CUMMINS Onan HDZAA Operator Manual
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Operator Manual
Quiet Diesel Generator Set
HDZAA
English 9−2009 983−0103 (Issue 4)
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
Table of Contents
SECTION PAGE
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining the Battery and Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . .
i
ii
SAFETY PRECAUTIONS
Thoroughly read the OPERATOR’S MANUAL
before operating the generator set. Safe op- eration and top performance can only be obtained when equipment is properly operated and maintained.
The following symbols in this manual alert you to potential hazards to the operator, service person and equipment.
DANGER alerts you to an immediate hazard that will result in severe personal injury or death.
WARNING alerts you to a hazard or unsafe practice that can result in severe personal injury or death.
CAUTION alerts you to a hazard or unsafe practice that can result in personal injury or equipment damage.
When equipped with an integral or add−on Automatic Generator Starting System (AGS) control, exhaust carbon monoxide (CO), electric shock, and moving parts hazards are possible due to unexpected starting. Turn off AGS whenever performing maintenance or service, when the vehicle is stored between uses, is awaiting service, or is parked in a garage or other confined area.
ENGINE EXHAUST IS DEADLY
• Inspect for exhaust leaks at every startup and after every eight hours of running.
• Learn the symptoms of carbon monoxide poisoning in the generator set Operator’s Manual.
• Never sleep in the vehicle while the generator set is running unless the vehicle is equipped with a working carbon monoxide detector.
• Do not operate the generator set when the vehicle is parked in a confined space, such as a garage.
• The exhaust system must be installed in accordance with the generator set Installation
Manual.
iii
• Engine cooling air must not be used for heating the vehicle.
GENERATOR VOLTAGE IS DEADLY
• Disable the automatic genset feature (AGS) of an inverter−charger or other automatic starting device before servicing the genset to avoid electric shock from an unexpected start.
• Generator electrical output connections must be made by a trained and experienced electrician in accordance with applicable codes.
• The generator set must not be connected to shore power (utility). Back-feed to shore power can cause electrocution and damage to equipment. An approved switching device must be used to prevent interconnections.
• Use caution when working on live electrical equipment. Remove jewelry, make sure clothing and shoes are dry, stand on a dry wooden platform or rubber insulating mat and use tools with insulated handles.
DIESEL FUEL IS COMBUSTIBLE
• Do not smoke or turn electrical switches ON or OFF where fuel fumes are present or in areas sharing ventilation with fuel tanks or equipment. Keep flames, sparks, pilot lights, arc-producing equipment and all other sources of ignition well away.
• Fuel lines must be secured, free of leaks and separated or shielded from electrical wiring.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
• Disable the automatic genset starting feature
(AGS) of an inverter−charger or other automatic starting device before servicing the genset to avoid unexpected starting.
• Do not wear loose clothing or jewelry near moving parts such as fans and other moving parts.
• Keep hands away from moving parts.
• Keep guards in place over fans and other moving parts.
BATTERY GAS IS EXPLOSIVE
• Wear safety glasses.
• Do not smoke.
• To reduce arcing when disconnecting or reconnecting battery cables, always disconnect the negative (−) battery cable first and reconnect it last.
FLAMMABLE VAPORS CAN BE IGNITED
BY OPERATION OF COACH ELECTRICAL
SYSTEMS AND CAUSE DIESEL ENGINES
TO OVERSPEED
• Stop the generator set before fueling the coach to reduce the risk of igniting flammable vapors.
• Do not operate the diesel-powered generator set where there are or can be flammable vapors created by fuel spills, gas leaks, etc.
Flammable vapors drawn into a diesel engine air intake system can cause the engine to overspeed, which can result in fire, explosion and equipment damage. The owners and operators of the generator set are solely responsible for safe operation.
GENERAL PRECAUTIONS
• Keep children away from the generator set.
• Do not use evaporative starting fluids. They are highly explosive.
• To prevent accidental or remote starting while working on the generator set, press the Stop button and disconnect the battery cables at the batteries to prevent starting during maintenance and service. (Always disconnect negative [−] first and reconnect last to prevent sparks between tools and vehicle frame.)
• Keep the generator set and its compartment clean. Excess oil and oily rags can catch fire.
Dirt and gear stowed in the compartment can restrict cooling air.
• Make sure all fasteners are secure and torqued properly.
• Do not work on the generator set when mentally or physically fatigued or after consuming alcohol or drugs.
• You must be trained and experienced to make adjustments while the generator set is running—hot, moving or electrically live parts can cause severe personal injury or death.
• Used engine oil has been identified by some
U. S. state and federal agencies as causing cancer or reproductive toxicity. Do not ingest, inhale, or contact used oil or its vapors.
• Keep multi-class ABC fire extinguishers readily at hand. Class A fires involve ordinary combustible materials such as wood and cloth. Class B fires involve combustible and flammable liquids and gaseous fuels.
Class C fires involve live electrical equipment. See NFPA No. 10 (Portable Fire Extinguishers) or equivalent—BS EN 3-7:2004.
• Generator set installation and operation must comply with all applicable local, state and federal codes and regulations.
iv
1. Introduction
ABOUT THIS MANUAL
This is the Operator Manual for the generator sets listed on the front cover. Read and carefully observe all of the instructions and precautions in this manual. Keep this manual with the vehicle.
