CUMMINS Onan HGJBB Operator's Manual

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OperatorOperator ManualManual

RV Generator Set

HGJBB (Spec A)

English Original Instructions 10-2014 A031C171 (Issue 4)

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1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1

1.1 Overview ................................................................................................................................. 1

1.2 Warning, Caution, and Note Styles Used In This Manual ...................................................... 1

1.3 General Safety Precautions .................................................................................................... 1

1.4 Automatic Generator Start Control Hazards ........................................................................... 3

1.5 Electrical Shock and Arc Flash Can Cause Severe Personal Injury or Death ....................... 3

1.6 Generator Voltage Is Deadly .................................................................................................. 3

1.7 Engine Exhaust/Carbon Monoxide Is Deadly ......................................................................... 4

1.8 Fuel Is Flammable and Explosive ........................................................................................... 5

1.9 Battery Gas Is Explosive......................................................................................................... 5

1.10 Moving Parts Can Cause Severe Personal Injury or Death ................................................. 5

1.11 CARB .................................................................................................................................... 6

1.12 Generator Set Warning Labels ............................................................................................. 6

2. INTRODUCTION............................................................................................................................ 9

2.1 About this Manual ................................................................................................................... 9

2.2 Related Literature ................................................................................................................... 9

2.3 Model Identification ............................................................................................................... 10

2.3.1 Nameplate Location ................................................................................................... 11

2.4 How to Obtain Service .......................................................................................................... 11

2.4.1 In North America ........................................................................................................ 11

2.4.2 Outside North America............................................................................................... 12

2.4.3 Information To Have Available................................................................................... 12

3. OVERVIEW .................................................................................................................................. 13

3.1 Electromagnetic Compatibility Compliance........................................................................... 13

3.2 Information for Generator Set Users (Spark-Ignited Exhaust Emissions) ............................ 13

3.3 Build Standards..................................................................................................................... 14

3.4 Specifications ........................................................................................................................ 15

3.4.1 Gasoline Model Specifications ................................................................................... 15

3.4.2 LPG Model Specifications .......................................................................................... 16

3.5 List of Acronyms ................................................................................................................... 17

4. OPERATION ................................................................................................................................ 21

4.1 Key Component Locations.................................................................................................... 21

4.2 Control Panel ........................................................................................................................ 23

4.2.1 Generator Set Control Panel...................................................................................... 23

4.2.2 Remote Control Panel................................................................................................ 23

4.3 Starting and Stopping the Generator Set ............................................................................. 25

4.3.1 Pre-start Checks ........................................................................................................ 25

4.3.2 Priming the Fuel System ........................................................................................... 25

4.3.3 Starting the Generator Set ......................................................................................... 26

4.3.4 Stopping the Generator Set ....................................................................................... 26

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4.4 Loading the Generator Set ................................................................................................... 26

4.4.1 Power Versus Altitude................................................................................................ 28

4.5 Exercising the Generator Set................................................................................................ 29

4.6 Resetting Line Circuit Breakers ............................................................................................ 29

4.7 Connecting Shore Power ...................................................................................................... 30

4.8 Operating in Weather Extremes ........................................................................................... 30

4.9 Operating in Dusty Environments ......................................................................................... 30

4.10 Care of New or Rebuilt Engine ........................................................................................... 31

5. MAINTENANCE ........................................................................................................................... 33

5.1 Periodic Maintenance ........................................................................................................... 33

5.1.1 Periodic Maintenance Schedule ................................................................................ 33

5.2 Consumable Parts ................................................................................................................ 34

5.3 General Inspection................................................................................................................ 34

5.4 Maintaining the Battery ......................................................................................................... 34

5.5 Maintaining the Lubrication System...................................................................................... 35

5.5.1 Oil Level ..................................................................................................................... 35

5.5.2 Engine Oil Recommendations ................................................................................... 36

5.5.3 Changing Engine Oil and Oil Filter ............................................................................ 36

5.6 Maintaining the Fuel System ................................................................................................ 38

5.6.1 Fuel System ............................................................................................................... 38

5.6.2 Fuel Recommendations ............................................................................................. 38

5.6.3 Replacing the Fuel Filter ............................................................................................ 39

5.7 Exhaust System .................................................................................................................... 41

5.8 Mechanical System............................................................................................................... 41

5.9 Replacing the Air Filter Element ........................................................................................... 42

5.10 Replacing the Spark Plug(s) ............................................................................................... 42

5.11 Cleaning the Spark Arrester ............................................................................................... 43

5.12 Storing the Generator Set................................................................................................... 44

5.12.1 Carburetor Float Bowl Drain Valve .......................................................................... 46

5.13 Returning the Generator Set to Service ............................................................................. 46

6. TROUBLESHOOTING ................................................................................................................. 49

6.1 Overview ............................................................................................................................... 49

6.2 Fault Codes........................................................................................................................... 49

6.2.1 Code 2 - Low Oil Pressure......................................................................................... 50

6.2.2 Code 3 - Service Check............................................................................................. 50

6.2.3 Code 4 - Over Crank.................................................................................................. 50

6.2.4 Code 12 - Over Voltage............................................................................................. 51

6.2.5 Code 13 - Under Voltage........................................................................................... 51

6.2.6 Code 14 - Over Frequency ........................................................................................ 51

6.2.7 Code 15 - Under Frequency ...................................................................................... 51

6.2.8 Code 27 - Voltage Sense........................................................................................... 52

6.2.9 Code 29 - High Battery Voltage ................................................................................. 52

6.2.10 Code 31 - Over Speed............................................................................................. 52

6.2.11 Code 32 - Low Cranking Speed............................................................................... 52

6.2.12 Code 35 - Control Card Failure................................................................................ 52

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6.2.13 Code 36 - Engine Stopped ...................................................................................... 53

6.2.14 Code 37 - Invalid Generator Set Configuration........................................................ 53

6.2.15 Code 38 - Over Current (Field Overload) ................................................................ 53

6.2.16 Code 41 - Generator Rotor...................................................................................... 54

6.2.17 Code 42 - Processor ................................................................................................ 54

6.2.18 Code 43 - Processor ................................................................................................ 54

6.2.19 Code 45 - Speed Sense .......................................................................................... 54

6.2.20 Code 47 - Ignition..................................................................................................... 54

6.2.21 Code 48 - Generator Field Sense............................................................................ 54

6.3 Symptom Based.................................................................................................................... 54

6.3.1 Status Indicator Not Working ..................................................................................... 54

6.3.2 Starting Batteries Run Down...................................................................................... 55

6.3.3 Starter Engages-Disengages..................................................................................... 55

6.3.4 Status Indicator Goes Out While Cranking—No Start ............................................... 55

6.3.5 No Power—Generator Set Running, Status Light On................................................ 56

7. MAINTENANCE RECORD........................................................................................................... 57

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iv A031C171 (Issue 4)

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1 Important Safety Instructions

1.1 Overview

Thoroughly read the Operator Manual before operating the generator set. It contains important instructions that should be followed during operation and maintenance. Safe operation and top performance can only be achieved when equipment is properly operated and maintained. The owners and operators of the generator set are solely responsible for its safe operation.

Generator set operation, maintenance, and installation must comply with all applicable local, state, and federal codes and regulations. Electricity, fuel, exhaust, moving parts, and batteries present hazards which can result in severe personal injury or death. Only trained and experienced personnel with knowledge of fuels, electricity, and machinery hazards should perform generator set installation or adjustment procedures; or remove, dismantle, or dispose of the generator set.

1.2 Warning, Caution, and Note Styles Used In This Manual

The following safety styles and symbols found throughout this manual indicate potentially hazardous conditions to the operator, service personnel, or equipment.

DANGER

Indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

NOTICE

Indicates information considered important, but not hazard-related (e.g., messages relating to property damage).

1.3 General Safety Precautions

WARNING

Operation of equipment is unsafe when mentally or physically fatigued. Do not operate equipment in this condition, or after consuming any alcohol or drug.

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1. Important Safety Instructions 10-2014

WARNING

Maintaining or installing a generator set can cause severe personal injury. Wear personal protective equipment such as safety glasses, protective gloves, hard hats, steel-toed boots, and protective clothing when working on equipment.

WARNING

Running the generator set without the cover or service door can cause severe personal injury or equipment damage. Do not operate the generator set with the cover or service doors removed.

WARNING

Starting fluids, such as ether, can cause explosion and generator set engine damage. Do not use.

WARNING

Benzene, found in some fuels, has been identified by some state and federal agencies to cause cancer or reproductive toxicity. Do not ingest, breathe the fumes, or contact gasoline when checking, draining, or adding gasoline.

WARNING

Used engine oils have been identified by some state and federal agencies to cause cancer or reproductive toxicity. Do not ingest, breathe the fumes, or contact used oil when checking or changing engine oil.

CAUTION

To prevent accidental or remote starting while working on the generator set, disconnect the negative (-) battery cable at the battery using an insulated wrench.

CAUTION

Unsecured or loose fasteners can cause equipment damage. Make sure all fasteners are secure and properly torqued.

CAUTION

Oily rags and other material can cause fire and restrict cooling. Keep the generator set, drip pan, and compartment clean.

