CUMMINS QD 3200 HDZAA User manual

Brand: CUMMINS

Model: QD 3200 HDZAA

Category: Power generators

Type: User manual

Operator Manual

Onan Generator Set for RV

HDZAA (Spec A−E)

English

Original Instructions 12-2018 0983−0103 (Issue 15)

Warning: Natural Gas/Liquid Propane Gas engine exhaust and

some of its constituents are known to the State of California to

cause cancer, birth defects, and other reproductive harm.

Proposition 65 Warning

California

Table of Contents

SECTION PAGE

Table of Contents i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY PRECAUTIONS iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. INTRODUCTION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this Manual 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nameplate 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Obtain Service 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Emissions Compliance 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Typical Generator Set 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. OPERATION 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Fuel 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Engine Oil 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Batteries 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stop Switch 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Operator Panel 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre-Start Checks 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loading the Generator Set 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resetting Circuit Breakers 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting to Utility Power 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating in Cold Weather 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating in Hot Weather 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating at High Altitude 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating in Dusty Environments 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Breaking In a New Engine 2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exercising the Generator Set 2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storing the Generator Set 2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. PERIODIC MAINTENANCE 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Inspection 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents

SECTION PAGE

Maintaining the Battery and Battery Connections 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Engine Oil Level 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Engine Oil 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Engine Oil Strainer 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Air Filter Element 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Spark Arrester 3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Fuel Filter 3-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. TROUBLESHOOTING 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Status Messages 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Messages 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning Messages 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Messages 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Symptom Diagnostics 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. SPECIFICATIONS 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load on engine 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Consumption 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. MAINTENANCE RECORD 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii

SAFETY PRECAUTIONS

Thoroughly read the OPERATOR’S MANUAL

before operating the generator set. Safe op-

eration and top performance can only be ob-

tained when equipment is properly operated

and maintained.

The following symbols in this manual alert you to

potential hazards to the operator, service person

and equipment.

DANGER

alerts you to an immediate hazard

that will result in severe personal injury or

death.

WARNING

alerts you to a hazard or unsafe

practice that can result in severe personal in-

jury or death.

CAUTION

alerts you to a hazard or unsafe

practice that can result in personal injury or

equipment damage.

When equipped with an integral or add−on Auto-

matic Generator Starting System (AGS) control,

exhaust carbon monoxide (CO), electric shock,

and moving parts hazards are possible due to un-

expected starting. Turn off AGS whenever per-

forming maintenance or service, when the vehicle

is stored between uses, is awaiting service, or is

parked in a garage or other confined area.

ENGINE EXHAUST IS DEADLY

 Inspect for exhaust leaks at every startup and

after every eight hours of running.

 Learn the symptoms of carbon monoxide poi-

soning in the generator set Operator’s Manu-

al.

 Never sleep in the vehicle while the generator

set is running unless the vehicle is equipped

with a working carbon monoxide detector.

 Do not operate the generator set when the

vehicle is parked in a confined space, such as

a garage.

 The exhaust system must be installed in ac-

cordance with the generator set Installation

Manual.

 Engine cooling air must not be used for heat-

ing the vehicle.

AUTOMATIC GENERATOR START

CONTROL HAZARDS

WARNING

Accidental starting can cause se-

vere personal injury or death. Turn off AGS

whenever performing maintenance or service,

when the vehicle is sotred 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 to:

 Unexpected generator starting

 Moving parts hazards

 Electric shock

 Exhaust carbon monoxide (CO)

GENERATOR VOLTAGE IS DEADLY

 Disable the automatic generator set feature

(AGS) of an inverter−charger or other auto-

matic starting device before servicing the

generator set to avoid electric shock from an

unexpected start.

 Generator electrical output connections must

be made by a trained and experienced elec-

trician in accordance with applicable codes.

 The generator set must not be connected to

shore power (utility). Back-feed to shore pow-

er can cause electrocution and damage to

equipment. An approved switching device

must be used to prevent interconnections.

 Use caution when working on live electrical

equipment. Remove jewelry, make sure

clothing and shoes are dry, stand on a dry

wooden platform or rubber insulating mat and

use tools with insulated handles.