The following sections, Operation, Periodic Mainte-
nance and Troubleshooting provide the instructions necessary for operating the generator set and maintaining top performance. The owner is responsible for performing maintenance in accordance with the
PERIODIC MAINTENANCE SCHEDULE (p. 3-1).
WARNING This generator set is not a life support system. It can stop without warning. Children, persons with physical or mental limitations, and pets could suffer personal injury or death. A personal attendant, redundant power or alarm system must be used if generator set operation is critical.
WARNING Improper service or replacement of parts can lead to severe personal injury or death and damage to equipment and property. Service personnel must be qualified to perform electrical and mechanical service.
Unauthorized modifications or replacement of fuel, exhaust, air intake or speed control system components that affect engine emissions are prohibited by law in the State of California.
NAMEPLATE
Be ready to provide the generator set model and serial numbers on the nameplate when contacting
Cummins Onan for parts, service or information.
Figure 1-1 illustrates typical model and serial num-
bers.
Record the numbers on your generator set name-
plate in Figure 1-2 so that they are easy to find when
needed. Each character in these numbers is significant. The last character of the model number is the specification letter, which is important for obtaining the right parts. Genuine Cummins Onan replacement parts are recommended for best results. Refer to the generator set Parts Catalog.
1-1
FIGURE 1-1. TYPICAL NAMEPLATE
FIGURE 1-2. RECORD NUMBERS HERE
HOW TO OBTAIN SERVICE
Call the nearest authorized Cummins Onan distributor for service, parts and product literature (such as the generator set Service Manual or Parts Catalog).
Factory-trained representatives will handle your requests for generator set parts and service.
In North America
Call 1−800−888−6626 to contact the nearest Cummins Onan distributor in the United States or Canada. (This automated service utilizes touch-tone phones only).
If you are unable to contact a distributor using the automated service, consult the Yellow Pages. Typically, our distributors are listed under:
GENERATORS − ELECTRIC,
ENGINES − GASOLINE OR DIESEL, or
RECREATIONAL VEHICLES − EQUIPMENT,
PARTS AND SERVICE.
If you have difficulty in arranging service or resolving a problem, please contact the Service Manager at the nearest Cummins Onan distributor for assistance.
Outside North America
Call Cummins Onan at 1−763−574−5000 from
7:30 AM to 4:00 PM, Central Standard Time,
Monday through Friday, or fax 1−763−528−7229.
Worldwide
Go to internet site www.cumminsonan.com for
Cummins Onan distributor contact information.
Information to Have Ready
Before calling for service, have the following information available:
1. The complete generator set model number and serial number. See About This Manual
2. The date of purchase
3. The nature of the problem. See Section 4. Trou-
bleshooting.
1-2
ENGINE EMISSIONS COMPLIANCE
The label that states compliance with applicable engine emissions regulations is located on the air
cleaner cover as shown circled in Figure 1-3. Refer
also to the FEDERAL EMISSION DESIGN AND
DEFECT LIMITED WARRANTY FOR C. I. EN-
GINES (DIESELS) that was shipped in the same package as the Operator’s Manual.
FIGURE 1-3. EMISSIONS LABEL LOCATION
1-3
TYPICAL GENERATOR SET
Figure 1-4 illustrates a typical generator set show-
ing connection points and maintenance access.
GENERATOR SET
STOP SWITCH
INTERNAL
MUFFLER
SERVICE
ACCESS
AC OUTPUT, BATTERY POS (+)
& REMOTE CONTROL
CONNECTIONS
COOLING &
VENTILATING
AIR INLET
BATTERY NEG (−)
CONNECTION
MAINTENANCE ACCESS
(AIR, FUEL & OIL FILTERS)
BOTTOM EXHAUST &
HOT AIR DISCHARGE
BOTTOM
OIL DRAIN
FUEL
CONNECTIONS
CHASSIS
GROUND
FIGURE 1-4. TYPICAL GENERATOR SET
1-4
THIS PAGE LEFT INTENTIONALLY BLANK
1-5
2. Operation
RECOMMENDED FUEL
WARNING Diesel fuel is combustible and can cause severe personal injury or death. Do not smoke near fuel tanks or fuel-burning equipment or in areas sharing ventilation with such equipment. Keep flames, sparks, pilot flames, electrical arcs and switches and all other sources of ignition well away. Keep a multiclass ABC fire extinguisher handy.
High quality Grade 2-D diesel fuel is necessary for good performance and long engine life. Diesel fuels specified by ASTM D975 or EN 590 are recommended. Use Grade 1-D diesel fuel when ambient temperatures are below freezing. The fuel should have a Cetane number of at least 45 for reliable starting.
RECOMMENDED ENGINE OIL
Use API (American Petroleum Institute) performance Class CF engine oil or better. Also look for the SAE (Society of Automotive Engineers) viscos-
ity grade. Referring to Figure 2-1, choose the vis-
cosity grade appropriate for the ambient temperatures expected until the next scheduled oil change.
Multi-grade oils such as SAE 15W-40 are recommended for year-round use.
See Section 5. Specifications for oil capacity.