CAUTION

Accumulated grease and oil can cause overheating and engine damage presenting a potential fire hazard. Keep the generator set clean and repair any oil leaks promptly.

NOTICE

Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible materials such as wood and cloth. Class B fires involve combustible and flammable liquid fuels and gaseous fuels. Class C fires involve live electrical equipment. (Refer to NFPA No. 10 in applicable region.)

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10-2014 1. Important Safety Instructions

1.4 Automatic Generator Start Control Hazards

WARNING

Accidental starting can cause severe personal injury or death. Turn off the 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.

Unexpected starting may occur if the generator set is equipped with an inverter-charger or other Automatic Generator Start (AGS) control. This may cause exposure to:

• Unexpected generator starting

• Moving parts hazards

• Electric shock

• Exhaust carbon monoxide (CO)

1.5 Electrical Shock and Arc Flash Can Cause Severe Personal Injury or Death

WARNING

Electrical shocks and arc flashes can cause severe personal injury or death. Adhere to the following guidelines:

• Only qualified service personnel certified and authorized to work on power circuits should

work on exposed energized power circuits.

• All relevant service material must be available for any electrical work performed by certified

service personnel.

• Exposure to energized power circuits with potentials of 50 VAC or 75 VDC or higher poses a

significant risk of electrical shock and electrical arc flash.

• Refer to standard NFPA 70E, or equivalent safety standards in corresponding regions, for

details of the dangers involved and for safety requirements.

1.6 Generator Voltage Is Deadly

WARNING

Improperly connected generator electrical output connections can cause equipment damage, severe personal injury, or death. Electrical connections must be made by a trained and experienced electrician in accordance with applicable codes.

WARNING

Improper installations can cause equipment damage, severe personal injury, or death. All installations must be conducted by trained and experienced personnel in accordance with the installation instructions and all applicable codes.

WARNING

Back feed to shore power can cause electrocution and damage to equipment. The generator set must not be connected to shore power or to any other source of electrical power. An approved switching device must be used to prevent interconnections.

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1. Important Safety Instructions 10-2014

WARNING

Live electrical equipment can cause electrocution. 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.

1.7 Engine Exhaust/Carbon Monoxide Is Deadly

WARNING

Substances in exhaust gases have been identified by some state and federal agencies to cause cancer or reproductive toxicity. Do not breathe in or come into contact with exhaust gases.

WARNING

Carbon monoxide is a poisonous gas. Inhalation of this gas can cause severe personal injury or death. Adhere to the following bullet points to make sure carbon monoxide is not being inhaled by occupants of the vehicle as well as others working on or around the generator set.

• Inspect for exhaust leaks, and test and confirm that all carbon monoxide detectors are

working in accordance with the manufacturer's instructions or owner's manual, prior to every startup, and after every 8 hours of running.

• Never occupy the vehicle while the generator set is running unless the vehicle is equipped

with a working carbon monoxide detector.

• Never operate the generator set when the vehicle is in a confined space, such as a garage,

basement, or building of any kind.

• Make sure the exhaust system is installed in accordance with the generator set installation

manual.

• Never use engine cooling air for heating a working or living space compartment.

Carbon Monoxide (CO) is odorless, colorless, tasteless, and non-irritating. It cannot be seen or smelled. Exposure, even to low levels of CO for a prolonged period can lead to asphyxiation (lack of oxygen).

Mild effects of CO poisoning include:

• headache

• dizziness

• drowsiness

• fatigue

• chest pain

• confusion

More extreme symptoms include:

• vomiting

• seizure

• loss of consciousness

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10-2014 1. Important Safety Instructions

1.8 Fuel Is Flammable and Explosive

WARNING

Fuel and fuel vapor is highly explosive. Adhere to the following bullets to avoid igniting fuel and fuel vapors.

• 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 flame, sparks, pilot lights, arc-producing equipment and all other sources of ignition

well away from fuel lines and sources.

• Fuel lines must be secured, free of leaks, and separated or shielded from electrical wiring.

Leaks can lead to explosive accumulations of gas.

• LPG sinks when released and can accumulate inside housings and basements and other below-grade spaces.

NOTICE

Natural gas is identifiable by a rotten egg smell.

1.9 Battery Gas Is Explosive

WARNING

Battery gas is highly explosive and may cause personal injury or death if ignited. Take the proper precautions to avoid personal injury.

• For personal safety, wear appropriate PPE when working on or around the generator set.

• To make sure battery gas is not ignited, do not smoke around the generator set.

• To reduce arcing when disconnecting or reconnecting battery cables, always disconnect

the negative (–) battery cable first and reconnect it last.

1.10 Moving Parts Can Cause Severe Personal Injury or Death

WARNING

Moving parts can cause severe personal injury or death, and hot exhaust parts can cause severe burns. Make sure all protective guards are properly in place before starting the generator set.

WARNING

Hot moving, and electrically live parts can cause severe personal injury or death. Keep children away from the generator set.

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1. Important Safety Instructions 10-2014

WARNING

Hot, moving, and electrically live parts can cause severe personal injury or death. Only trained and experienced personnel should make adjustments while the generator set is running.

WARNING

Moving parts can catch on loose items such as clothing or jewelry. Do not wear loose clothing or jewelry near moving parts such as PTO (power take-off) shafts, fans, belts, and pulleys.

WARNING

Moving parts can entangle appendages such as fingers. Keep the protective guards in place over fans, belts, pulleys, and other moving parts and keep hands away from all moving parts.

1.11 CARB

CAUTION

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.

The California Air Resources Board (CARB) has requirements regarding modification & repair of fuel system & exhaust components.

1.12 Generator Set Warning Labels

Warning signs are provided on the generator set at or near the point of risk. To avoid injury, always take the necessary precautions as indicated on the sample signs shown below.

Caution or Warning. Indicates a risk of personal injury.

Caution or Warning of Temperature Hazard. Indicates a risk of personal injury from high temperature.

Caution or Warning of High Voltage Hazard. Indicates a risk of personal injury from electric shock or electrocution.

Caution or Warning of Engine Coolant Pressure Hazard. Indicates a risk of personal injury from hot pressurized engine coolant.

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10-2014 1. Important Safety Instructions

Caution or Warning. Indicates to read Operator Manual for additional information.

Caution or Warning of No Step. Indicates a risk of personal injury or equipment damage from stepping on equipment.

Caution or Warning of Combustion or Explosion Hazard. Indicates a risk of personal injury from explosion.

Caution or Warning of Belt and Rotating Part Hazard. Indicates a risk of personal injury from entanglement in moving parts.

Caution or Warning of Chemical (ingestion or burn) Hazard. Indicates a risk of personal injury or asphyxiation from poisonous fumes or toxic gases.

Caution or Warning of High Voltage or Current Source Hazard. Indicates a risk of personal injury from electrical shock or electrocution.

Caution or Warning of Fan and Rotating Part Hazard. Indicates a risk of personal injury from entanglement in moving parts.

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2 Introduction

2.1 About this Manual

This is the Operator Manual for the generator set or sets listed on the front cover. Each operator should study this manual carefully and observe all of its instructions and safety precautions. Keep this manual readily available for reference.

The information contained within the manual is based on information available at the time of printing. In line with Cummins Power Generation policy of continuous development and improvement, information may change at any time without notice. The users should therefore make sure that before commencing any work, they have the latest information available. The latest version of this manual is available on QuickServe Online (https://qsol.cummins.com/info/index.html).

The Operation, Maintenance, and Troubleshooting Chapters of this manual provide instructions necessary for operating the generator set and maintaining it at top performance. The owner is responsible for performing maintenance in accordance with the information provided in Chapter

5 on page 33.

This manual also includes generator set specifications and information on how to obtain service, emissions regulation compliance, and model identification.

See the Parts Manual for part identification numbers and required quantities. Genuine Cummins Onan replacement parts are recommended for best results.

2.2 Related Literature

Before any attempt is made to operate the generator set, the operator should take time to read all of the manuals supplied with the generator set, and to familiarize themselves with the warnings and operating procedures.

A generator set must be operated and maintained properly if you are to expect safe and reliable operation. The Operator manual includes a maintenance schedule and a troubleshooting guide.

The Health and Safety manual must be read in conjunction with this manual for the safe operation of the generator set:

• Health and Safety Manual (0908-0110)

The relevant manuals appropriate to your generator set are also available, the documents below are in English:

• Operator Manual for RV Generator Set HGJBB (Spec A) (A031C171)

• Installation Manual for RV Generator Set HGJBB (Spec A) (A031C172)

• Generator Set Service Manual for RV Generator Set HGJBB (Spec A) (A031C173)

• Recommended Spares List (RSL) for RV Generator Set HGJBB (Spec A) (A043W890)

• Parts Manual for RV Generator Set HGJBB (Spec A) (A035B506)

CAUTION

• Standard Repair Times - CY Family (A031C174)

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2. Introduction 10-2014

• Service Tool Manual (A043D529)

• Failure Code Manual (F1115C)

• Warranty Manual (A040W374)

• Global Commercial Warranty Statement (A028U870)

2.3 Model Identification

Each generator set is provided with a nameplate that contains the model and serial numbers. This information is needed when contacting Cummins Onan for parts, service, and product information.

