Thoroughly read the OPERATOR’S MANUAL
before operating the generator set. Safe operation and top performance can only be ob-tained when equipment is properly operatedand maintained.
The following symbols in this manual alert you topotential hazards to the operator, service personand equipment.
DANGER
that will result in severe personal injury ordeath.
WARNING
practice that can result in severe personal in-jury or death.
CAUTION
practice that can result in personal injury orequipment damage.
When equipped with an integral or add−on Auto-matic Generator Starting System (AGS) control,exhaust carbon monoxide (CO), electric shock,and moving parts hazards are possible due to un-expectedstarting. Turn off AGS whenever per-formingmaintenance or service, when the vehicleis stored between uses, is awaiting service, or isparked in a garage or other confined area.
alerts you to an immediate hazard
alerts you to a hazard or unsafe
alerts you to a hazard or unsafe
ENGINE EXHAUST IS DEADLY
•Inspect forexhaust leaks at every startup andafter every eight hours of running.
•Learnthe symptoms of carbon monoxide poi-soning in the generator set Operator’s Manu-al.
•Neversleep in the vehicle while the generatorset is running unless the vehicle is equippedwith 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.
• 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 automaticstarting device before servicing the genset toavoid electric shock from an unexpectedstart.
•Generatorelectrical output connections mustbe made by a trained and experienced elec-trician in accordance with applicable codes.
•The generator set must not be connected toshorepower (utility). Back-feed to shore pow-er can cause electrocution and damage toequipment.An approved switching devicemust be used to prevent interconnections.
•Use caution when working on live electricalequipment. Remove jewelry, make sureclothing and shoes are dry, stand on a drywoodenplatform or rubber insulating mat anduse tools with insulated handles.
DIESEL FUEL IS COMBUSTIBLE
•Do not smoke or turn electrical switches ONor OFF where fuel fumes are present or inareassharing ventilation with fuel tanks orequipment. Keep flames, sparks, pilot lights,arc-producing equipment and all othersources of ignition well away.
•Fuel lines must be secured, free of leaks andseparated 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 auto-maticstarting device before servicing thegenset 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.
iii
Page 6
BATTERY GAS IS EXPLOSIVE
• Wear safety glasses.
• Do not smoke.
• To reduce arcing when disconnecting or re-
connecting battery cables, always disconnect the negative (−) battery cable first andreconnect it last.
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 canrestrict cooling air.
FLAMMABLE VAPORS CAN BE IGNITED
BY OPERATION OF COACH ELECTRICAL
SYSTEMS AND CAUSE DIESEL ENGINES
TO OVERSPEED
•Stop the generator set before fueling thecoachto reduce the risk of igniting flammablevapors.
•Do not operate the diesel-powered generatorset where there are or can be flammable va-pors created by fuel spills, gas leaks, etc.Flammablevapors drawn into a diesel engineair intake system can cause the engine tooverspeed,which can result in fire, explosionand equipment damage. The owners and op-erators of the generator set are solely re-sponsible for safe operation.
GENERAL PRECAUTIONS
•Keep children away from the generator set.
•Do not use evaporative starting fluids. They
are highly explosive.
•Make sure all fasteners are secure andtorqued properly.
•Do not work on the generator set when men-tally or physically fatigued or after consumingalcohol or drugs.
•You must be trained and experienced tomake adjustments while the generator set isrunning—hot,moving or electrically live partscan cause severe personal injury or death.
•Used engine oil has been identified by someU. S. state and federal agencies as causingcancer or reproductive toxicity. Do not ingest,inhale, or contact used oil or its vapors.
•Keep multi-class ABC fire extinguishersreadily athand. Class A fires involve ordinarycombustiblematerials such as wood andcloth. Class B fires involve combustible andflammable liquids and gaseous fuels.Class C fires involve live electrical equip-ment.See NFPANo. 10 (Portable Fire Extin-guishers) or equivalent—BS EN 3-7:2004.
•To prevent accidental or remote starting whileworking on the generator set, press the Stopbuttonand disconnect the battery cables at
•Generatorset installation and operation mustcomply with all applicable local, state and fed-eral codes and regulations.
iv
Page 7
1. Introduction
ABOUT THIS MANUAL
This is the Operator Manual for the generator setslisted onthe front cover. Read and carefully observeall of the instructions and precautions in this manu-al. Keep this manual with the vehicle.