STARTING BATTERIES
The generator set requires a 12 volt battery to power its control and starting circuits. Reliable generator set starting and starter service life depend upon adequate battery system capacity and maintenance.
See MAINTAINING THE BATTERY AND BATTERY
CONNECTIONS (p. 3-2) and Section 5. Specifi-
cations for minimum battery ratings.
Note: Ultra Low Sulfur Diesel (ULSD) fuel that meets the ASTM D975 standard for lubricity is suitable for use with this generator set. The 1 to 2 percent less energy content of the fuel can have a slight effect on maximum engine power.
Note: B5 Bio-Diesel fuel that meets industry specifications and quality is suitable for use with this generator set.
FIGURE 2-1. OIL VISCOSITY VS. TEMPERATURE
2-1
STOP SWITCH
Press the stop switch (Figure 2-2) to stop the gener-
ator set or to prevent it from starting while performing maintenance and service. To allow the generator set to run, press the switch again. The switch must stay in its “1” position for the generator set to run.
Note: This is not a start switch. The generator set can only be started using the remote operator panel
FIGURE 2-2. STOP SWITCH
2-2
REMOTE OPERATOR PANEL
The remote operator panel (Figure 2-3) has the fol-
lowing features:
Display ON / Gen OFF Button − Press this button to wake the generator set and display screen prior to pressing the START button. This also starts the fuel pump, which will prime the fuel system for five minutes if the generator set does not start.
Press this button to stop the generator set.
START Button − To start the generator set, press and hold this button when “GEN OFF” appears on the display screen after having pressed the Display
ON button.
Display Screen − The display screen displays generator set status, battery voltage, hours run and
warning and shutdown messages (see Section 4.
Troubleshooting).
Low Oil Indicator Light − This light warns that engine oil pressure is low or temperature is too high.
FIGURE 2-3. OPERATOR PANEL
2-3
WARNING
EXHAUST GAS is deadly.
All engine exhaust contains carbon monoxide; an odorless, colorless, poisonous gas that can cause unconsciousness and death. Symptoms of carbon monoxide poisoning include:
• Dizziness • Headache
• Nausea • Weakness and Sleepiness
• Vomiting • Inability to Think Coherently
IF YOU EXPERIENCE ANY OF THESE SYMP-
TOMS, GET INTO FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the generator set and do not operate it until it has been inspected and repaired.
Never sleep in the vehicle while the generator set is running unless the vehicle has a working carbon monoxide detector. The exhaust system must be installed in accordance with the generator set Installation Manual. Make sure there is ample fresh air when operating the generator set in a confined area.
PRE-START CHECKS
Before the first start of the day and after every eight hours of operation, inspect the generator set as
instructed under GENERAL INSPECTION (p. 3-2).
Keep a log of maintenance and the hours run and perform any maintenance that may be due. See Re-
turning the Generator Set to Service (p. 2-7) if the vehicle has been in storage.
Before each start:
1. Make sure all vehicle carbon monoxide (CO) detectors are working.
2. Check for fuel and oil leaks and damage to the exhaust system.
3. To prevent overheating and to reduce fouling with dust and debris, make sure the generator set’s normal ground clearance is not being reduced by sloping ground, curbs, logs or other objects. Repark the vehicle if necessary and/or remove any objects blocking the air inlet or air outlet.
4. Turn off air conditioners and other large appliances.
STARTING
1. Perform the PRE-START CHECKS.
2. Start the generator set at the remote operator panel.
A. Press and release the Display ON button.
B. Wait for “GEN OFF” to appear. If the generator set ran out of fuel and it is necessary to prime the fuel system, wait at least one minute before pressing the START button to allow the fuel pump to prime fuel.
C. Press and hold the START button until the generator set starts. The generator set will make up to three attempts to start. “GEN
ON” will appear on the display screen when the generator set starts. “GEN
WAIT” will appear during rest periods between start attempts.
3. Press the GEN OFF button to reset the control if the generator set does not start after three at-
tempts. See Section 4. Troubleshooting if the
generator set still does not start.
4. Let the generator set warm up a few minutes until it is running smoothly before connecting the vehicle electrical loads (appliances).
5. Check for fuel, oil and exhaust leaks. Stop the generator set immediately if there is leak and have it repaired.
STOPPING
Run the generator set under no load for a few minutes to allow the engine to cool down and then press and release the Gen OFF button.
2-4
LOADING THE GENERATOR SET
The generator set can power AC motors, air conditioners, AC/DC converters, battery chargers and other appliances. How much appliance load* can be powered depends upon the generator set power rating. The generator set will shut down if the sum of the loads exceeds generator set power. See Sec-
To avoid overloading the generator set and causing shutdowns, compare the sum of the loads of the appliances that are likely to be used at the same time to the power rating of the generator set. It may be nec- essary to run fewer appliances at the same time—the sum of the loads must not be greater than generator set rating.