Every character of the model number is significant. The last character of the model number is the specification letter which is important for obtaining the correct parts.

Record the generator set model and serial numbers in the figure below to have them available if needed.

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10-2014 2. Introduction

2.3.1 Nameplate Location

FIGURE 1. NAMEPLATE LOCATION

2.4 How to Obtain Service

For generator set parts, service, and literature, contact the nearest authorized Cummins Onan distributor. You may go to the Internet site www.power.cummins.com for information on contacting our distributors worldwide.

2.4.1 In North America

Call +1 800 8886626 for the nearest Cummins Onan distributor in the United States or Canada. Press 1 (option 1) to be automatically connected.

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2. Introduction 10-2014

If you are unable to contact a distributor using the automated service, consult the Yellow Pages. Typically, our distributors are listed under: generators - electric.

2.4.2 Outside North America

If you are outside North America, refer to www.cumminspower.com and select Distributor Locator, or send an email to ask.powergen@cummins.com.

2.4.3 Information To Have Available

• model number

• serial number

• date of purchase

• nature of the problem (see Chapter 6 on page 49)

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3 Overview

3.1 Electromagnetic Compatibility Compliance

Generator sets emit and receive electromagnetic (radio frequency) energy. If the generator set affects operation of nearby devices, or nearby devices affect generator set operation, increase the distance between them.

When used in countries where compliance to the EMC directive is required: This generator set has been evaluated for use in the residential, commercial, and light industrial environments.

3.2 Information for Generator Set Users (Spark-Ignited Exhaust Emissions)

This generator set meets the requirements of exhaust emissions standards for 50-state operation as stated on the nameplate.

As a user of this generator set, please be aware that unauthorized modifications or replacement of fuel, exhaust, air intake, or speed control system components that affect engine emissions are prohibited. Unauthorized modification, removal, or replacement of the generator set label is prohibited.

Carefully review Operator (Owner), Installation, and other manuals and information you receive with the generator set. If unsure that the installation, use, maintenance, or service of the generator set is authorized, seek assistance from an approved Cummins Onan dealer.

Generator set users may use the following table as an aid in locating information related to the requirements for emissions control.

TABLE 1. EMISSIONS CONTROL INFORMATION

Generator Set Warranty Information located in the same packet of information as this manual when the

Engine Valve Lash See Section 3.4 on page 15.

Engine Ignition Timing See Section 3.4 on page 15.

Engine Fuel Requirements

Engine Lubricating Oil Requirements See Section 5.5 on page 35 for engine oil recommendations.

Engine Fuel Mixture Settings

Engine Adjustments None.

Engine Emission Control System and, in some cases, an exhaust aftertreatment system incorporating a

The EPA and California emissions control warranty statements are

generator set is shipped from the factory.

Gasoline Models: The engine is certified to operate on unleaded gasoline.

LPG Models:The engine is certified to operate on LPG. See Section 5.6 on page 38 for fuel recommendations.

The generator set engines have precision-manufactured carburetors which are not adjustable.

The engine emission control system consists of inherent engine design

three-way catalyst and pulse secondary air injection.

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3. Overview 10-2014

3.3 Build Standards

The generator set and its control system have been designed, constructed and tested generally in accordance with the following Standards where applicable.

Standard Title

BS EN 1037:1995+a1:2008 Safety of machinery - Prevention of unexpected start up.

BS EN ISO 14121-1:2007 Safety of machinery. Risk assessment principles.

BS EN ISO 13857:2008 Safety of machinery. Safety distances to prevent hazard zones being

BS EN 349:1993+A1:2008 Safety of machinery - Minimum gaps to avoid crushing parts on the human

BS EN 547-1:1996+A1:2008 Safety of machinery - Human body dimensions - Part 1: Principles for

BS EN 547-2:1996+A1:2008 Safety of machinery - Human body dimensions - Part 2: Principles for

BS EN 547-3:1996+A1:2008 Safety of machinery - Human body dimensions - Part 3: Anthropomorphic

BS EN 60204-1:2006+A1:2009 Safety of machinery. Electrical equipment of machines. General

BS EN 614-1:2006+A1:2009 Safety of machinery. Ergonomic design principles. Terminology and

BS EN 953:1997+A1:2009 Safety of machinery - Guards - General requirements for the design and

BS EN ISO 12100-1:2003+A1:2009 Safety of machinery. Basic concepts, general principles for design. Basic

BS EN ISO 12100-2:2003+A1:2009 Safety of machinery. Basic concepts, general principles for design.

BS EN ISO 13732-1:2008 Ergonomics of the thermal environment. Methods for the assessment of

BS EN ISO 13849-1:2008 Safety of machinery - Safety-related parts of control systems

BS EN ISO 13850:2006 Safety of machinery - Emergency stop. Principles for design.

BS EN 61310-1:2008 Safety of machinery - Indication, marking and actuation - Part

BS EN 61310-2:2008 Safety of machinery - Indication, marking and actuation - Part 2:

BS EN 61000-6-1:2007 Electromagnetic compatibility (EMC). Generic standards. Immunity

BS EN 61000-6-3:2007 Electromagnetic compatibility (EMC). Generic standards. Emission

BS EN 1299:1997+A1:2008 Mechanical vibration and shock - Vibration isolation of machines -

BS EN 1679-1:1998 Reciprocating internal combustion engines - Safety - Part 1: Compression

BS EN 12601:2001 Reciprocating internal combustion engine driven generating sets - Safety

reached by upper and lower limbs.

body.

determining the dimensions required for openings for whole body access into machinery.

determining the dimensions required for access openings.

data.

requirements.

general principles.

construction of fixed and movable guards.

terminology, methodology

Technical principles

human responses to contact with surfaces. Hot surfaces

1:Requirements for visual, auditory and tactile signals.

Requirements for marking.

standard for residential, commercial and light-industrial environments.

Information for the application of source isolation

ignition engines

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10-2014 3. Overview

3.4 Specifications

3.4.1 Gasoline Model Specifications

TABLE 2. GASOLINE MODEL SPECIFICATIONS

2.8 HGJBB 2.3 HGJBB 2.8 HGJBB

GENERATOR: 2-Pole Revolving Field, Self-Excited, 1-Phase, Electronically Regulated, Direct Drive

Power 2800 Watts 2300 Watts 2800 Watts

Frequency

Voltage 120 Volts 230 Volts 100 Volts

Current 23.3 Amps 10 Amps 28 Amps

Breaker 25 Amps 10 Amps 30 Amps

Speed 3600 RPM 3000 RPM 3600 RPM

FUEL CONSUMPTION:

No Load 0.78 l/h (0.2 gph) 0.69 l/h (0.18 gph) 0.78 l/h (0.2 gph)

Half Load 1.32 l/h (0.35 gph) 1.18 l/h (0.31 gph) 1.32 l/h (0.35 gph)

Fuel Load 1.75 l/h (0.46 gph) 1.56 l/h (0.41 gph) 1.75 l/h (0.46 gph)

ENGINE: 1-Cylinder, 4-Cyle, Spark Ignited, OHC, Air-Cooled

Bore 67 mm (2.64 in)

Stroke 60 mm (2.36 in)

Displacement 211 cm3(12.87 in3)

Compression Ratio 8.5 : 1

Oil Capacity 0.6 liters (0.63 qt)

Intake Valve Lash (Cold)

Exhaust Valve Lash (Cold)

Spark Plug Gap 0.6–0.7 mm (0.024-0.028 in)

Ignition Timing 23° BTDC, non-adjustable

Ignition Coil Gap 0.3–0.7 mm (0.012-0.020 in)

Compression 3.9 kgf/cm2(55.47 lbf/in2) @ 500 RPM

DC SYSTEM:

Battery Voltage 12 Volts

Minimum Battery Rating

INSTALLATION:

Minimum Free Air Inlet Area

Weight 57 kg (125 lbs)

Minimum Compartment Size (H x D x W)

60 Hz 50 Hz 60 Hz

0.12-0.15 mm (0.0047-0.0059 in)

360 CCA @ –18 °C (0 °F)

232 cm2(36 in2)

325 mm x 415 mm x 560 mm (12.8 in x 16.3 in x 22.0 in)

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3. Overview 10-2014

2.8 HGJBB 2.3 HGJBB 2.8 HGJBB

1. 60 Hz models are listed by CSA and the US Testing Company.