DIESEL FUEL IS COMBUSTIBLE

 Do not smoke or turn electrical switches ON

or OFF where fuel fumes are present or in

areas sharing ventilation with fuel tanks or

equipment. Keep flames, sparks, pilot lights,

arc-producing equipment and all other

sources of ignition well away.

 Fuel lines must be secured, free of leaks and

separated or shielded from electrical wiring.

MOVING PARTS CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH

 Disable the automatic generator set starting

feature (AGS) of an inverter−charger or other

automatic starting device before servicing the

generator set to avoid unexpected starting.

 Do not wear loose clothing or jewelry near

moving parts such as fans and other moving

parts.

 Keep hands away from moving parts.

 Keep guards in place over fans and other

moving parts.

BATTERY GAS IS EXPLOSIVE

 Wear safety glasses.

 Do not smoke.

 To reduce arcing when disconnecting or re-

connecting battery cables, always discon-

nect the negative (−) battery cable first and

reconnect it last.

FLAMMABLE VAPORS CAN BE IGNITED

BY OPERATION OF COACH ELECTRICAL

SYSTEMS AND CAUSE DIESEL ENGINES

TO OVERSPEED

 Stop the generator set before fueling the

coach to reduce the risk of igniting flammable

vapors.

 Do not operate the diesel-powered generator

set where there are or can be flammable va-

pors created by fuel spills, gas leaks, etc.

Flammable vapors drawn into a diesel engine

air intake system can cause the engine to

overspeed, which can result in fire, explosion

and equipment damage. The owners and op-

erators of the generator set are solely respon-

sible for safe operation.

GENERAL PRECAUTIONS

 Keep children away from the generator set.

 Do not use evaporative starting fluids. They

are highly explosive.

 To prevent accidental or remote starting while

working on the generator set, press the Stop

button and disconnect the battery cables at

the batteries to prevent starting during main-

tenance and service. (Always disconnect

negative [−] first and reconnect last to prevent

sparks between tools and vehicle frame.)

 Keep the generator set and its compartment

clean. Excess oil and oily rags can catch fire.

Dirt and gear stowed in the compartment can

restrict cooling air.

 Make sure all fasteners are secure and

torqued properly.

 Do not work on the generator set when men-

tally or physically fatigued or after consuming

alcohol or drugs.

 You must be trained and experienced to

make adjustments while the generator set is

running—hot, moving or electrically live parts

can cause severe personal injury or death.

 Used engine oil has been identified by some

U. S. state and federal agencies as causing

cancer or reproductive toxicity. Do not ingest,

inhale, or contact used oil or its vapors.

 Keep multi-class ABC fire extinguishers

readily at hand. Class A fires involve ordinary

combustible materials such as wood and

cloth. Class B fires involve combustible and

flammable liquids and gaseous fuels.

Class C fires involve live electrical equip-

ment. See NFPA No. 10 (Portable Fire Extin-

guishers) or equivalent—BS EN 3-7:2004.

 Generator set installation and operation must

comply with all applicable local, state and fed-

eral codes and regulations.

 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.

 Running the generator set without the cover

or service door can cause severe personal in-

jury or equipment damage. Do not operator

the generator set with the cover or service

doors removed.

 Starting fluids, such as ether, can cause ex-

plosion and generator set engine damage.

Do not use.

 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 gas-

oline when checking, draining, or adding gas-

oline.

 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.

 To prevent accidental or remote starting while

working on the generator set, disconnect the

negative (−) battery cable at the battery using

an insulated wrench.

 Unsecured or loos fasteners can cause

equipment damage. Make sure all fasteners

are secure and properly torqued.

 Oily rags and other material can cause fire

and restrict cooling. Keep the generator set,

drip pan, and compartment clean.

 Accumulated grease and oil can cause over-

heating and engine damage presenting a po-

tential fire hazard. Keep the generator set

clean and repair any oil leaks promptly.

THIS PAGE LEFT INTENTIONALLY BLANK

1-1

1. Introduction

ABOUT THIS MANUAL

This is the Operator Manual for the generator sets

listed on the front cover. Read and carefully observe

all of the instructions and precautions in this manu-

al. Keep this manual with the vehicle.