The following sections, Operation, Periodic Mainte-nance and Troubleshooting provide the instructionsnecessary for operating the generator set and main-taining top performance. The owner is responsiblefor performing maintenance in accordance with thePERIODIC MAINTENANCE SCHEDULE (p. 3-1).
WARNING
port system. It can stop without warning. Chil-dren, persons with physical or mental limita-tions,and pets could suffer personal injury ordeath. A personal attendant, redundant poweror alarm system must be used if generator setoperation is critical.
WARNING
parts can lead to severe personal injury or deathand damage to equipment and property. Servicepersonnel must be qualified to perform electri-cal and mechanical service.
Unauthorized modifications or replacement offuel,exhaust, air intake or speed control systemcomponents that affect engine emissions areprohibited by law in the State of California.
This generator set is not a life sup-
Improper service or replacement of
NAMEPLATE
Be ready to provide the generator set model and se-rial numbers on the nameplate when contactingCummins Onan for parts, service or information.Figure 1-1 illustrates typical model and serial num-bers.
FIGURE 1-1. TYPICAL NAMEPLATE
Record the numbers on your generator set name-plate inFigure 1-2so 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.
FIGURE 1-2. RECORD NUMBERS HERE
1-1
Page 8
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 Cum-mins Onandistributor in the United States or Cana-da. (This automated service utilizes touch-tonephones only).
If you are unable to contact a distributor using theautomatedservice, consult the Yellow Pages. Typi-cally, our distributors are listed under:
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,
Mondaythrough Friday, or fax 1−763−528−7229.
Worldwide
Go to internet site www.cumminsonan.com forCummins Onan distributor contact information.
Information to Have Ready
Before calling for service, have the following infor-mation available:
GENERATORS − ELECTRIC,ENGINES − GASOLINE OR DIESEL, orRECREATIONAL VEHICLES − EQUIPMENT,PARTS AND SERVICE.
If you have difficulty in arranging service or resolv-ing a problem, please contact the Service Manager
1.Thecomplete generator set model number andserial number. See About This Manual(Page 1-1).
2.The date of purchase
3.The nature ofthe problem. See Section 4.Trou-bleshooting.
1-2
Page 9
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. ENGINES (DIESELS) that was shipped in the samepackage as the Operator’s Manual.
FIGURE 1-3. EMISSIONS LABEL LOCATION
1-3
Page 10
TYPICAL GENERATOR SET
Figure 1-4 illustrates a typical generator set showing connection points and maintenance access.
INTERNAL
MUFFLER
SERVICE
ACCESS
MAINTENANCE ACCESS
(AIR, FUEL & OIL FILTERS)
GENERATOR SET
STOP SWITCH
BOTTOM EXHAUST &HOT AIR DISCHARGE
BOTTOM
OIL DRAIN
AC OUTPUT, BATTERY POS (+)
& REMOTE CONTROL
CONNECTIONS
FUEL
CONNECTIONS
COOLING &
VENTILATING
AIR INLET
BATTERY NEG (−)
CONNECTION
CHASSISGROUND
FIGURE 1-4. TYPICAL GENERATOR SET
1-4
Page 11
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1-5
Page 12
2. Operation
RECOMMENDED FUEL
WARNING
cause severe personal injury or death. Do notsmoke near fuel tanks or fuel-burning equip-ment or in areas sharing ventilation with suchequipment. Keep flames, sparks, pilot flames,electrical arcs and switches and all othersources of ignition well away. Keep a multi-class ABC fire extinguisher handy.
High quality Grade 2-D diesel fuel is necessary forgood performance and long engine life. Diesel fuelsspecified by ASTM D975 or EN 590 are recom-mended. Use Grade 1-D diesel fuel when ambienttemperatures are below freezing. The fuel shouldhave a Cetane number of at least 45 for reliablestarting.
Diesel fuel is combustible and can
RECOMMENDED ENGINE OIL
Use API (American Petroleum Institute) perfor-mance Class CF engine oil or better. Also look forthe SAE (Society of Automotive Engineers) viscos-ity grade. Referring to Figure 2-1, choose the vis-cosity grade appropriate for the ambient tempera-tures expected until the next scheduled oil change.Multi-grade oils such as SAE 15W-40 are recom-mended for year-round use.