2. See the Installation Manual for additional considerations when sizing the generator set compartment.

3.4.2 LPG Model Specifications

TABLE 3. LPG MODEL SPECIFICATIONS

2.5 HGJBB 2.3 HGJBB

GENERATOR: 2-Pole Revolving Field, Self-Excited, 1-Phase, Electronically Regulated, Direct Drive

Power 2500 Watts 2300 Watts

Frequency

Voltage 120 Volts 230 Volts

Current 20.8 Amps 10 Amps

Breaker 21 Amps 10 Amps

Speed 3600 RPM 3000 RPM

FUEL CONSUMPTION:

No Load 0.53 kg/h (1.17 lbs/h) 0.49 kg/h (1.08 lbs/h)

Half Load 0.76 kg/h (1.66 lbs/h) 0.69 kg/h (1.53 lbs/h)

Full Load 1.02 kg/h (2.25 lbs/h) 0.94 kg/h (2.07 lbs/h)

ENGINE: 1-Cylinder, 4-Cycle, Spark Ignited, OHC, Air-Cooled

Bore 67 mm (2.64 in)

Stroke 60 mm (2.36 in)

Displacement 211 cm3(12.87 in3)

Compression Ratio 8.5 : 1

Oil Capacity 0.6 liters (0.63 qt)

Intake Valve Lash (Cold) 0.12-0.15 mm (0.0047-0.0059 in)

Exhaust Valve Lash (Cold) 0.12-0.15 mm (0.0047-0.0059 in)

Spark Plug Gap 0.6–0.7mm (0.024-0.028 in)

Ignition Timing 23° BTDC, non-adjustable

Ignition Coil Gap 0.3–0.7 mm (0.012-0.020 in)

Compression 3.9 kgf/cm2(55.47 lbf/in2) @ 500 RPM

DC SYSTEM:

Battery Voltage 12 Volts

Minimum Battery Rating 360 CCA @ –18 °C (0 °F)

INSTALLATION:

Minimum Free Air Inlet Area 232 cm2(36 in2)

LPG Vapor Supply Pressure 229–330 mm (9–13 in) WC

LPG Liquid Connection Pressure 1/4-18 NPTF Tank Pressure

Weight 57 kg (125 lbs)

60 Hz 50 Hz

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2.5 HGJBB 2.3 HGJBB

Minimum Compartment Size (H x D x W)

1. 60 Hz models are listed by CSA and the US Testing Company.

2. See the Installation Manual for additional considerations when sizing the generator set compartment.

325 mm x 415 mm x 560 mm (12.8 in x 16.3 in x 22.0 in)

3.5 List of Acronyms

TABLE 4. ACRONYM DEFINITIONS

Acronym Definition

AC Alternating Current

AGS Automatic Generator Start

AISI American Iron and Steel Institute

ANSI American National Standards Institute

API American Petroleum Institute

ASTM American Society for Testing and Materials (now known as ASTM International)

BS Build Standard

BTDC Before Top Dead Center

CARB California Air Resources Board

CCA Cold Cranking Amp

CO Carbon Monoxide

CPG Cummins Power Generation

CSA Canadian Standards Association

DC Direct Current

EEPROM Electronically Erasable Programmable Read Only Memory

EMC Electromagnetic Compatibility

EPA Environmental Protection Agency

GFCI Grounded Fault Circuit Interrupters

hp High Pressure

I.D. Inside Diameter

ISO International Organization for Standardization

LED Light-emitting Diode

LPG Liquid Petroleum Gas

NFPA National Fire Protection Agency

NPTF National Pipe Taper Fuel

O.D. Outside Diameter

PTO Power Take-Off

PPE Personal Protective Equipment

RAM Random Access Memory

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Acronym Definition

ROM Read Only Memory

RV Recreational Vehicle

RVIA RV Industry Association

SAE Society of Automotive Engineers

UNC Unified National Coarse

US, U.S. United States

WC Water Column

TABLE 5. ACRONYMS FOR UNITS OF MEASUREMENT

Acronym Definition

Amp Ampere

C Celsius

cm centimeter

D Depth

F Fahrenheit

ft Feet, foot

ft-lbs Foot-pounds

gph Gallons per hour

H Height

Hz Hertz

in Inch

kg kilogram

kg/h kilograms per hour

kgf/cm

kW kilowatt

l/h Liters per hour

lb Pound

lbf/in2OR psi Pound per square inch

lbs/h Pounds per hour

m Meter

mm millimeter

Nm Newton meter

psi OR lbf/in2Pound per square inch

qt Quart

RPM Revolutions per Minute

VAC Volts Alternating Current

VDC Volts Direct Current

kilogram-force per square centimeter

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Acronym Definition

W Watts, Width

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4 Operation

4.1 Key Component Locations

The control panel and the components requiring attention during periodic maintenance (see

Section 5.1 on page 33) are located behind a removable access cover. The figure below

illustrates the components of a typical generator set. There may be some variation depending on the generator set model.

• To remove the access cover:

1. Slide the cover latches up and pull the cover outward from the bottom.

2. Lower the cover to remove it from the housing.

• To replace the access cover:

1. Position the tabs on the top of the cover into the openings on the housing.

2. Slide the latches up and push the bottom of the cover in place.

3. Hold the cover in place firmly and release the latches.

WARNING

Operating the generator set with the access cover off can result in severe personal injury or equipment damage. Hot components are exposed when the access cover is removed and generator set cooling air does not circulate properly. Do not operate the generator set with the access cover removed.

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No. Description No. Description

1 Removable Access Cover 5 Air Filter Cover

2 Muffler (inside) 6 Oil Drain Plug

3 Spark Plug 7 Control Panel

4 Oil Fill Cap and Dipstick 8 Fuel Filter

FIGURE 2. KEY COMPONENT LOCATIONS

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4.2 Control Panel

4.2.1 Generator Set Control Panel

No. Name Description

1 Status Indicator LED in the control switch that blinks rapidly during cranking. Stays on

2 Control Switch Used to start and stop the generator set, and to prime the engine fuel system.

3 Line Circuit Breaker Protects the AC power leads connected to the generator set from overloads

FIGURE 3. GENERATOR SET CONTROL PANEL

continuously after generator set is running. If the generator set shuts down abnormally, the indicator blinks a numerical code to indicate the cause of the shutdown (see Chapter 6 on page 49).

Hold the switch in its START position to crank and start the generator set. Press the switch to the STOP position to stop the generator set. Hold the switch in its STOP/PRIME position to prime the fuel system (gasoline models only).

and equipment short circuits.

4.2.2 Remote Control Panel

A remote control panel may be installed inside the vehicle. Cummins Onan offers 3 remote control panel kits.

• Control switch with status indicator.

• Control switch with status indicator and an hour meter.

• Control switch with status indicator and a DC voltmeter.

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No. Name Description

1 Control Switch Used to start and stop the generator set, and to prime the engine fuel system.

2 Status Indicator LED in the control switch that blinks rapidly during preheat and cranking.

3 Hour Meter Records the total running time of the generator set. Cannot be reset.

4 DC Voltmeter Displays voltage of the generator set. If the voltage across the 12 VDC control

Hold the switch in its Start position to crank and start the generator set. Press the switch to the Stop position to stop the generator set. Hold the switch in its Stop position to prime the fuel system.

Stays on continuously after generator set is running. If the generator set shuts down abnormally, the indicator flashes a numerical code to indicate the cause of the shutdown (see Chapter 6 on page 49).

system consistently stays above or below 12 VDC, see Section 5.4 on page

34.

FIGURE 4. REMOTE CONTROL PANELS

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4.3 Starting and Stopping the Generator Set

4.3.1 Pre-start Checks

WARNING

EXHAUST GAS IS DEADLY!

Exhaust gases contain carbon monoxide, an odorless, colorless gas. Carbon monoxide is poisonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning include:

• Dizziness

• Muscular twitching

• Weakness and sleepiness

• Throbbing in temples

• Headache

• Inability to think clearly

• Nausea

• Vomiting

IF YOU OR ANYONE ELSE EXPERIENCES ANY OF THESE SYMPTOMS, GET OUT INTO THE 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 occupy the vehicle with the generator set running unless the vehicle is equipped with a working carbon monoxide detector. However, primary protection against inhaling carbon monoxide is proper installation of the exhaust system, and daily (every 8 hours) inspection for visible and audible exhaust system leaks.

Perform pre-start checks before the first start of the day and after every 8 hours of operation. See Chapter 5 if the vehicle has been in storage.

1. Make sure all vehicle CO detectors are working properly.

2. Remove access cover.

3. Inspect the generator set as instructed in Chapter 5.

4. Perform any maintenance due (Section 5.1 on page 33).

5. Keep a maintenance log (Chapter 7 on page 57).

6. Check for signs of fuel and exhaust leaks and for damage to the exhaust system.

7. Replace access cover.

8. Turn off the air conditioner and other large appliances.

4.3.2 Priming the Fuel System

The fuel system should be primed after the fuel filter is replaced or after the generator set runs out of fuel.

Position the control switch to STOP/PRIME for 30 seconds. The status indicator stays on while the pump is on.

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4.3.3 Starting the Generator Set

1. Visually inspect for fuel and exhaust leaks. Do not start the generator set until any fuel or exhaust leak is repaired.

2. Position and hold the control switch to START until the generator set starts. The status indicator on the switch flashes while cranking. It will stay on continuously when the generator set is running.

3. If the generator set fails to start, cranking will stop in approximately 30 seconds. The status indicator will blink, indicating an over crank fault. Wait 5 seconds for the control to reset before trying again. After 5 tries, let the starter motor cool down for 30 seconds before trying again. See Chapter 6 on page 49 if the generator set does not start after several tries.