Altitude
(Elevation above Sea Level) at/below 500 ft (152 m) at 2500 ft (762 m) at 5500 ft (1676 m) above 5500 ft (1676 m)
TABLE 2-1. TYPICAL APPLIANCE LOADS
Appliance Load (watts)
Air Conditioner
Battery Charger
1400-2000
Up to 3600
DC Converter
Refrigerator
Microwave Oven
Electric Frying Pan or Wok
300-900
600-1000
1000-1500
1000-1500
Electric Stove Element
Electric Water Heater
Electric Iron
Electric Hair Dryer
Coffee Percolator
Television
Radio
Electric Drill
Electric Broom
Electric Blanket
350-1000
1000-1500
500-1200
800-1500
550-750
200-600
50-200
250-750
200-500
50-200
The generator set may shut down due to overload when a large motor or air conditioner is started or cycles off and then on again, even though the sum of the loads is less than generator set rating. The reason for this is that a motor’s startup load is much larger than its running load. It may be necessary to run fewer appliances when large motors and air conditioners are cycling on and off.
Maximum power decreases as altitude increases because air density decreases. For every 1000-foot
(305 m) increase in elevation you can expect power to decrease approximately 3.5 percent. It may be necessary to run fewer appliances at higher altitudes.
TABLE 2-2. POWER VS. ALTITUDE
Maximum Power
3200 W (rated)
2980 W
2640 W
2640 W minus 112 W every 1000 ft (305 m)
* Appliance load and generator set power are measured in terms of watts (W) or kilowatts (kW), where 1 kilowatt (kW) = 1000 watts (W).
2-5
RESETTING CIRCUIT BREAKERS
Note: The generator set does not have a power output circuit breaker.
If a circuit breaker in the main power distribution panel of the vehicle trips, either a circuit shorted or too many appliances were running.
If a circuit breaker trips, disconnect or turn off as many loads as possible and reset the circuit breaker. (Push the circuit breaker to OFF to reset it and then to ON to reconnect the circuit.) If the circuit breaker trips right away, either the electrical distribution system has a short or the circuit breaker is faulty. Call a qualified electrician.
If the circuit breaker does not trip right away, reconnect the appliances, one by one, up to a total load that does not overload the generator set.
Electrical appliances and tools must be used and maintained properly and be properly grounded to cause the line circuit breakers to trip when short circuits occur.
WARNING Short circuits in electrical appliances and tools can cause fire and electrical shock leading to severe personal injury or death. Read and follow the equipment and tool manufacturer’s instructions and warnings regarding use, maintenance and proper grounding.
CONNECTING TO UTILITY POWER
A vehicle with provisions for connecting utility power must have an approved device to keep the generator set and utility from being interconnected. See the generator set Installation Manual for more information.
WARNING Interconnecting the generator set and the public utility can lead to electrocution of utility line workers, equipment damage and fire.
Use an approved switching device to prevent interconnections.
OPERATING IN COLD WEATHER
Make sure the engine oil viscosity is appropriate for the cold ambient temperatures. See ENGINE OIL
RECOMMENDATIONS (p. 2-1). Be sure to change the oil if a sudden drop in temperature occurs.
OPERATING IN HOT WEATHER
Pay particular attention to the following items when operating the generator set in hot weather:
1. Make sure nothing blocks airflow to and from the generator set.
2. Make sure the engine oil viscosity is appropriate for the hot ambient temperatures. See EN-
GINE OIL RECOMMENDATIONS (p. 2-1).
3. Keep the generator set clean.
4. Perform maintenance due. See PERIODIC
MAINTENANCE SCHEDULE (p. 3-1).
OPERATING AT HIGH ALTITUDE
For the effect of altitude on maximum power, see
LOADING THE GENERATOR SET (p. 2-5).
OPERATING IN DUSTY ENVIRONMENTS
Pay particular attention to the following items when operating the generator set in dusty environments:
1. Do not let dirt and debris accumulate inside the generator set compartment. Keep the generator set clean.
2. Perform air cleaner maintenance more often.
See PERIODIC MAINTENANCE SCHEDULE
3. Change engine oil more often. See PERIODIC
MAINTENANCE SCHEDULE (p. 3-1).
4. Keep containers of engine oil that have been opened tightly closed to keep out dust.
2-6
BREAKING IN A NEW ENGINE
Proper engine break-in on a new generator set or on one with a rebuilt engine is essential for top engine performance and acceptable oil consumption. Do not exceed 70 percent of rated power during the first
50 hours of operation. See LOADING THE GENER-
Proper engine oil and oil level are especially critical during break-in because of the higher engine temperatures that can be expected. Change the oil if not appropriate for the ambient temperatures during break-in. See ENGINE OIL RECOMMENDATIONS
(p. 2-1). Change the oil after the first 50 hours of operation.
EXERCISING THE GENERATOR SET
Exercise the generator set at least 2 hours each month if use is infrequent. Run the generator set at approximately 1/2 rated power. See LOADING THE
GENERATOR SET (p. 2-5). A single two hour exercise period is better than several shorter periods.
Exercising a generator set drives off moisture, re-lubricates the engine, replaces stale fuel and removes oxides from electrical contacts. The result is better starting, more reliable operation and longer engine life.
STORING THE GENERATOR SET
Proper storage is essential for preserving top generator set performance and reliability when the generator set cannot be exercised regularly and will be idle for more than 120 days.
