

Page 15: ...2 for details WARNING Interconnecting the APU and shore power can lead to electrocution of utility line workers equipment damage and fire Use an ap proved switching device to prevent intercon nections Ignition Interlock If it is desired to always shut down the APU when the vehicle engine is started connect a normally open ignition relay or switch to the blue leads in the APU remote harness See Pag...

Page 16: ...4874 OPERATOR PANEL 300 6249 APU HVAC UNIT P2 P6 P3 P7 J3 J2 HVAC CONNECTOR LEADS WITH INSULATED COLOR CODED BUTT SPLICE CONNECTORS FOR CONNECTING IGNITION SHORE POWER INTERLOCKS STOW INSIDE JUNCTION BOX ALONG WITH P3 J3 AND P7 FIGURE 6 2 REMOTE CONTROL CONNECTIONS ...

Page 17: ... be cut to proper length Use a proper crimping tool to crimp on the extra terminals Insulate the terminal shanks with heat shrink insulating tubing so that loose cable strands will not contact other terminals Mark cable polarity positive or negative Note Connect the APU cables at the same terminals as the main engine cables so that all batteries are re charged uniformly when the APU is running Con...

Page 18: ...rol wiring and battery cables The control panel on the APU is accessible for starting and stopping the APU and resetting the circuit breaker There is access for checking adding and drain ing engine oil and coolant There is access for replacing the oil fuel and air filters The air inlet and outlet openings are free of ob structions The exhaust tailpipe is connected and secure The fuel dip tubes in ...

Page 19: ...el Injection Timing BTDC 18 20 Injection Order 1 2 Fuel Nozzle Injection Pressure 1991 psi 13 73 mPa Valve Lash Intake Exhaust cold 0 0059 0 0073 inch 0 145 0 185 mm Oil Capacity with filter 3 2 quart 3 0 liter Cooling System Capacity 2 5 quart 2 4 liter Lubricating Oil Pressure 14 to 64 psi over speed range Cylinder Compression Pressure 414 to 469 psi 327 psi minimum DC SYSTEM Nominal Battery Vol...

Page 20: ...A 1 630 3368 CONTROL SCHEMATIC SHEET 1 ...

Page 21: ...A 2 630 3368 CONTROL SCHEMATIC SHEET 2 ...

Page 22: ...A 3 500 4572 OUTLINE DRAWING SHEET 1 ...

Page 23: ...A 4 500 4572 OUTLINE DRAWING SHEET 2 ...

Page 24: ...A 5 500 4572 NOT TO SCALE SEE FUEL KIT INSTRUCTION SHEET OUTLINE DRAWING SHEET 3 ...