CAUTION

The starter motor can be damaged by overheating. Allow it to cool down for 30 seconds after every fifth crank.

4. For top performance and engine life, especially in colder weather, let the engine warm up for 2 minutes before connecting appliances.

5. See Chapter 6 on page 49 if the generator set shuts down and the status indicator blinks, indicating a fault.

4.3.4 Stopping the Generator Set

1. Turn off the air conditioner and other large appliances.

2. Run generator set for 2 minutes to allow for cool down.

3. Press the control switch in its STOP position.

4.4 Loading the Generator Set

The power rating (kW) on the generator set nameplate determines how much electrical load (motors, fans, heaters, air conditioners, and other appliances) the generator set can power. If the sum of the loads exceeds the generator set power rating, the generator set will shut down or its line circuit breakers will trip.

NOTICE

It may be necessary to run fewer appliances at the same time—the sum of the loads must not be greater than the generator set power rating.

To avoid shutdowns due to generator set overload, use the electrical ratings on the nameplates of equipment (if available) to compare the sum of the electrical loads that are likely to be used at the same time to the generator set power rating. Refer to the table below for typical appliance ratings.

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Appliance load and generator set power are measured in terms of Watts (W) or kilowatts (kW), where 1 kilowatt (kW) = 1000 Watts (W).

• If the equipment is marked in Amps and Volts only, multiply the Amps times the Volts to obtain the load in Watts.

• Divide Watts by 1000 to obtain load in terms of kilowatts.

It is possible that the generator set circuit breaker may trip even though the sum of the steady state loads is less than the generator set power rating. When a large motor or air conditioner is started last or cycles off and on, the startup load is larger than its normal running load, causing the load to temporarily exceed the generator set power rating.

Typical "invisible" charging loads:

• During startup, air conditioners need "reserve" power and can draw 3–4 times the typical 1400–2400 Watts needed to run. Too much baseload can prevent air conditioners from starting.

• Battery chargers are activated automatically and can draw a large load (up to 3000 Watts). Manage electrical loads by adjusting battery charge rates to best suit your needs. Consult your inverter/charger manual or manufacturer.

TABLE 6. TYPICAL APPLIANCE LOADS

Appliance Average Required Wattage Amps

Air Compressor (1hp) 900-1800 7.5-15

Air Conditioner 1200-2400 10-20

Battery Charger

Blender 450-700 3.3-5.8

Broiler 1400-1700 11.6-14

Broom/Vacuum 1000-1440 8.3-12

CD/mp3 Player & Speakers 85 0.7

Coffeepot 900-1200 7.5-10

Computer 60-270 0.5-2.25

Laptop 20-50 0.16-0.41

Converter 500-1000 4-8

Curling Iron 20-50 0.16-0.41

Dishwasher 1200-2400 10-20

Drill 250-1000 2-8

Electric Blanket 60-100 0.5-0.8

Fan 10-175 0.08-1.45

Flat Iron 40-80 0.3-0.6

Frying Pan/Wok 1000-1350 8-11.25

Game Console 19-200 0.16-1.6

Hair Dryer 1200-1875 10-15.6

Iron 1000-1800 8-15

Light Bulbs 13-100 0.1-0.8

Up to 3000 6-28

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Appliance Average Required Wattage Amps

Microwave/Convection Oven 750-1100 6.25-9.2

Radio 50-200 0.4-1.6

Refrigerator 400-1000 3.3-8

Shaver 15-20 0.12-0.16

Space Heater 750-1500 6.25-12.5

Stove 900-2500 7.5-20.8

Television 43-600 0.35-5

Toaster 800-1400 6.6-11.6

VCR/DVD/Blu-ray Player 6-30 0.05-0.25

Washer/Dryer 350-500/1800-5000 3-4/15-42

Water Heater 1000-1500 8-12.5

Water Pump 250-1100 2-9.16

Battery chargers can be a source of significant load and will be on whether they are connected to shore power or

the generator set.

4.4.1 Power Versus Altitude

The generator set is rated at standard barometric pressure, humidity, and air temperature (reference ISO 3046). Low barometric pressure (high altitude) or high ambient temperature decreases engine power.

• As ambient temperature increases, rated generator set engine power decreases approximately 1% for every 5.5 °C (10 °F) above 25 °C (77 °F).

• Power decreases approximately 3.5% of rated power each 305 m (1000 ft) of increase in elevation. Refer to the table below for typical elevation/generator set power calculations.

NOTICE

It may be necessary to run fewer appliances at higher altitudes and ambient temperatures.

TABLE 7. POWER VERSUS ALTITUDE

Elevation Above Mean Sea

Level

Up to 152 m (500 ft) 2500 Watts (rated) 2800 Watts (rated)

762 m (2500 ft) 2325 Watts 2600 Watts

1676 m (5500 ft) 2060 Watts 2310 Watts

Above 1676 m (5500 ft)

1. - Does not take into account the effect circuit breakers may have in limiting maximum power.

Maximum Generator Set Power

2060 Watts minus 87.5 Watts each 305 2310 Watts minus 98 Watts each 305 m

m (1000 ft) (1000 ft)

Maximum Generator Set Power

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4.5 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. A single 2-hour exercise period is better than several shorter periods.

Exercising a generator set drives off moisture, relubricates the engine, replaces stale fuel in fuel lines, and removes oxides from electrical contacts and generator slip rings. The result is better starting, longer engine life, and greater reliability.

4.6 Resetting Line Circuit Breakers

If a generator set line circuit breaker or a circuit breaker in the power distribution panel trips, either a short circuit has occurred or too many loads were connected.

NOTICE

The generator set continues to run if its circuit breaker trips.

If a circuit breaker trips:

1. Disconnect or turn off as many electrical loads as possible.

2. Reset the circuit breaker.

3. If the circuit breaker trips right away, either the appliance (or electrical load) has a short or the circuit breaker is faulty. Call a qualified electrician.

NOTICE

It may be necessary to push the circuit breaker OFF to reset it and ON to reconnect the circuit.

4. If the circuit breaker does not trip right away, reconnect loads one-by-one making sure not to overload the generator set or cause a circuit breaker to trip. If a circuit breaker trips right away when an appliance is connected, that appliance or circuit probably has a short.

FIGURE 5. CIRCUIT BREAKER CONNECTIONS

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WARNING

Short circuits in electrical equipment can cause fire and electrical shock leading to severe personal injury or death. Electrical equipment and its grounding must be maintained properly to protect against short circuits.

Electrical equipment must be used and maintained properly, and be properly grounded, to cause the line circuit breakers to trip when short circuits occur.

Electrical appliances and tools must be used and maintained in accordance with their manufacturer's instructions and safety precautions. Proper grounding is needed to reduce the risk of electric shock and fire.

4.7 Connecting Shore Power

WARNING

Interconnecting the generator set and shore power can lead to electrocution of utility line workers, equipment damage, and fire. Use an approved switching device to prevent interconnections.

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.

4.8 Operating in Weather Extremes

Pay particular attention to the following items when operating the generator set in cold or hot weather.

1. Make sure nothing blocks airflow to and from the generator set.

2. Make sure engine oil viscosity is appropriate for the ambient temperature. See Section 5.5

on page 35 for engine oil recommendations.

3. Keep the generator set clean.

4. Perform maintenance due. See Section 5.1 on page 33.

4.9 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 filter element maintenance more often.

3. Change engine oil more often.

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4.10 Care of New or Rebuilt 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. Run the generator set at approximately 1/2 rated power for the first 2 hours and at 3/4 rated power for 2 more hours.

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 the oil is not appropriate for the ambient temperatures during break-in. See Section 5.5 on page 35 for engine oil recommendations.

Check oil level twice a day or every 4 hours during the first 20 hours of operation and change the oil after the first 20 hours of operation.

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5 Maintenance

Only authorized and competent personnel who are familiar with the equipment and its operation should carry out maintenance.

5.1 Periodic Maintenance

Periodic maintenance is essential for top performance and long generator set life. Use the Periodic Maintenance Schedule below for normal periodic maintenance. In hot and dusty environments some maintenance procedures should be performed more frequently, as indicated by the footnotes in the schedule. Keeping a log of maintenance performed and hours run will help keep generator set maintenance regular and provide a basis for supporting warranty claims (see Chapter 7 on page 57).

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 Service Representative.

WARNING

5.1.1 Periodic Maintenance Schedule

TABLE 8. PERIODIC MAINTENANCE SCHEDULE

MAINTENANCE FREQUENCY

MAINTENANCE PROCEDURE

General Inspection X

Check Engine Oil Level X

Clean and Check Battery X

Clean Spark Arrester X

Change Engine Oil X

Replace Air Filter Element X

Clean Engine Cooling Fins X

Replace Spark Plug(s) X

Replace Fuel Filter X

Adjust Valve Lash X

Every Day or Every 8

Hours

After First Every Every 150 Every 450 Every 500

20 Hours Month Hours Hours Hours

2, 3, 4

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MAINTENANCE FREQUENCY

MAINTENANCE PROCEDURE

1 - As a part of engine break-in, change the engine oil after the first 20 hours of operation. 2 - Perform more often when operating in dusty environments. 3 - Perform more often when operating in hot weather. 4 - Perform at least once a year. 5 - Perform sooner if engine performance deteriorates. 6 - Must be performed by a qualified mechanic (authorized Cummins Onan Service Representative). 7 - Must be completed for optimum performance.