See Section 5. Specifications for oil capacity.
STARTING BATTERIES
The generator set requires a 12 volt battery to powerits control and starting circuits. Reliable generatorset starting and starter service life depend upon ad-equate battery system capacity and maintenance.
See MAINTAINING THE BATTERYAND BATTERYCONNECTIONS (p. 3-2) and Section 5. Specifi-cations for minimum battery ratings.
Note: Ultra Low Sulfur Diesel (ULSD) fuel that meetsthe ASTM D975 standard for lubricity is suitable foruse with this generator set. The 1 to 2 percent lessenergy content of the fuel can have a slight effect onmaximum engine power.
Note: B5 Bio-Diesel fuel that meets industry specifi-cations and quality is suitable for use with this gener-ator set.
FIGURE 2-1. OIL VISCOSITY VS. TEMPERATURE
2-1
Page 13
STOP SWITCH
Press the stop switch (Figure 2-2) to stop the generator 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
(p. 2-3).
FIGURE 2-2. STOP SWITCH
2-2
Page 14
REMOTE OPERATOR PANEL
The remote operator panel (Figure 2-3) has the following features:
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 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 fuelpump, which will prime the fuel system for five min-utes if the generator set does not start.
Press this button to stop the generator set.
Display Screen − The display screen displays gen-
erator set status, battery voltage, hours run and
warning and shutdown messages (see Section 4.Troubleshooting).
Low Oil Indicator Light −This light warns that en-gine oil pressure is low or temperature is too high.
FIGURE 2-3. OPERATOR PANEL
2-3
Page 15
WARNING
gine 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. Ifsymptomspersist, seek medical attention. Shutdownthe generator set and do not operate it un-til it has been inspected and repaired.
Never sleep in the vehicle while the generatorset is running unless the vehicle has a workingcarbonmonoxide detector.The exhaust systemmust be installed in accordance with the gener-ator set Installation Manual. Make sure there isample fresh air when operating the generatorset in a confined area.
EXHAUST GAS is deadly. All en-
PRE-START CHECKS
Before the first start of the day and after every eighthours of operation, inspect the generator set asinstructed under GENERAL INSPECTION (p. 3-2).Keep a log of maintenance and the hours run andperformany maintenance that may be due. See Re-turning the Generator Set to Service (p. 2-7) if thevehicle 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 theexhaust system.
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 operatorpanel.
A.Press and release the Display ON button.
B.Wait for “GEN OFF” to appear. If the gen-
eratorset ran out of fuel and it is necessaryto prime the fuel system, wait at least oneminute before pressing the START buttonto allow the fuel pump to prime fuel.
C.Press and hold the START button until the
generatorset starts. The generator set willmake up to three attempts to start. “GENON” will appear on the display screenwhen the generator set starts. “GENWAIT” will appear during rest periods be-tween start attempts.
3.Press the GEN OFF button to reset the controlif the generator set does not start after three at-tempts. See Section 4. Troubleshooting if thegenerator set still does not start.
4.Let the generator set warm up a few minutesuntil it is running smoothly before connectingthe vehicle electrical loads (appliances).
5.Check for fuel, oil and exhaust leaks. Stop thegenerator set immediately if there is leak andhave it repaired.
3.To prevent overheating and to reduce foulingwith dust and debris, make sure the generatorset’s normal ground clearance is not being re-duced by sloping ground, curbs, logs or otherobjects.Repark the vehicle if necessary and/or
STOPPING
Run the generator set under no load for a few min-utes toallow the engine to cool down and then pressand release the Gen OFF button.
2-4
Page 16
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 ofthe loads exceeds generator set power. See Sec-tion 4. Troubleshooting.
To avoid overloading the generator set and causingshutdowns, compare the sum of the loads of the ap-pliances that are likely to be used at the same time tothe power rating of the generator set. It may be nec-
essary to run fewer appliances at the sametime—the sum of the loads must not be greaterthan generator set rating.
The generator set may shut down due to overloadwhen a large motor or air conditioner is started orcycles offand then on again, even though the sum ofthe loads is less than generator set rating. The rea-son for this is that a motor’s startup load is muchlarger than its running load. It may be necessary to
run fewer appliances when large motors and airconditioners are cycling on and off.