Storing the Generator Set
1. Change the engine oil and attach a tag indicating oil viscosity. See ENGINE OIL REC-
2. Disconnect the battery cables (negative [−] cable first) from the starting battery and store the battery according to the battery manufacturer’s recommendations. See MAINTAINING
THE BATTERY AND BATTERY CONNEC-
3. Plug the exhaust tail pipe to keep out dirt, moisture, bugs, etc.
4. Close the fuel supply valve (if so equipped).
Returning the Generator Set to Service
1. Check the oil tag on the generator set and change the oil if the viscosity indicated is not appropriate for the temperatures expected.
See ENGINE OIL RECOMMENDATIONS
2. Reconnect the starting battery (negative [−] cable last). See MAINTAINING THE BATTERY
AND BATTERY CONNECTIONS (p. 3-2).
3. Remove the plug from the exhaust tailpipe.
4. Change the air filter element if it is dirty (p. 3-6).
5. Open the fuel supply valve (if so equipped).
6. Inspect the generator set. See GENERAL IN-
2-7
THIS PAGE LEFT INTENTIONALLY BLANK
2-8
3. Periodic Maintenance
Periodic maintenance is essential for top perfor-
mance and long generator set life. Use Table 3-1 as
a guide for normal periodic maintenance. In hot and dusty environments some maintenance procedures should be performed more frequently, as indicated by the footnotes in the table.
Maintenance, replacement or repair of emission control devices and systems may be performed by any engine repair establishment or individual. However, warranty work must be completed by an authorized Cummins Onan dealer.
WARNING Accidental or remote starting can cause severe personal injury or death. Push the
Stop Switch Off and disconnect the battery cables at the batteries to prevent starting during maintenance and service. (Always disconnect negative [−] first and reconnect last to prevent sparks between tools and vehicle frame.)
TABLE 3-1. PERIODIC MAINTENANCE SCHEDULE
FREQUENCY
MAINTENANCE TASK
After First
50 Hrs
Every
Day
Every
Month
Every
250 Hrs
Every
500 Hrs
Every
1000 Hrs Page
General Inspection
Check Engine Oil Level
Check Battery & Battery Connections 1
•
•
•
Change Engine Oil
Clean Spark Arrestor
• •
•
Replace Engine Air Filter
Replace Fuel Filter
•
•
Adjust Engine Valve Lash
Clean the Oil Filter
Check Fuel Injector Pressure 4, 5
•
•
•
1. Perform more often when operating in hot weather.
2. Perform more often when operating in dusty conditions.
3. Perform at least once a year.
4. Must be performed by trained and experienced personnel (authorized Cummins Onan service representatives).
5. EPA requirement.
−
−
3-1
GENERAL INSPECTION
Inspect the generator set before the first start of the day and after every eight hours of operation.
Oil Level
Check engine oil level (Figure 3-1).
Exhaust System
WARNING EXHAUST GAS IS DEADLY! Do not operate the generator set if there is an exhaust leak or any danger of exhaust gases entering or being drawn into the vehicle.
Look and listen for exhaust system leaks while the generator set is running. Shut down the generator set if a leak is found and have it repaired before operating the generator set again.
Look for openings or holes between the generator set compartment and vehicle cab or living space if the generator set engine sounds louder than usual.
Have all such openings or holes closed off or sealed to prevent exhaust gases from entering the vehicle.
Replace dented, bent or severely rusted sections of the tailpipe and make sure the tailpipe extends at least 1 inch (25.4 mm) beyond the perimeter of the vehicle.
WARNING Do not park the vehicle in high grass or brush. Contact with the exhaust system can cause a fire.
Park the vehicle so that the generator set exhaust gases can disperse away from the vehicle. Barriers such as walls, snow banks, high grass and brush and other vehicles can cause exhaust gases to accumulate in and around the vehicle.
Do not operate power ventilators or exhaust fans while the vehicle is standing with the generator set running. The ventilator or fan can draw exhaust gases into the vehicle.
Fuel System
Check for leaks at hose, tube and pipe fittings in the fuel supply system while the generator set is running and while it is stopped. Check flexible fuel hose sections for cuts, cracks, and abrasions. Make sure the fuel line is not rubbing against other parts. Replace worn or damaged fuel line parts before leaks occur.
WARNING Diesel fuel leaks can lead to fire. Do not operate the generator set if operation causes fuel to leak.
Mechanical
Look for mechanical damage and listen for unusual noises. Check the generator set mounting bolts.
To prevent overheating and to reduce fouling with dust and debris, make sure the generator set’s normal ground clearance is not being reduced by sloping ground, curbs, logs or other objects. Repark the vehicle if necessary and/or remove any objects blocking the air inlet or air outlet.
MAINTAINING THE BATTERY AND
BATTERY CONNECTIONS
WARNING Flames, sparks and arcing at battery terminals, light switches and other equipment can ignite battery gas causing severe personal injury—Ventilate battery area before working on or near battery—Wear safety glasses—Do not smoke—Switch work light ON or OFF away from battery—Stop generator set and disconnect charger before disconnecting battery cables—Disconnect negative (−) cable first and reconnect last.