Every Day or Every 8

Hours

After First Every Every 150 Every 450 Every 500

20 Hours Month Hours Hours Hours

5.2 Consumable Parts

The following is a list of consumables associated with the generator models covered in this manual:

TABLE 9. CONSUMABLE PARTS

Part Number Description Quantity

0167-1652 Spark Plug 1

0149-2661 Fuel Filter 1

A030Y328 Air Filter 1

A043H188 Brush Block 1

5.3 General Inspection

1. Check battery connections (Section 5.4 on page 34).

2. Check engine oil level (Section 5.5 on page 35).

3. Check fuel system (Section 5.6 on page 38).

4. Check exhaust system (Section 5.7 on page 41).

5. Check mechanical system (Section 5.8 on page 41).

5.4 Maintaining the Battery

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.

Flames, sparks, or arcing at battery terminals, light switches, or other equipment can ignite battery gas, causing severe personal injury. Ventilate the battery area before working on or near a battery, wear safety glasses, and do not smoke. Turn work light on or off away from the battery. When performing maintenance procedures or when servicing a battery, stop the generator set and disconnect the charger before disconnecting battery cables. Using an insulated wrench, disconnect the negative (–) cable first and reconnect it last.

WARNING

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Refer to Section 5.1 on page 33 for the battery maintenance schedule and follow the battery manufacturer's instructions. Have the battery charging system serviced if DC system voltage is consistently low or high.

Check the battery terminals for clean, tight connections. Loose or corroded connections have high electrical resistance which makes starting harder.

1. Keep the battery case and terminals clean and dry.

2. Keep the battery terminals tight.

3. Remove battery cables with a battery terminal puller.

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.

5.5 Maintaining the Lubrication System

Keep dirt, water, and other contaminants from entering the lubrication system and corroding or clogging lubrication components.

5.5.1 Oil Level

Park the vehicle on level ground and stop the generator set before checking engine oil level.

WARNING

Engine components (drains, filters, hoses, etc.) can be hot and cause severe burns, lacerations of the skin, and liquid splash. Use personal protective equipment when working with or around hazardous materials. Examples of personal protective equipment include (but are not limited to) safety glasses, protective gloves, hard hats, steel toed boots, and protective clothing.

WARNING

Crankcase pressure can blow hot engine oil out the fill opening causing, severe burns. Always stop the generator set before removing the oil fill cap.

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.

CAUTION

Too little oil can cause severe engine damage. Too much oil can cause high oil consumption. Keep the oil level between the high and low beads (or markings) on the dipstick.

1. Unscrew the oil fill cap/dipstick.

2. Wipe off the dipstick and thread back into the fill neck.

3. Remove the dipstick to check oil level.

4. Add or drain oil as necessary. Keep the oil level between the full and add marks.

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5. Insert the dipstick and screw the oil fill cap back on securely.

FIGURE 6. OIL FILL CAP AND DIPSTICK

5.5.2 Engine Oil Recommendations

• Use API (American Petroleum Institute) performance Class SJ, SH or SG engine oil, which may be in combination with performance Class CH-4, CG-4 or CF-4 (for example: SJ/CH-

4).

• Look for the SAE (Society of Automotive Engineers) viscosity grade. Choose the viscosity grade appropriate for the ambient temperatures expected until the next scheduled oil change.

• Single-grade SAE 30 oil is preferable when temperatures are consistently above freezing. Multigrade oils are better when wide temperature variations are expected.

TABLE 10. OIL VISCOSITY VS. TEMPERATURE

EXPECTED AMBIENT TEMPERATURES SAE VISCOSITY GRADE

0 °C (32 °F) and higher 30 (OnaMax)

–12 to 38 °C (10 to 100 °F) 15W-40 (OnaMax)

–18 to 27 °C (0 to 80 ° F) 10W-30 10W-40

–28 to 10 °C (–20 to 50 °F) 5W-30

5.5.3 Changing Engine Oil and Oil Filter

WARNING

Accidental or remote starting can cause severe personal injury or death. Before removing a panel or access door, or before working on the generator set, use an insulated wrench to disconnect the negative (-) cable from the battery to prevent accidental starting.

WARNING

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WARNING

Refer to Section 5.1 on page 33 for the engine oil change schedule. Change oil more often in hot or dusty environments.

1. Run the generator set under load until it is up to operating temperature, stop it, and disconnect the negative (–) battery cable at the battery.

WARNING

Crankcase pressure can blow hot engine oil out the fill opening causing, severe burns. Always stop the generator set before removing the oil fill cap.

2. Remove the oil fill cap.

3. Place a pan underneath the oil drain plug and remove the plug (see Oil Change Values and Drain Plug Location below). Let all oil drain from the engine.

4. Replace the plug.

5. Spin off the oil filter and thoroughly wipe off the filter mounting surface. Remove the gasket if it does not come off with the filter.

6. Apply a film of oil to the new filter gasket and spin the new filter on by hand until the gasket just touches the mounting pad. Tighten 1/2 to 3/4 of a turn.

CAUTION

Too little oil can cause severe engine damage. Too much oil can cause high oil consumption. Keep the oil level between the high and low beads (or markings) on the dipstick.

7. Refill with oil (see Oil Change Values below). Check the oil level and add or drain oil as necessary.

8. Screw the oil fill cap on securely.

9. Reconnect the negative battery cable.

10. Run the generator for a few minutes, shut it down, and recheck for proper oil level and leaks.

11. Dispose of the used oil and oil filter in accordance with local environmental regulations.

5.5.3.1 Oil Change Values and Drain Plug Location

TABLE 11. OIL CHANGE VALUES

Drain Plug Bolt Plug Torque Oil Amount

9/16 inch 6.78–13.56 Nm (5–10 ft-lbs) 0.6 liters (0.63 qt)

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FIGURE 7. OIL DRAIN PLUG(S)

5.6 Maintaining the Fuel System

Keep dirt, water, and other contaminants from entering the fuel system and corroding or clogging fuel system components.

5.6.1 Fuel System

WARNING

Fuel leaks can lead to fire. Repair leaks immediately. Do not run the generator set if it causes fuel to leak.

1. Check for leaks at the hose, tube, and pipe fittings in the fuel supply system while the generator set is running and while it is stopped.

2. Check flexible fuel hoses sections for cuts, cracks, abrasions, and loose hose clamps.

3. Make sure the fuel line does not rub against other parts of the vehicle or generator set.

4. Replace worn or damaged fuel line parts before leaks occur.

5. If an LPG generator set and gas odor is detected, close the LPG container shutoff valve and have the generator set serviced.

5.6.2 Fuel Recommendations

WARNING

Gasoline and LPG are highly flammable and explosive and can cause severe personal injury or death. Do not smoke or turn electical switches ON or OFF where fuel fumes, tanks, or equipment are present; or in areas sharing ventilation. Keep flames, sparks, pilot lights, arc-producing equipment and switches, and all other sources of ignition well away. Keep a type ABC fire extinguisher in the vehicle.

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5.6.2.1 Gasoline Models

Use clean, fresh unleaded gasoline having a minimum octane rating (Anti-Knock Index) of 87.

• Ethanol Blend - Not more than 10% ethanol

• Methanol Blend - Not more than 5% methanol and the fuel must also contain solvents and corrosion inhibitors.

CAUTION

Using gasoline containing more than 5% methanol, or gasoline additives containing methanol, can be corrosive to fuel system components.

NOTICE

Avoid using leaded gasoline because of the extra engine maintenance required.

5.6.2.2 LPG Models

Use clean, fresh HD-5 grade liquified petroleum gas (LPG) or equivalent product consisting of at least 90 percent propane. Commercial LPG fuels may contain more than 2.5 percent butane which can result in poor fuel vaporization and poor engine starting in low ambient temperatures (below 0oC (32oF)).

Satisfactory performance on low-pressure LPG models requires that the LPG vapor be supplied at a pressure within the range indicated in the specifications chapter.

High LPG supply pressure can cause gas leaks which can lead to fire and severe personal injury or death. LPG supply pressure must be adjusted to Specifications by trained and experienced personnel.

5.6.3 Replacing the Fuel Filter

WARNING

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WARNING

Gasoline is highly flammable and explosive and can cause severe personal injury or death. Do not smoke or turn electical switches ON or OFF where fuel fumes, tanks, or equipment are present; or in areas sharing ventilation. Keep flames, sparks, pilot lights, arc-producing equipment and switches, and all other sources of ignition well away. Keep a type ABC fire extinguisher in the vehicle.

Refer to Section 5.1 on page 33 for scheduled fuel filter replacement. Replace the fuel filter if the engine lacks power.

1. Disconnect the negative (–) cable at the battery to prevent the engine from starting.

2. Remove the front access door.

3. Let engine cool down to prevent igniting any fuel that may be spilled when disconnecting the fuel filter.

4. Loosen the fuel line hose clamps and remove the fuel filter. Plug the fuel lines to prevent fuel leakage and vapor accumulation.