TABLE 2-1. TYPICAL APPLIANCE LOADS
Appliance
Air Conditioner1400-2000
Battery ChargerUp to 3600
DC Converter300-900
Refrigerator600-1000
Microwave Oven1000-1500Electric Frying Pan or Wok1000-1500Electric Stove Element350-1000Electric Water Heater1000-1500Electric Iron500-1200Electric Hair Dryer800-1500Coffee Percolator550-750Television200-600Radio50-200Electric Drill250-750Electric Broom200-500Electric Blanket50-200
Load (watts)
Maximum power decreases as altitude increasesbecause air density decreases. For every 1000-foot(305 m)increase in elevation you can expect powerto decrease approximately 3.5 percent. It may be
necessary torun fewer appliances at higher alti-tudes.
TABLE 2-2. POWER VS. ALTITUDE
Altitude
(Elevation above Sea Level)
at/below 500 ft (152 m)3200 W (rated)
at 2500 ft (762 m)2980 W
at 5500 ft (1676 m)2640 W
above 5500 ft (1676 m)2640 W minus 112 W every 1000 ft (305 m)
Maximum Power
* 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
Page 17
RESETTING CIRCUIT BREAKERS
OPERATING IN COLD WEATHER
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 asmany loads as possible and reset the circuit break-er. (Push the circuit breaker to OFF to reset it andthen to ON to reconnect the circuit.) If the circuitbreaker trips right away, either the electrical dis-tributionsystem has a short or the circuit breaker isfaulty. Call a qualified electrician.
If the circuit breaker does not trip right away, recon-nect the appliances, one by one, up to a total loadthat does not overload the generator set.
Electrical appliances and tools must be used andmaintained properly and be properly grounded tocause the line circuit breakers to trip when short cir-cuits occur.
WARNING
pliances and tools can cause fire and electricalshock leading to severe personal injury ordeath. Read and follow the equipment and toolmanufacturer’s instructions and warnings re-garding use, maintenance and proper ground-ing.
Short circuits in electrical ap-
CONNECTING TO UTILITY POWER
A vehicle with provisions for connecting utility powermust have an approved device to keep the genera-tor set and utility from being interconnected. See thegenerator set Installation Manual for more informa-tion.
WARNING
and the public utility can lead to electrocution ofutilityline workers, equipment damage and fire.Use an approved switching device to prevent in-terconnections.
Interconnecting the generator set
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 whenoperating the generator set in hot weather:
1.Make sure nothing blocks airflow to and fromthe generator set.
2.Make sure the engine oil viscosity is appropri-ate for the hot ambient temperatures. See EN-GINE OIL RECOMMENDATIONS (p. 2-1).
3.Keep the generator set clean.
4.Perform maintenance due. See PERIODICMAINTENANCE SCHEDULE(p. 3-1).
OPERATING AT HIGH ALTITUDE
For the effect of altitude on maximum power, seeLOADING THE GENERATOR SET (p. 2-5).
OPERATING IN DUSTY ENVIRONMENTS
Pay particular attention to the following items whenoperating the generator set in dusty environments:
1.Do not let dirt and debris accumulate inside thegenerator set compartment. Keep the genera-tor set clean.
2.Perform air cleaner maintenance more often.See PERIODIC MAINTENANCE SCHEDULE(p. 3-1).
3.Changeengine oil more often. See PERIODICMAINTENANCE SCHEDULE(p. 3-1).
4.Keep containers of engine oil that have beenopened tightly closed to keep out dust.
2-6
Page 18
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-ATOR SET(p. 2-5).
Properengine oil and oil level are especially criticalduring break-in because of the higher engine tem-peraturesthat can be expected. Change the oil if notappropriate for the ambient temperatures duringbreak-in.See ENGINE OIL RECOMMENDATIONS(p. 2-1).Change the oil after the first 50 hours ofoperation.
ator 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 RECOMMENDATIONS (p. 2-1).
2.Disconnect the battery cables (negative [−]cable first) from the starting battery and storethe battery according to the battery manufac-turer’s recommendations. See MAINTAININGTHE BATTERY AND BATTERY CONNEC-TIONS (p. 3-2).