The following sections, Operation, Periodic Mainte-

nance and Troubleshooting provide the instructions

necessary for operating the generator set and main-

taining top performance. The owner is responsible

for performing maintenance in accordance with the

PERIODIC MAINTENANCE SCHEDULE (p. 3-1).

WARNING

This generator set is not a life sup-

port system. It can stop without warning. Chil-

dren, persons with physical or mental limita-

tions, and pets could suffer personal injury or

death. A personal attendant, redundant power

or alarm system must be used if generator set

operation is critical.

WARNING

Improper service or replacement of

parts can lead to severe personal injury or death

and damage to equipment and property. Service

personnel must be qualified to perform electri-

cal and mechanical service.

Unauthorized modifications or replacement of

fuel, exhaust, air intake or speed control system

components that affect engine emissions are

prohibited by law in the State of California.

NAMEPLATE

Be ready to provide the generator set model and se-

rial numbers on the nameplate when contacting

Cummins for parts, service or information. Fig-

ure 1-1 illustrates typical model and serial numbers.

Record the numbers on your generator set name-

plate in Figure 1-2 so that they are easy to find when

needed. Each character in these numbers is signifi-

cant. The last character of the model number is the

specification letter, which is important for obtaining

the right parts. Genuine Cummins replacement

parts are recommended for best results. Refer to

the generator set Parts Manual.

FIGURE 1-1. TYPICAL NAMEPLATE

FIGURE 1-2. RECORD NUMBERS HERE

1-2

HOW TO OBTAIN SERVICE

Call the nearest authorized Cummins distributor for

service, parts and product literature (such as the

generator set Service Manual or Parts Manual).

Factory-trained representatives will handle your re-

quests for generator set parts and service.

In U.S. and Canada

Call 1−800−Cumminst(1−800−286−6467) to con-

tact the nearest Cummins distributor (touchtone

phone access only).

If you are unable to contact a distributor using the

automated service, consult the Yellow Pages. Typi-

cally, our distributors are listed under:

GENERATORS − ELECTRIC,

ENGINES − GASOLINE OR DIESEL, or

RECREATIONAL VEHICLES − EQUIPMENT,

PARTS AND SERVICE.

Worldwide

Go to internet site http://cummins.com/support

for Cummins distributor contact information.

Information to Have Ready

Before calling for service, have the following infor-

mation available:

1. The complete generator set model number and

serial number. See About This Manual

(Page 1-1).

2. The date of purchase

3. The nature of the problem. See Section 4. Trou-

bleshooting.

ENGINE EMISSIONS COMPLIANCE

The label that states compliance with applicable en-

gine emissions regulations is located on the air

cleaner cover as shown circled in Figure 1-3. Refer

also to the FEDERAL EMISSION DESIGN AND

DEFECT LIMITED WARRANTY FOR C. I. EN-

GINES (DIESELS) that was shipped in the same

package as the Operator’s Manual.

FIGURE 1-3. EMISSIONS LABEL LOCATION

1-3

TYPICAL GENERATOR SET

Figure 1-4 illustrates a typical generator set show-

ing connection points and maintenance access.

FUEL

CONNECTIONS

BATTERY NEG (−)

CONNECTION

MAINTENANCE ACCESS

(AIR, FUEL & OIL FILTERS)

AC OUTPUT, BATTERY POS (+)

& REMOTE CONTROL

CONNECTIONS

INTERNAL

MUFFLER

BOTTOM EXHAUST &

HOT AIR DISCHARGE

SERVICE

ACCESS

COOLING &

VENTILATING

AIR INLET

BOTTOM

OIL DRAIN

GENERATOR SET

STOP SWITCH

CHASSIS

GROUND

FIGURE 1-4. TYPICAL GENERATOR SET

1-4

THIS PAGE LEFT INTENTIONALLY BLANK

2-1

2. Operation

RECOMMENDED FUEL

WARNING

Diesel fuel is combustible and can

cause severe personal injury or death. Do not

smoke near fuel tanks or fuel-burning equip-

ment or in areas sharing ventilation with such

equipment. Keep flames, sparks, pilot flames,

electrical arcs and switches and all other

sources of ignition well away. Keep a multi-

class ABC fire extinguisher handy.