5. Connect the new fuel filter to the fuel line.

6. Prime the engine for at least 30 seconds to fill the new fuel filter. Check for leaks as the generator set runs for several minutes.

7. Tighten the clamps, if necessary.

8. Replace the front access door.

9. Connect the negative (–) cable at the battery.

10. Dispose of the old filter in accordance with local environmental regulations.

No. Description No. Description

1 Fuel Filter 2 Clamps

FIGURE 8. FUEL FILTER

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5.7 Exhaust System

WARNING

EXHAUST GAS IS DEADLY! Do not operate the generator set if there is an exhaust leak or any danger of exhaust gasses entering or being drawn into the vehicle.

WARNING

Grass or brush in contact with the exhaust system can cause fire. Do not park the vehicle in high grass or brush.

1. 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.

2. 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 and sealed to prevent exhaust gases from entering the vehicle.

3. Replace dented, bent, or severely rusted sections of the tailpipe and make sure the tailpipe extends at least 25.4 mm (1 in) beyond the perimeter of the vehicle.

4. Park the vehicle so that generator set exhaust gases disperse away from the vehicle. Barriers such as walls, snow banks, high grass, brush, and other vehicles can cause exhaust gases to accumulate in and around the vehicle.

5. 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.

6. Check all CO monitors to assure proper operation.

5.8 Mechanical System

Compressed air, pressure washers, and steam cleaners can cause severe eye injury. Always wear safety glasses when using.

1. Look for mechanical damage and listen for unusual noises and vibrations.

2. Check the generator set mounting bolts.

3. Check to see that the generator set air inlet and outlet openings are not clogged with debris or blocked.

4. Clean accumulated dust and dirt from the generator set. Do not clean the generator set while it is running or still hot. Protect the generator, air cleaner, control panel, and electrical connections from water, soap, and cleaning solvents.

WARNING

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5.9 Replacing the Air Filter Element

WARNING

Refer to Section 5.1 on page 33 for scheduled air filter element replacement. Under dusty operating conditions, inspect and replace more often.

1. Remove the front access cover.

2. Unlatch the air filter cover from the base and slide out the cover and filter together.

3. Remove air filter element from the cover.

4. Install new air filter element into the cover and slide back into position, making sure the two tabs at the rear of the cover are inserted into slots in the base.

5. Engage the latch.

6. Replace the front access cover.

No. Description No. Description

1 Air Filter Cover 2 Air Filter Element

FIGURE 9. AIR FILTER ELEMENT

5.10 Replacing the Spark Plug(s)

Refer to Section 5.1 on page 33 for scheduled spark plug replacement. The spark plug(s) must be in good condition for proper engine starting and performance. A spark plug that fouls frequently or has heavy soot deposits indicates that the engine needs service. Refer to Chapter

6 on page 49.

1. Remove the front access cover.

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2. Unscrew the spark plug and remove.

3. Thread the spark plug in by hand until it seats. Tighten to 17 Nm (13 ft-lbs).

NOTICE

Always thread the spark plug in by hand until it seats to prevent cross-threading.

NOTICE

If a torque wrench is not available, turn the spark plug an additional 1/4 turn if being reused, or 3/8 to 1/2 turn for a new spark plug.

4. Replace the front access cover.

FIGURE 10. SPARK PLUG(S)

5.11 Cleaning the Spark Arrester

WARNING

A hot muffler can cause severe burns. Let the muffler cool down before removing or installing spark arrester cleanout plugs or screens.

Refer to Section 5.1 on page 33 for scheduled spark arrester muffler cleaning (meets U.S. Forest Service requirements). Cleaning is required for maximum generator set performance.

The spark arrester screen is mounted inside the muffler outlet.

1. Loosen the U-bolt clamp that secures the tailpipe to the muffler (inside the generator set housing) and move the tailpipe aside.

2. Remove the screw that secures the spark arrester tube/screen inside the muffler outlet.

3. Remove the spark arrester tube and inspect the screen inside for damage and clogging. Replace if damaged.

4. Lightly tap the spark arrester and remove any remaining deposits with a wire brush. Use a commercial solvent to loosen hard deposits. (Carefully follow the solvent manufacturer's instructions and safety precautions.)

5. Reinstall the spark arrester and tailpipe.

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FIGURE 11. SPARK ARRESTER

5.12 Storing the Generator Set

Proper storage is essential for preserving top generator set performance and reliability. If the generator set is not going to be exercised on a regular basis and not be used for more than 120 days, the generator set should be prepared for storage.

1. If the generator set is a gasoline model, perform the following steps.

Gasoline preservatives (stabilizers) are toxic. Follow the instructions on the container. Avoid skin contact. Wash hands with soap and water after using.

a. Fill the fuel tank with fresh fuel and add a fuel preservative (such as OnaFresh),

following the instructions on the container label.

If a preservative (stabilizer) is not added to the gasoline, the gasoline in the fuel system deteriorates causing fuel system corrosion, gum formation, and varnish-like deposits which can lead to hard starting and rough operation.

WARNING

NOTICE

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b. Run the generator set for about 30 minutes plus 2 minutes per foot of fuel line at

approximately 1/2 rated power to fill the fuel lines with fresh fuel and preservative.

2. Change the engine oil and attach a tag indicating the oil grade viscosity.

3. Remove the air filter and restart the generator set. While the generator set is running, spray an engine fogger (such as OnaGard) into the carburetor, following the instructions on the container label.

NOTICE

The engine fogger leaves a protective coat of oil on the internal surfaces of the engine.

4. Stop the generator set.

5. Disconnect all appliances.

6. Disconnect the battery cables, negative (–) cable first, from the starting battery and store the battery according to the battery manufacturer's recommendations.

7. Cap the exhaust tail pipe to keep out dirt, moisture, rodents, and other foreign materials.

8. Close the fuel supply valve (if so equipped).

9. Position the line circuit breaker to OFF.

WARNING

LPG leaks can lead to explosive accumulation in pits, sumps, or other below-grade locations. Comply will all local ordinances regarding the garaging of vehicles with LPG engine fuel systems.

10. If the generator set is an LPG model, check the local ordinances if the vehicle is going to be garaged. Generally, ordinances require that the LPG system be leak-free, that the LPG container not be filled beyond specified limits, that the container shutoff valve be closed, and that the vehicle not be parked near sources of heat or ignition.

WARNING

Do not open the carburetor drain when the engine is hot. Close the drain immediately after draining. Failure to heed this warning can lead to fire resulting in severe personal injury or death.

11. If the generator set is a gasoline model, perform the following steps to drain the carburetor float bowl.

NOTICE

Draining the float bowl prevents deposits of gum from clogging the tiny passages in the carburetor because the gasoline in the bowl evaporates during storage.

a. Let the engine cool down thoroughly.

b. Place paper towels under the drain to absorb all of the drainage (less than 1/2 cup).

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WARNING

Opening the carburetor drain when the engine is hot can lead to fire resulting in severe personal injury or death. Do not open the drain when the engine is hot. Close the drain immediately after draining.

c. Open the drain valve by turning counter-clockwise with a screwdriver.

d. When draining is done, close the drain valve, turning clockwise with a screwdriver

until just snug.

5.12.1 Carburetor Float Bowl Drain Valve

FIGURE 12. CARBURETOR FLOAT BOWL DRAIN VALVE

5.13 Returning the Generator Set to Service

1. Verify that the oil viscosity is appropriate for expected temperatures (see Maintaining the

Lubrication System ) and change the oil if the viscosity is not appropriate for the

temperatures expected.

2. Reconnect the starting battery (negative [–] cable last).

3. Inspect the air filter element. Use a new air filter element if it is dirty.

4. Inspect the generator set.

5. If the generator set is a gasoline or diesel model, prime the generator set fuel system by positioning the control switch to STOP/PRIME for 30 seconds. The status indicator stays on while the pump is on.

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6. Start the generator set. There may be smoke and rough operation for a few minutes until the oil from the fogger burns off. If the engine does not start, clean or replace the spark plug, which may have been fouled by the fogger.

7. Position the line circuit breaker to ON when the generator set is ready to power loads.

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6 Troubleshooting

6.1 Overview

Hot engine parts can cause severe burns. Always allow the engine to cool down before performing any maintenance or service.

The following paragraphs provide fault code faults and symptom-based faults. If a problem is not resolved after taking the corrective actions suggested, contact a local dealer or distributor. See Section 2.4 on page 11.

Maintaining engine oil level, keeping battery connections clean and tight, watching the fuel gauge, not overloading the generator set, etc. will prevent most shutdowns.

When the generator set and vehicle engine share a common fuel tank, the fuel dip tubes are usually arranged so that the generator set will run out of fuel first. Marking the generator set empty point on the fuel gauge will make it easier to tell when to stop the generator set before running it out of fuel.

WARNING

NOTICE

6.2 Fault Codes

The generator set control contains extensive diagnostics to detect shutdown faults. Following a fault shutdown, the control indicates the fault code by flashing the numeric code on the status indicator in the control switch.