3.Plug the exhaust tail pipe to keep out dirt, mois-ture, bugs, etc.
EXERCISING THE GENERATOR SET
Exercise the generator set at least 2 hours eachmonth if use is infrequent. Run the generator set atapproximately1/2 rated power. See LOADING THEGENERATOR SET(p. 2-5). A single two hour ex-ercise period is better than several shorter periods.
Exercising agenerator set drives offmoisture, re-lu-bricates the engine, replaces stale fuel and re-movesoxides from electrical contacts. The result isbetter starting, more reliable operation and longerengine life.
STORING THE GENERATOR SET
Proper storage is essential for preserving top gener-ator set performance and reliability when the gener-
4.Close the fuel supply valve (if so equipped).
Returning the Generator Set to Service
1.Check the oil tag on the generator set andchange the oil if the viscosity indicated is notappropriate for the temperatures expected.See ENGINE OIL RECOMMENDATIONS(p. 2-1).
2.Reconnect the starting battery (negative [−]cable last). See MAINTAINING THE BATTERYAND 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-SPECTION (p. 3-2).
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Page 19
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2-8
Page 20
3. Periodic Maintenance
Periodic maintenance is essential for top performance and long generator set life. Use Table 3-1 as
ever, warranty work must be completed by an au-
thorized Cummins Onan dealer.
a guide for normal periodic maintenance. Inhot anddusty environments some maintenance proceduresshould be performed more frequently, as indicatedby the footnotes in the table.
WARNING
cause severe personal injury or death. Push the
Stop Switch Off and disconnect the battery
Accidental or remote starting can
cables atthe batteries to prevent starting during
Maintenance, replacement or repair of emissioncontrol devices and systems may be performed byany engine repair establishment or individual. How-
TABLE 3-1. PERIODIC MAINTENANCE SCHEDULE
MAINTENANCE TASK
General Inspection•3-2
Check Engine Oil Level•3-3
Check Battery & Battery Connections
Change Engine Oil
Clean Spark Arrestor
Replace Engine Air Filter
Replace Fuel Filter
Adjust Engine Valve Lash
1,2,3
3
2,3
3
4
After First
50 Hrs
1
••3-4
maintenance and service. (Always disconnect
negative [−] first and reconnect last to prevent
sparks between tools and vehicle frame.)
FREQUENCY
Every
Day
Every
Month
•3-2
Every
250 Hrs
•3-7
Every
500 Hrs
•3-6
•3-8
Every
1000 Hrs
•−
Page
Clean the Oil Filter•3-5
Check Fuel Injector Pressure
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.
4,5
•−
3-1
Page 21
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
operate the generator set if there is an exhaustleak orany danger of exhaust gases entering orbeing drawn into the vehicle.
Look and listen for exhaust system leaks while thegenerator set is running. Shut down the generatorset if a leak is found and have it repaired before op-erating the generator set again.
Look for openings or holes between the generatorset compartment and vehicle cab or living space ifthe generator set engine sounds louder than usual.Have all such openings or holes closed off or sealedto prevent exhaust gases from entering the vehicle.
Replace dented, bent or severely rusted sections ofthe tailpipe and make sure the tailpipe extends atleast 1 inch (25.4 mm) beyond the perimeter of thevehicle.
WARNING
or brush. Contact with the exhaust system cancause a fire.
Park the vehicle so that the generator set exhaustgases can disperse away from the vehicle. Barrierssuch as walls, snow banks, high grass and brushand other vehicles can cause exhaust gases to ac-cumulate in and around the vehicle.
Do not operate power ventilators or exhaust fanswhile the vehicle is standing with the generator setrunning. The ventilator or fan can draw exhaustgases into the vehicle.
EXHAUST GAS IS DEADLY! Do not
Do not park the vehicle in high grass
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. Re-
place worn or damaged fuel line parts before leaks
occur.
WARNING
not operate the generator set if operation
causes fuel to leak.
Diesel fuel leaks can lead to fire. Do
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’snor-
mal ground clearance is not being reduced by slop-
ing 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
tery terminals, light switches and other equip-
ment can ignite battery gas causing severe per-
sonalinjury—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
anddisconnect 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 in-
structions. Ifbattery (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 anddry and the terminals tight.