Refer to Table 3-1 for scheduled battery mainte-
nance and follow the battery manufacturer’s instructions. If battery (DC) voltage is consistently low or high, have the vehicle battery charging system serviced. (The generator set does not recharge the battery.) Always:
1. Keep the battery case and terminals clean and dry and the terminals tight.
2. Use a battery terminal puller to remove the cable clamps on post-type battery terminals.
3. Tighten threaded-stud battery terminals as recommended by the battery manufacturer.
4. Make sure which terminal is positive (+) and which is negative (−) before making battery connections, always removing the negative (−) cable first and reconnecting it last to reduce arcing.
3-2
CHECKING ENGINE OIL LEVEL
WARNING State and federal agencies have determined that contact with used engine oil can cause cancer or reproductive toxicity. Avoid skin contact and breathing of vapors. Use rubber gloves and wash exposed skin.
To check engine oil level:
1. Park the vehicle on level ground, shut down the generator set and remove the front access door.
2. Pull out the oil dip stick, wipe it clean, reinsert it and pull it out again to check the oil level (Fig-
3. Add or drain oil as necessary. See REC-
OMMENDED ENGINE OIL (p. 2-1). Keep the
oil level between the MIN / MAX marks.
CAUTION Too much oil can cause high oil consumption. Too little oil can cause severe engine damage. Keep the oil level between the MIN / MAX marks.
4. Reinsert the dipstick and secure the oil fill cap and front access door.
FIGURE 3-1. CHECKING ENGINE OIL LEVEL
3-3
CHANGING ENGINE OIL
WARNING Accidental or remote starting can cause severe personal injury or death. Push the
Stop Switch Off and disconnect the battery cables at the batteries to prevent starting during maintenance and service. (Always disconnect negative [−] first and reconnect last to prevent sparks between tools and vehicle frame.)
Refer to Table 3-1 for scheduled engine oil change.
Change oil more often in hot and dusty environments. To change engine oil:
1. Place a pail under the oil drain plug (Fig-
2. Remove the maintenance access door and the oil fill cap, unscrew the oil drain cap and drain all the oil from the engine. Reinstall the oil
drain cap securely.
3. Refill with approximately 0.7 quarts of oil, check
oil level (Figure 3-1) and secure the front ac-
cess door.
4. Dispose of the used oil according to local environmental regulations.
5. Secure the front access door.
FIGURE 3-2. CHANGING ENGINE OIL
3-4
CLEANING THE ENGINE OIL STRAINER
WARNING Accidental or remote starting can cause severe personal injury or death. Push the
Stop Switch Off and disconnect the battery cables at the batteries to prevent starting during maintenance and service. (Always disconnect negative [−] first and reconnect last to prevent sparks between tools and vehicle frame.)
WARNING Wear safety glasses when using compressed air to clean the oil strainer to protect your eyes from severe injury from flying debris.
Refer to Table 3-1 for scheduled cleaning of the en-
gine oil strainer. Clean the oil strainer more often in hot and dusty environments. The oil strainer is ac-
cessible through the front access door (Figure 3-3).
To replace the oil strainer:
1. Remove the maintenance access door.
2. Loosen the center screw of the strainer (about five turns) and withdraw the strainer from the engine block.
3. Use compressed air to clean the strainer. Blow the debris from inside out.
4. Replace the O-rings or strainer if damaged.
5. Lubricate the O-rings with clean oil and insert the strainer until it stops.
6. Check for spring tension against the strainer and tighten the center screw.
7. Secure the front access door.
FIGURE 3-3. CLEANING ENGINE OIL STRAINER
3-5
REPLACING THE AIR FILTER ELEMENT
WARNING Accidental or remote starting can cause severe personal injury or death. Push the
Stop Switch Off and disconnect the battery cables at the batteries to prevent starting during maintenance and service. (Always disconnect negative [−] first and reconnect last to prevent sparks between tools and vehicle frame.)
Refer to Table 3-1 for scheduled air filter replace-
ment. Replace it more often in dusty environments.
The air filter is accessible through the front access
door (Figure 3-4). To replace the air filter:
1. Remove the filter cover
2. Unscrew the the knurled nut and remove the old filter element.
3. Clean dust and debris from the filter housing and install the new filter element.
4. Secure the front access door.
FIGURE 3-4. REPLACING THE AIR FILTER ELEMENT
3-6
CLEANING THE SPARK ARRESTOR
Refer to Table 3-1 for scheduled cleaning of the in-
line tail pipe spark arrestor canister (Figure 3-5),
which meets U.S. Forest Service requirements.
Cleaning is required for maximum generator set performance.
WARNING A hot muffler can cause severe burns. Let the muffler cool down before removing or installing the cleanout plug.
To clean the in-line tailpipe spark arrestor:
1. Remove the cleanout plug on the side of the spark arrestor canister.
2. Start the generator set and load it nearly to full power. Let the generator set run for about five minutes to expel the soot.
3. Stop the generator set, allow the muffler to cool down, and reinstall the cleanout plug.
FIGURE 3-5. TYPICAL LOCATION OF SPARK ARRESTOR IN TAILPIPE
3-7
REPLACING THE FUEL FILTER
See Table 3-1 for scheduled fuel filter replacement.
A dirty fuel filter may be the cause of a failure to start.
WARNING Diesel fuel is combustible and can cause severe personal injury or death. Do not smoke near diesel fuel tanks or equipment.