High quality Grade 2-D diesel fuel is necessary for

good performance and long engine life. Diesel fuels

specified by ASTM D975 or EN 590 are recom-

mended. Use Grade 1-D diesel fuel when ambient

temperatures are below freezing. The fuel should

have a Cetane number of at least 45 for reliable

starting.

Note: Ultra Low Sulfur Diesel (ULSD) fuel that meets

the ASTM D975 standard for lubricity is suitable for

use with this generator set. The 1 to 2 percent less

energy content of the fuel can have a slight effect on

maximum engine power.

Note: B5 Bio-Diesel fuel that meets industry specifi-

cations and quality is suitable for use with this gener-

ator set.

RECOMMENDED ENGINE OIL

Use API (American Petroleum Institute) perfor-

mance Class CH−4 or better engine oil or better.

Also look for the SAE (Society of Automotive Engi-

neers) viscosity grade. Referring to Figure 2-1,

choose the viscosity grade appropriate for the ambi-

ent temperatures expected until the next scheduled

oil change. Multi-grade oils such as SAE 15W-40

are recommended for year-round use.

See Section 5. Specifications for oil capacity.

STARTING BATTERIES

The generator set requires a 12 volt battery to power

its control and starting circuits. Reliable generator

set starting and starter service life depend upon ad-

equate battery system capacity and maintenance.

See MAINTAINING THE BATTERY AND BATTERY

CONNECTIONS (p. 3-2) and Section 5. Specifica-

tions for minimum battery ratings.

FIGURE 2-1. OIL VISCOSITY VS. TEMPERATURE

2-2

STOP SWITCH

Press the stop switch (Figure 2-2) to stop the gener-

ator set or to prevent it from starting while perform-

ing maintenance and service. To allow the genera-

tor 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

2-3

REMOTE OPERATOR PANEL

The remote operator panel (Figure 2-3) has the fol-

lowing features:

Display ON / Gen OFF Button − Press this button

to wake the generator set and display screen prior to

pressing the START button. This also starts the fuel

pump, which will prime the fuel system for five min-

utes if the generator set does not start. At low ambi-

ent temperatures the intake air preheater will en-

gage.

Press this button to stop the generator set.

START Button − To start the generator set, press

and hold this button when “GEN OFF” appears on

the display screen after having pressed the Display

ON button.

Display Screen − The display screen displays gen-

erator set status, battery voltage, hours run and

warning and shutdown messages (see Section 4.

Troubleshooting).

Low Oil Indicator Light − This light indicates that

engine oil pressure is low or temperature is too high.

The generator will shutdown if this light turns on.

FIGURE 2-3. OPERATOR PANEL

2-4

WARNING

EXHAUST GAS is deadly. All en-

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. If

symptoms persist, seek medical attention. Shut

down the generator set and do not operate it un-

til it has been inspected and repaired.

Never sleep in the vehicle while the generator

set is running unless the vehicle has a working

carbon monoxide detector. The exhaust system

must be installed in accordance with the gener-

ator set Installation Manual. Make sure there is

ample fresh air when operating the generator

set in a confined area.

PRE-START CHECKS

Before the first start of the day and after every eight

hours of operation, inspect the generator set as

instructed under GENERAL INSPECTION (p. 3-2).

Keep a log of maintenance and the hours run and

perform any maintenance that may be due. See Re-

turning the Generator Set to Service (p. 2-7) if the

vehicle has been in storage.

Before each start:

1. Make sure all vehicle carbon monoxide (CO)

detectors are working.

2. Check for fuel and oil leaks and damage to the

exhaust system.

3. To prevent overheating and to reduce fouling

with dust and debris, make sure the generator

set’s normal ground clearance is not being re-

duced by sloping ground, curbs, logs or other

objects. Repark the vehicle if necessary and/or

remove any objects blocking the air inlet or air

outlet.

4. Turn off air conditioners and other large ap-

pliances.