Determine the fault code as follows:

• 3 flashes indicates a service fault (Code 3 fault).

1. Press STOP/PRIME on the control switch once to have the 2-digit service fault code flash.

The 2-digit code consists of two sets of flashes. The first set is of flashes represents the 10s digit of the code. After a brief pause, the second digit of the code flashes representing the unit digit of the code. This is followed by a long pause before repeating the flashing of the fault code.

For example, Fault Code 36 appears as: blink-blink-blink—pause—blink-blink-blinkblink-blink-blink—long pause—repeat

2. Press STOP/PRIME to stop flashing the fault code.

• 4 flashes indicates that cranking exceeded 30 seconds without the engine starting (Code 4 fault).

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NOTICE

Fault codes 33 and 34 are not assigned as fault codes. Be careful of interpreting Fault Codes 3 and 4 as second-level faults.

The fault code stops flashing after 5 minutes. Pressing STOP/PRIME 3 times within 5 seconds causes the fault code to resume flashing.

NOTICE

The last fault logged continues to flash even though the condition that caused the shutdown has been corrected.

6.2.1 Code 2 - Low Oil Pressure

Indicates that the low oil pressure cutoff switch did not open.

A. Check Engine Oil Level

1. If the dipstick indicates oil is low, add oil.

2. If oil is above the full mark on dipstick, drain excess oil.

6.2.2 Code 3 - Service Check

See second-level fault code.

6.2.3 Code 4 - Over Crank

Indicates that cranking exceeded 30 seconds without engine starting.

A. Check Fuel Level

1. If fuel level is low, fill the fuel tank.

The generator set fuel pickup tube could be higher up in the fuel tank than the vehicle engine pickup.

2. Prime the engine fuel system by positioning the control switch to STOP/PRIME for 30 seconds.

B. Check LPG Level

Check and fill the LPG container, as necessary.

NOTICE

On cold days, the LPG container may have to be kept at least half full to provide the rate of vaporization necessary to keep up with the generator set fuel demand.

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C. Check Spark Plug(s)

1. Secure the spark plug lead(s) on the spark plug(s).

2. Replace the spark plug(s).

D. Check Air Filter Element

Replace the air filter if dirty.

E. Replace Engine Oil

Replace engine oil with oil of proper viscosity for the ambient temperature.

NOTICE

High oil viscosity can slow down cranking speed.

F. Check Fuel Fittings

1. Tighten any fuel fitting if there is a fuel or air leak.

2. Reprime the engine fuel system by positioning the control switch to STOP/PRIME for 30 seconds.

G. Replace Fuel Filter

6.2.4 Code 12 - Over Voltage

Indicates the control is unable to maintain rated voltage.

A. Contact Local Dealer or Distributor

6.2.5 Code 13 - Under Voltage

Indicates the control is unable to maintain rated voltage.

A. Reduce Load

Reduce the number of connected appliances, especially air conditioners and battery chargers. (Review load management in Loading the Generator Set.)

6.2.6 Code 14 - Over Frequency

Indicates the engine governor is unable to maintain rated frequency.

A. Contact Local Dealer or Distributor

6.2.7 Code 15 - Under Frequency

Indicates the engine governor is unable to maintain rated frequency.

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A. Reduce Load

Reduce the number of connected appliances, especially air conditioners and battery chargers. (Review load management in Loading the Generator Set.)

6.2.8 Code 27 - Voltage Sense

Indicates the control is unable to sense output voltage.

A. Contact Local Dealer or Distributor

6.2.9 Code 29 - High Battery Voltage

Indicates that voltage across the battery system is greater than 19 Volts.

A. Check Battery

1. Check battery bank connections and reconnect if necessary so that the 12 Volt batteries serving the generator set are connected in parallel (12 Volt) rather than in series (24 Volt).

2. Select a lower battery boost charge rate.

6.2.10 Code 31 - Over Speed

Indicates that engine speed is greater than 3400 RPM.

A. Contact Local Dealer or Distributor

6.2.11 Code 32 - Low Cranking Speed

Indicates that cranking speed is less than 180 RPM for more than 2 seconds.

A. Check Battery

1. Clean and tighten the positive (+) and negative (–) battery cable connections at the battery and at the generator set.

2. Recharge or replace the battery. Refer to the battery manufacturer's recommendations.

B. Replace Engine Oil

Replace engine oil with oil of proper viscosity for the ambient temperature.

NOTICE

High oil viscosity can slow down cranking speed.

6.2.12 Code 35 - Control Card Failure

Indicates that a microprocessor EEPROM error occurred during self test.

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A. Contact Local Dealer or Distributor

6.2.13 Code 36 - Engine Stopped

Indicates that the engine stopped without receiving a command from the control.

A. Check Fuel Level

1. If fuel level is low, fill the fuel tank.

NOTICE

The generator set fuel pickup tube could be higher up in the fuel tank than the vehicle engine pickup.

2. Prime the engine fuel system by positioning the control switch to STOP/PRIME for 30 seconds.

B. Check LPG Level

Check and fill the LPG container, as necessary.

NOTICE

On cold days, the LPG container may have to be kept at least half full to provide the rate of vaporization necessary to keep up with the generator set fuel demand.

C. Check Spark Plug(s)

1. Secure the spark plug lead(s) on the spark plug(s).

2. Replace the spark plug(s).

D. Check Air Filter Element

Replace the air filter if dirty.

E. Check for Mechanical Damage

6.2.14 Code 37 - Invalid Generator Set Configuration

Indicates that the frequency/RPM ratio is wrong.

A. Contact Local Dealer or Distributor

6.2.15 Code 38 - Over Current (Field Overload)

Indicates low power factor loads.

A. Reduce Load

Reduce the number of connected appliances, especially air conditioners and battery chargers. (Review load management in Loading the Generator Set.)

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B. Check Appliances for Proper Operation

Have air conditioners and other appliances checked for proper operation.

6.2.16 Code 41 - Generator Rotor

Indicates control is unable to sense field or output voltage.

A. Contact Local Dealer or Distributor

6.2.17 Code 42 - Processor

Indicates that a microprocessor ROM error occurred during self test.

A. Contact Local Dealer or Distributor

6.2.18 Code 43 - Processor

Indicates that a microprocessor RAM error occurred during self test.

A. Contact Local Dealer or Distributor

6.2.19 Code 45 - Speed Sense

Indicates the control is unable to sense quadrature frequency.

A. Contact Local Dealer or Distributor

6.2.20 Code 47 - Ignition

Indicates the control is unable to sense ignition.

A. Contact Local Dealer or Distributor

6.2.21 Code 48 - Generator Field Sense

Indicates the control is unable to sense field voltage.

A. Contact Local Dealer or Distributor

6.3 Symptom Based

Diagnosis of some problems involves observing system operation.

6.3.1 Status Indicator Not Working

Indicates that there could be faulty connections or no battery voltage.

A. Check Other Control Switch

Try the generator set control switch if the remote control switch start doesn't work, and vice versa.

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B. Check Battery

1. Clean and tighten the positive (+) and negative (–) battery cable connections at the battery and at the generator set.

2. Recharge or replace the battery. Refer to the battery manufacturer's recommendations.

6.3.2 Starting Batteries Run Down

Indicates problem with batteries, connections, charging system, or parasitic loads.

A. Check Battery

1. Clean and tighten the positive (+) and negative (–) battery cable connections at the battery and at the generator set.

2. Recharge or replace the battery. Refer to the battery manufacturer's recommendations.

B. Battery Charging System

Install or service a battery charging system in the vehicle.

6.3.3 Starter Engages-Disengages

Indicates cranking voltage dips below 6 Volts.

A. Use Vehicle to Start Generator Set

Run the vehicle propulsion engine while trying to start the generator set—the battery charging alternator may be able to maintain starting voltage high enough to start the generator set.

B. Check Battery

1. Clean and tighten the positive (+) and negative (–) battery cable connections at the battery and at the generator set.

2. Recharge or replace the battery. Refer to the battery manufacturer's recommendations.

C. Change Battery Cables

Increase battery cable size or run parallel cables.

6.3.4 Status Indicator Goes Out While Cranking—No Start

Indicates an internal short circuit caused an automatic-reset circuit protective device to trip.

A. Try Starting Again

If the status indicator flashes and goes out again without the engine starting, call local dealer or distributor.

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6.3.5 No Power—Generator Set Running, Status Light On

Indicates line circuit breaker is OFF, or tripped due to short circuit or overload.

A. Check Line Circuit Breakers

1. Turn on or reset the line circuit breaker on the generator set.

2. Turn on or reset the line circuit breaker on the main distribution panel in the vehicle.

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7 Maintenance Record

TABLE 12. MAINTENANCE RECORD

Record all periodic and unscheduled maintenance/service. See Periodic Maintenance section.

DATE METER MAINTENANCE OR SERVICE PERFORMED

HOUR

READING

Record the name, address, and phone number of your authorized Cummins Onan service center.

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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 Copyright © 2014 Cummins Power Generation, Inc. All rights reserved. Cummins, Onan, the "C" logo, and "Performance you rely on." are

trademarks of Cummins Inc.