Keep flames, sparks, pilot lights, electrical switches, arc-producing equipment and all other sources of ignition well away. Have a type
ABC fire extinguisher ready to use.
Close any fuel line shutoff valve before disconnecting the fuel line from the filter.
WARNING Accidental or remote starting can cause severe personal injury or death. Push the
Stop Switch Off and disconnect the battery cables at the batteries to prevent starting during maintenance and service. (Always disconnect negative [−] first and reconnect last to prevent sparks between tools and vehicle frame.)
CAUTION Dirt can damage the fuel system.
Make sure to wipe dirt off the fuel hose fittings before disconnecting.
The fuel filter is accessible through the front access
door (Figure 3-6). To replace the fuel filter:
1. Have paper towels or rags ready to clean the two fuel hose fittings and absorb any fuel that spills.
2. Clean the two fuel hose fittings to keep dirt from entering the fuel hoses.
3. Loosen the two fuel hose clamps and the filter body clamp and replace the filter element.
Make sure the arrow on the filter element points up in the direction of fuel flow.
4. Dispose of the fuel filter and paper towels or rags in accordance with local environmental regulations.
5. Secure the front access door.
FIGURE 3-6. FUEL FILTER
3-8
4. Troubleshooting
Note: Most generator set shutdowns and failures to start can be avoided by performing periodic mainte-
nance on schedule (TABLE 3-1. PERIODIC MAINTE-
NANCE SCHEDULE) and by making sure that the generator set does not run out of fuel. In this regard it should also be noted that the vehicle manufacturer has probably arranged the fuel tank dip tubes such that the generator set will run out of fuel before the fuel gauge reads EMPTY, thus reserving fuel for the propulsion engine.
STATUS MESSAGES
The Operator Panel displays the following status and periodic maintenance messages. Warning and
Fault messages, once cleared, cannot be retrieved.
To clear faults turn display off/on.
Note: Operator warning and fault messages, once cleared, cannot be retrieved.
GEN OFF Indicates that the generator set is off but ready to start.
GEN ON Indicates that the generator set is running.
GEN START If this message appears while pressing START, but the engine does not crank, check the
stop switch inside the generator set (p. 2-2) and
push it on.
GEN CAL This message appears during generator set start-up indicating that it is in calibration mode and not yet ready to produce AC output voltage.
Wait a few seconds.
RESTART GEN? This message appears any time the generator set stops. Turn off and restart the generator set.
GEN WAIT The generator set is delaying the next start attempt to allow the starter motor to cool down.
Or, more time is being allowed for engine preheating because the ambient temperature is below freezing.
Try restarting when the message turns off.
LOW BATTERY Battery voltage is below the minimum value (9 VDC) necessary to start the generator set. Check battery connections and recharge or replace the battery.
MAINTENANCE MESSAGES
OIL CHANGE / CHECK OIL LEVEL These messages appear every time the generator set hour counter reaches preset oil check/change intervals
(change after first 50 hours and then every 250 hours). The generator set continues to run. Fill or change oil as necessary. The generator set must be running to reset the message. Hold START until the message clears. If not reset, the message will reappear after an hour of running.
WARNING MESSAGES
SHORT CIRCUIT A connected appliance probably has a short circuit. AC output voltage is turned off but the engine is kept running to cool the generator set. Disconnect all appliances, press STOP to stop the engine and then restart the generator set. Reconnect appliances one by one to find out which one shorted and have it repaired or replaced.
FAULT MESSAGES
OIL TEMP-PRESS
Possible Cause: The engine lubricating oil temperature is too high or the pressure is too low. The oil pressure and temperature switches are connected in parallel. When the engine is at rest and cold, the pressure switch is closed and the temperature switch is open.
Diagnosis/Repair—Low Oil Pressure:
1. Check Oil level and refill as necessary.
Diagnosis/Repair—High Oil Temperature:
GENERATOR ALERT
Possible Cause There are three possible causes:
1. The Operator Panel in the vehicle must be able to communicate with the inverter in the generator set. If communication is interrupted this fault will likely occur when attempting to start the generator set.
2. Without power from the PMA auxiliary windings
AC3 and AC4, the inverter will not be able to communicate with the Operator Panel. If the output frequency detected by the inverter is too high (engine speed greater than 4200rpm) the
4-1
inverter will shut down the generator set.
See PMA information in section 4−9 for engine speed calculation.
3. Faulty inverter.
CAUTION Always perform stator check before replacing the invertor. Failure to do so will result in damage to the inverter.
Diagnosis/Repair:
1. Contact an authorized Cummins Onan dealer.
CAUTION Always perform stator check before replacing the invertor. Failure to do so will result in damage to the inverter.
OVER TEMPERATURE (INVERTER)
Possible Cause Inverter temperature detected to be over 70° C.
Diagnosis/Repair:
1. Reduce loads.
CAUTION Always perform stator check before replacing the invertor. Failure to do so will result in damage to the inverter.
OVERLOAD
Possible Cause Too many applications are connected, or the inverter is defective.
Diagnosis/Repair:
1. Measure current draw. If it is greater than 32 amps, reduce the number of appliances connected in the coach and wait a few minutes for generator set to cool down. Press STOP to stop engine and restart the generator set.