STARTING

1. Perform the PRE-START CHECKS.

2. Start the generator set at the remote operator

panel.

A. Press and release the Display ON button.

B. Wait for “GEN OFF” to appear. If the gen-

erator set ran out of fuel and it is necessary

to prime the fuel system, wait at least one

minute before pressing the START button

to allow the fuel pump to prime fuel. At low

ambient temperatures the intake air pre-

heater will engage.

C. Press and hold the START button until the

generator set starts. The generator set will

make up to three attempts to start. “GEN

ON” will appear on the display screen

when the generator set starts. “GEN

WAIT” will appear during rest periods be-

tween start attempts.

3. Press the GEN OFF button to reset the control

if the generator set does not start after three at-

tempts. See Section 4. Troubleshooting if the

generator set still does not start.

4. Let the generator set warm up a few minutes

until it is running smoothly before connecting

the vehicle electrical loads (appliances).

5. Check for fuel, oil and exhaust leaks. Stop the

generator set immediately if there is leak and

have it repaired.

STOPPING

Run the generator set under no load for a few min-

utes to allow the engine to cool down and then press

and release the Gen OFF button.

2-5

LOADING THE GENERATOR SET

The generator set can power AC motors, air condi-

tioners, AC/DC converters, battery chargers and

other appliances. How much appliance load* can be

powered depends upon the generator set power rat-

ing. The generator set will shut down if the sum of

the loads exceeds generator set power. See Sec-

tion 4. Troubleshooting.

To avoid overloading the generator set and causing

shutdowns, compare the sum of the loads of the ap-

pliances that are likely to be used at the same time to

the power rating of the generator set. It may be nec-

essary to run fewer appliances at the same

time—the sum of the loads must not be greater

than generator set rating.

The generator set may shut down due to overload

when a large motor or air conditioner is started or

cycles off and then on again, even though the sum of

the loads is less than generator set rating. The rea-

son for this is that a motor’s startup load is much

larger than its running load. It may be necessary to

run fewer appliances when large motors and air

conditioners are cycling on and off.

TABLE 2-1. TYPICAL APPLIANCE LOADS

Appliance

Load (watts)

Air Conditioner 1400-2000

Battery Charger Up to 3600

DC Converter 300-900

Refrigerator 600-1000

Microwave Oven 1000-1500

Electric Frying Pan or Wok 1000-1500

Electric Stove Element 350-1000

Electric Water Heater 1000-1500

Electric Iron 500-1200

Electric Hair Dryer 800-1500

Coffee Percolator 550-750

Television 200-600

Radio 50-200

Electric Drill 250-750

Electric Broom 200-500

Electric Blanket 50-200

Generator set output is rated at 77_F (25_C). Power

output decreases 1% for every 10_F (5.5_C) in-

crease. Maximum power decreases as altitude in-

creases because air density decreases. For every

1000-foot (305 m) increase in elevation you can ex-

pect power to decrease approximately 3.5 percent.

It may be necessary to run fewer appliances at

higher altitudes.

TABLE 2-2. POWER VS. ALTITUDE

Altitude

(Elevation above Sea Level)

Maximum Power

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)

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

2-6

RESETTING CIRCUIT BREAKERS

Note: The generator set does not have a power out-

put circuit breaker.

If a circuit breaker in the main power distribution

panel of the vehicle trips, either a circuit shorted or

too many appliances were running.

If a circuit breaker trips, disconnect or turn off as

many loads as possible and reset the circuit break-

er. (Push the circuit breaker to OFF to reset it and

then to ON to reconnect the circuit.) If the circuit

breaker trips right away, either the electrical dis-

tribution system has a short or the circuit breaker is

faulty. Call a qualified electrician.

If the circuit breaker does not trip right away, recon-

nect the appliances, one by one, up to a total load

that does not overload the generator set.

Electrical appliances and tools must be used and

maintained properly and be properly grounded to

cause the line circuit breakers to trip when short cir-

cuits occur.

WARNING

Short circuits in electrical ap-

pliances and tools can cause fire and electrical

shock leading to severe personal injury or

death. Read and follow the equipment and tool

manufacturer’s instructions and warnings re-

garding use, maintenance and proper ground-

ing.