2.Use a battery terminal puller to remove thecable clamps on post-type battery terminals.
3.Tighten threaded-stud battery terminals as rec-ommended by the battery manufacturer.
4.Make sure which terminal is positive (+) andwhich is negative (−) before making battery
connections, always removing the negative (−)
cable first and reconnecting it last to reduce
arcing.
Flames, sparks and arcing at bat-
3-2
Page 22
CHECKING ENGINE OIL LEVEL
WARNING
termined 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 thegenerator set and remove the front accessdoor.
State and federal agencies have de-
2. Pull out the oil dip stick, wipe it clean, reinsert
it and pull it out again to check the oil level (Figure 3-1).
3. Add or drain oil as necessary. See RECOMMENDED ENGINE OIL (p. 2-1). Keep the
oil level between the MIN / MAX marks.
CAUTION
Too much oil can cause high oilconsumption. Toolittle oil can cause severeengine damage. Keep the oil level betweenthe MIN / MAX marks.
4.Reinsert the dipstick and secure the oil fill capand front access door.
FIGURE 3-1. CHECKING ENGINE OIL LEVEL
3-3
Page 23
CHANGING ENGINE OIL
1. Place a pail under the oil drain plug (Figure 3-2).
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 disconnectnegative [−] first and reconnect last to preventsparks between tools and vehicle frame.)
Refer to Table 3-1 for scheduled engine oil change.Change oil more often in hot and dusty environ-ments. To change engine oil:
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 oildrain cap securely.
3.Refill with approximately 0.7 quarts of oil, checkoil level (Figure 3-1) and secure the front ac-cess door.
4.Dispose of the used oil according to local envi-ronmental regulations.
5.Secure the front access door.
FIGURE 3-2. CHANGING ENGINE OIL
3-4
Page 24
CLEANING THE ENGINE OIL STRAINER
WARNING
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 preventsparks between tools and vehicle frame.)
WARNING
compressed air to clean the oil strainer to pro-tect your eyes from severe injury from flying de-bris.
Refer to Table 3-1 for scheduled cleaning of the en-gine oil strainer. Clean the oil strainer more often inhot and dusty environments. The oil strainer is ac-
Accidental or remote starting can
Wear safety glasses when using
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. Blowthe debris from inside out.
4.Replace the O-rings or strainer if damaged.
5.Lubricate the O-rings with clean oil and insertthe strainer until it stops.
6.Check for spring tension against the strainerand tighten the center screw.
7.Secure the front access door.
FIGURE 3-3. CLEANING ENGINE OIL STRAINER
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REPLACING THE AIR FILTER ELEMENT
ment. Replace it more often in dusty environments.
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 disconnectnegative [−] first and reconnect last to preventsparks between tools and vehicle frame.)
Refer to Table 3-1 for scheduled air filter replace-
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 housingand install the new filter element.
4.Secure the front access door.
FIGURE 3-4. REPLACING THE AIR FILTER ELEMENT
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CLEANING THE SPARK ARRESTOR
To clean the in-line tailpipe spark arrestor:
Refer to Table 3-1 for scheduled cleaning of the inline 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 severeburns. Let the muffler cool down before remov-ing or installing the cleanout plug.
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 cooldown, and reinstall the cleanout plug.
FIGURE 3-5. TYPICAL LOCATION OF SPARK ARRESTOR IN TAILPIPE
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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.
CAUTION
Dirt can damage the fuel system.
Make sure to wipe dirt off the fuel hose fittings
before disconnecting.
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, electricalswitches,arc-producing equipment and all oth-er sources of ignition well away. Have a typeABC fire extinguisher ready to use.
Close any fuel line shutoff valve before discon-necting the fuel line from the filter.
WARNING
Accidental or remote starting cancause severe personal injury or death. Push theStop Switch Off and disconnect the batterycables atthe batteries to prevent starting duringmaintenance and service. (Always disconnectnegative [−] first and reconnect last to preventsparks between tools and vehicle frame.)
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 thetwo fuel hose fittings and absorb any fuel thatspills.
2.Clean the two fuel hose fittings to keep dirt fromentering the fuel hoses.
3.Loosen the two fuel hose clamps and the filterbody clamp and replace the filter element.Make sure the arrow on the filter element pointsup in the direction of fuel flow.