2. If the generator set shuts down on ’Overload’ condition, disconnect it from the coach and bench-test with a load-bank. If the generator set runs fine without shutting down, then the problem likely exists within vehicle wiring and/ or appliances. In the event that it shuts down with no load connected, perform checks in Step
3. Ensure stator is not damaged and has no shorts internally or to Ground on all Main and
Auxiliary Windings. Test winding insulation resistance with a Megger. Replace state if necessary. If the stator is good, replace the inverter.
CAUTION Always perform stator check before replacing the invertor. Failure to do so will result in damage to the inverter.
LOW ENGINE POWER
Possible Cause Engine speed is below 2300 rpm
Diagnosis/Repair:
1. Contact an authorized Cummins Onan dealer.
SYMPTOM DIAGNOSTICS
DEAD OPERATOR PANEL
Possible Cause/Diagnosis/Repair
1. Contact an authorized Cummins Onan dealer.
A. Replace the 30 amp fuse on the internal control panel, if blown.
B. Check for 12 VDC at Pin 3 of the 10-pin connector on the internal control panel and for a good ground at Pin 10.
C. Check for 12 VDC at Pins 2, 3 and 6 of the
9-pin connector on the internal control panel and for a good ground at Pin 5 of the
6-pin connector.
D. Repair wiring and connectors as necessary.
ENGINE CRANKS BUT DOES NOT START
Note: The generator will make up to three start attempts, cranking each time for 5 seconds and pausing for 2 seconds if necessary before the next crank.
Gen Wait should appear on the display.
Possible Cause/Diagnosis/Repair
1. Clear the Gen Wait message from the Operator
Panel by cycling it off and on. Try starting again.
2. Check the fuel level and fill as necessary.
3. Press the stop switch (p. 2-2) if it is not in its “1”
position.
4. Replace the fuel if it is not of the specified grade
or suitable for the ambient temperature (p 2-1).
ENGINE SPITS/SPUTTERS/EXHAUSTS WHITE
SMOKE
Possible Cause/Diagnosis/Repair
1. Air in fuel system: Prime fuel system by turning on the display, lift pump should run for 5 minutes to prime system. If problem goes away
4-2
check for air leaks with soapy water at fittings and hoses.
ENGINE EXHAUSTS BLACK SMOKE
Possible Cause/Diagnosis/Repair
1. Contact an authorized Cummins Onan dealer.
ENGINE WON’T STOP
Possible Cause/Diagnosis/Repair
1. Contact an authorized Cummins Onan dealer.
ENGINE STOP
LEVER
FIGURE 4-1. ENGINE STOP LEVER
4-3
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
4-4
5. Specifications
GENSET CONTROL: Integrated Microprocessor-Based Engine and Generator Controller and AC Output Inverter
GENERATOR: Three-Phase, Permanent Magnet, 3600 RPM
Power (@1.0 power factor)
Voltage
Frequency
Number of Phases
Current
FUEL CONSUMPTION:
@ 1 kW
@ 2 kW
@ 3 kW
@ 3.5 kW
See Nameplate
120
60 Hz
1
26.7 amps
0.20 gph (0.76 lph)
0.27 gph (1.03 lph)
0.36 gph (1.37 lph)
0.38 gph (1.44 lph)
ENGINE: Single-Cylinder, Direct-Injection, Air-Cooled, 4-Stroke Diesel
Bore
Stroke
Displacement
Compression Ratio
Fuel Injection Timing (BTDC)
Fuel Nozzle Injection Pressure
Cylinder Compression Test
Valve Lash: Intake & Exhaust (cold)
Oil Capacity
3.15 in (80 mm)
2.72 in (69 mm)
21 in 3 (347 cc)
1:22
16 °
2900±174 psi (200±12 bar)
290 to 319 psi (20 to 22 bar)
0.004 in (0.1 mm)
1.1 quart (1.1 liter)
DC SYSTEM:
Nominal Battery Voltage
Minimum Battery Capacity
CCA (Cold Cranking Amps)
WEIGHT (WET): 205 lbs (93 kg)
SIZE (L x W x H): 30.17 x 17.3 x 18.02 in (766.4 x 439.4 x 457.7 cm)
12 volts
475 amps down to 0° F (−17° C)
650 amps down to −20° F (−29° C)
SOUND LEVEL: 68 dB(A) @ 10 ft (3 meters) quality. We therefore recommend a minimum engine load of 15%.
LOAD ON ENGINE
• Operating the engine for a lengthy period off− load or at very low loads can affect its running
• If operated at such low loads, it is best to operate the engine at a significantly higher load for a short period before switching it off.
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5-2
6. Maintenance Record
Record all periodic and unscheduled maintenance and service. See Section 3. Periodic Maintenance.
DATE
HOUR
METER
READING
MAINTENANCE OR SERVICE PERFORMED
Record the name, address, and phone number of your authorized Cummins Onan service center.
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6-2
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Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email www.cumminsonan.com/contact www.cumminsonan.com
Cummins R , Onan R , the “C” logo, and “Performance you rely on.” are trademarks of Cummins Inc.
E2009 Cummins Power Generation, Inc. All rights reserved.
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