CONNECTING TO UTILITY POWER

A vehicle with provisions for connecting utility power

must have an approved device to keep the genera-

tor set and utility from being interconnected. See the

generator set Installation Manual for more informa-

tion.

WARNING

Interconnecting the generator set

and the public utility can lead to electrocution of

utility line workers, equipment damage and fire.

Use an approved switching device to prevent in-

terconnections.

OPERATING IN COLD WEATHER

Make sure the engine oil viscosity is appropriate for

the cold ambient temperatures. See ENGINE OIL

RECOMMENDATIONS (p. 2-1). Be sure to

change the oil if a sudden drop in temperature oc-

curs.

OPERATING IN HOT WEATHER

Pay particular attention to the following items when

operating the generator set in hot weather:

1. Make sure nothing blocks airflow to and from

the generator set.

2. Make sure the engine oil viscosity is 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 PERIODIC

MAINTENANCE SCHEDULE (p. 3-1).

OPERATING AT HIGH ALTITUDE

For the effect of altitude on maximum power, see

LOADING THE GENERATOR SET (p. 2-5).

OPERATING IN DUSTY ENVIRONMENTS

Pay particular attention to the following items when

operating the generator set in dusty environments:

1. Do not let dirt and debris accumulate inside the

generator set compartment. Keep the genera-

tor set clean.

2. Perform air cleaner maintenance more often.

See PERIODIC MAINTENANCE SCHEDULE

(p. 3-1).

3. Change engine oil more often. See PERIODIC

MAINTENANCE SCHEDULE (p. 3-1).

4. Keep containers of engine oil that have been

opened tightly closed to keep out dust.

2-7

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

20 hours of operation. See LOADING THE GEN-

ERATOR SET (p. 2-5).

Proper engine oil and oil level are especially critical

during break-in because of the higher engine tem-

peratures that can be expected. Change the oil if not

appropriate for the ambient temperatures during

break-in. See ENGINE OIL RECOMMENDATIONS

(p. 2-1). Change the oil after the first 20 hours of

operation.

EXERCISING THE GENERATOR SET

Exercise the generator set at least 2 hours each

month if use is infrequent. Run the generator set at

approximately 1/2 rated power. See LOADING THE

GENERATOR SET (p. 2-5). A single two hour ex-

ercise period is better than several shorter periods.

Exercising a generator set drives off moisture, re-lu-

bricates the engine, replaces stale fuel and re-

moves oxides from electrical contacts. The result is

better starting, more reliable operation and longer

engine life.

STORING THE GENERATOR SET

Proper storage is essential for preserving top gener-

ator set performance and reliability when the gener-

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 indicat-

ing oil viscosity. See ENGINE OIL REC-

OMMENDATIONS (p. 2-1).

2. Disconnect the battery cables (negative [−]

cable first) from the starting battery and store

the battery according to the battery manufac-

turer’s recommendations. See MAINTAINING

THE BATTERY AND BATTERY CONNEC-

TIONS (p. 3-2).

3. Plug the exhaust tail pipe to keep out dirt, mois-

ture, bugs, etc.

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

Returning the Generator Set to Service

1. Check the oil tag on the generator set and

change the oil if the viscosity indicated is not

appropriate for the temperatures expected.

See ENGINE OIL RECOMMENDATIONS

(p. 2-1).

2. Reconnect the starting battery (negative [−]

cable last). See MAINTAINING THE BATTERY

AND BATTERY CONNECTIONS (p. 3-2).

3. Remove the plug from the exhaust tailpipe.

4. Change the air filter element if it is dirty (p. 3-6).

5. Open the fuel supply valve (if so equipped).

6. Inspect the generator set. See GENERAL IN-

SPECTION (p. 3-2).

2-8

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CUMMINS QD 3200 HDZAA User manual

Brand: CUMMINS

Model: QD 3200 HDZAA

Category: Power generators

Type: User manual

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CUMMINS QD 3200 HDZAA User manual

CUMMINS QD 3200 HDZAA User manual

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