4.Dispose of the fuel filter and paper towels orrags in accordance with local environmentalregulations.
5.Secure the front access door.
FIGURE 3-6. FUEL FILTER
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4. Troubleshooting
Note: Most generator set shutdowns and failures to
start can be avoided by performing periodic maintenance on schedule (TABLE 3-1. PERIODIC MAINTE-NANCE SCHEDULE) and by making sure that thegenerator set does not run out of fuel. In this regard itshould also be noted that the vehicle manufacturerhas probably arranged the fuel tank dip tubes suchthat the generator set will run out of fuel before thefuel gauge reads EMPTY, thus reserving fuel for thepropulsion engine.
STATUS MESSAGES
The Operator Panel displays the following statusand periodic maintenance messages. Warning andFault messages, once cleared, cannot be retrieved.To clear faults turn display off/on.
Note: Operator warning and fault messages, oncecleared, cannot be retrieved.
GEN OFF Indicates that the generator set is off but
ready to start.
MAINTENANCE MESSAGES
OIL CHANGE / CHECK OIL LEVEL These mes-
sages appear every time the generator set hourcounter reaches preset oil check/change intervals(change after first 50 hours and then every 250hours). The generator set continues to run. Fill orchange oil as necessary. The generator set must berunning toreset the message. Hold START until themessage clears. If not reset, the message will re-appear after an hour of running.
WARNING MESSAGES
SHORT CIRCUITA connected appliance probably
has a short circuit. AC output voltage is turned offbut the engine is kept running to cool the generatorset. Disconnect all appliances, press STOP to stopthe engine and then restart the generator set. Re-connect appliances one by one to find out which oneshorted and have it repaired or replaced.
FAULT MESSAGES
GEN ON Indicates that the generator set is run-
ning.
GEN START If this message appears while press-ingSTART, but the engine does not crank, check thestop switch inside the generator set (p. 2-2) andpush it on.
GEN CAL This message appears during generatorset start-up indicating that it is in calibration modeand not yet ready to produce AC output voltage.Wait a few seconds.
RESTART GEN? This message appears any timethe generator set stops. Turn off and restart the gen-erator set.
GEN WAIT The generator set is delaying the nextstart attempt to allow the starter motor to cool down.Or, more time is being allowed for engine preheatingbecause 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.
OIL TEMP-PRESS
PossibleCause: The engine lubricating oil temper-
ature is too high or the pressure is too low. The oilpressure and temperature switches are connectedin parallel. When the engine is at rest and cold, thepressure switch is closed and the temperatureswitch 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 ableto communicate with the inverter in the genera-tor set. If communication is interrupted this faultwill 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
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inverter will shut down the generator set.
See PMA information in section 4−9 for engine
speed calculation.
CAUTION
Always perform stator check before
replacing the invertor. Failure to do so will result
in damage to the inverter.
3. Faulty inverter.
CAUTION
Always perform stator check before
replacingthe invertor. Failure to do so will resultin damage to the inverter.
Diagnosis/Repair:
1.Contact an authorized Cummins Onan dealer.
CAUTION
Always perform stator check beforereplacingthe invertor. Failure to do so will resultin 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 beforereplacingthe invertor. Failure to do so will resultin damage to the inverter.
OVERLOAD
Possible Cause Too many applications are con-
nected, or the inverter is defective.
Diagnosis/Repair:
1.Measure current draw. If it is greater than 32amps, reduce the number of appliances con-nected in the coach and wait a few minutes forgeneratorset to cool down. Press STOP to stopengine and restart the generator set.
2.If the generator set shuts down on ’Overload’condition, disconnect it from the coach andbench-test with a load-bank. If the generatorset runs fine without shutting down, then theproblem likely exists within vehicle wiring and/or appliances. In the event that it shuts downwith noload connected, perform checks in Step
3.
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.
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 onthe internal control panel andfor 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 controlpanel and for a good ground at Pin 5 of the6-pin connector.
D.Repair wiring and connectors as neces-
sary.
ENGINE CRANKS BUT DOES NOT START
Note: The generator will make up to three start at-tempts, cranking each time for 5 seconds and paus-ing 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 OperatorPanel bycycling it off and on. Trystarting 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 gradeor 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
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check for air leaks with soapy water at fittings
and hoses.