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Cummins/Onan HDZAA Generator Set

The Cummins/Onan HDZAA is a diesel generator set. It is available at 120 V, single-phase, 60 Hz and rated 26.7 A. It holds about 1.1 L (0.3 gal) of oil. Starting uses battery rated 475 CCA at 12 V. The set measures 766.4×439.4×457.7 mm (30.2×17.3×18.0 in) and produces 68 dBA at 3 m.

1.1 L
Oil capacity
1
Document types

How to read your Cummins/Onan serial & model number →

Service parts for the HDZAA

Grouped by system, with how many of each the parts manual calls for.

Air intake

1 required
149-2834IAir filtersee priceAmazon

Fuel system

1 required
F102-1004Fuel filtersee priceAmazon

Oil system

1 required
140-4151IOil filtersee priceAmazon

Prices captured from merchant listings; some links are affiliate links. Confirm against your serial number before ordering.

Specifications

Fueldiesel
Frequency60.0 Hz
ControllerIntegrated Microprocessor-Based Engine and Generator Controller and AC Output Inverter
Oil capacity1.1 L
AlternatorPMA (Permanent Magnet Alternator)
Voltage options120 V
Phase1
Rated current26.7 A
Power factor1.0
Battery cranking475 CCA
Battery voltage12 V
Starting system12 V DC
Dimensions (L×W×H)766×439×457 mm
Wet weight93 kg
Sound level68.0 dBA @ 3 m

Maintenance & consumables

ItemSpecCapacityPart #Interval
Air filterAir Filter149-2834I Amazon eBay
Fuel filterFuel FilterF102-1004 Amazon eBay
Oil filterOil Filter140-4151I Amazon eBay
BatteryCranking batteries—
Belt—
Coolant—
FuelHigh quality Grade 2-D diesel fuel is necessary for good performance and long engine life. Diesel fuels specified by ASTM D975 or EN 590 are recommended. Use Grade 1-D diesel fuel when ambient temperatures are below freezing. The fuel should have a Cetane number of at least 45 for reliable starting.—
OilChange after first 50 hours and then every 250 hours1.2 liter—250 hr
Spark plug—

Service intervals

11
ItemActionHoursMonthsNotes
Engine oil levelCheck8 hr
General InspectionInspect8 hrInspect before the first start of the day and after every eight hours of operation
Generator setInspect8 hrBefore first start of the day and after every 8 hours of operation
Engine oilChange250 hrFirst service — Perform more often when operating in hot weather; perform at least once a year
Oil filter (engine oil strainer)Clean250 hr
Engine air filterReplace500 hrPerform more often in dusty conditions; perform at least once a year
Fuel filterReplace500 hrPerform at least once a year
Engine valve lashAdjust1000 hrMust be performed by trained and experienced personnel (authorized Cummins service representatives)
Fuel injector pressureCheck1000 hrEPA requirement; must be performed by trained and experienced personnel
Battery & battery connectionsCheck1 moPerform more often when operating in hot weather
Battery and battery connectionsCheck1 moTable 3-1, Every Month column

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Service specifications

60
TypeItemValueUnitCondition
Injection timingFuel injection timing (BTDC)16degreesBTDC
OtherFuel transfer pump flowat least 0.4 pints (200 mL)/minutepints/minute
OtherInternal control panel control circuit fuse30ampautomotive-type
PressureCylinder Compression Test290 to 319psi (20 to 22 bar)
PressureCylinder compression test290 to 319 psi (20 to 22 bar)psi
PressureFuel Nozzle Injection Pressure2900±174psi (200±12 bar)
PressureFuel nozzle injection pressure2900 +/- 174 psi (200 +/- 12 bar)psi
PressureNormal engine oil pressure36psiat 3100 RPM
PressureNormal oil pressure36psiat 3000 RPM
PressureOil pressure switch closes2.5 to 3.6psinormally closed; closes between 2.5 and 3.6 psi
PressureOil pressure switch closing pressure2.5 and 3.6psinormally closed
ResistancePMA auxiliary winding resistance (6-pin connector pins 2 and 3)0.3 ohms within 10 percentohms6-pin connector disconnected from internal control panel
ResistancePMA auxiliary winding resistance (9-pin connector pins 4 and 9)0.3 ohms within 10 percentohms9-pin connector disconnected from inverter
ResistancePMA auxiliary winding resistance (pins 2-3 on 6-pin)0.3 within 10 percentohms
ResistancePMA auxiliary winding resistance (pins 4-9 on 9-pin)0.3 within 10 percentohms
ResistancePMA main winding resistance (9-pin connector pins 1 and 2; 2 and 3; 3 and 1)1.1 ohms within 10 percentohms9-pin connector disconnected from inverter
ResistancePMA main winding resistance (pins 1-2, 2-3, 3-1)1.1 within 10 percentohms
SpeedEngine speed calculation from PMA frequency(HZ x 60) / 9 = Engine RPMrpm
SpeedEngine speed shutdown limit (PMA frequency high)4200rpmgreater than
SpeedInverter shutdown limit for high output frequency4200rpmengine speed greater than 4200 rpm
SpeedLow engine power condition2300rpmbelow
SpeedLow engine power threshold2300rpmengine speed below 2300 rpm
TemperatureInverter over-temperature threshold70Cinverter temperature detected to be over 70 C
TemperatureMaximum inverter temperature70°C
TemperatureOil temperature switch closes220 C (428 F)Cnormally open (cold); closes at 220 C
TemperatureOil temperature switch closing temperature220°C (428 °F)normally open (cold)
TemperatureRise over ambient (oil temperature)15°F
TorqueDC cable terminal nuts10ft-lbs (14 N-m)
TorqueDC cable terminal nuts10 ft-lbs (14 N-m)ft-lb
TorqueEngine harness connector screws10.6in-lbs (1.2 N-m)
TorqueEngine harness connector screws10.6 in-lbs (1.2 N-m)in-lb
TorqueEngine mounting bracket bolts (to engine)14ft-lbs (19 N-m)
TorqueEngine mounting bracket bolts (to engine)14 ft-lbs (19 N-m)ft-lb
TorqueEngine mounting isolator bolts (to generator set base)10ft-lbs (14 N-m)
TorqueEngine mounting isolator bolts (to generator set base)10 ft-lbs (14 N-m)ft-lb
TorqueExhaust clamp screws7.4ft-lbs (10 N-m)
TorqueExhaust clamp screws7.4 ft-lbs (10 N-m)ft-lb
TorqueExhaust flange nuts at the engine18-22 ft-lbs (25-30 N-m)ft-lbuse a new flange gasket
TorqueExhaust isolator screws13ft-lbs (18 N-m)
TorqueExhaust isolator screws13 ft-lbs (18 N-m)ft-lb
TorqueGenerator set mounting bracket to vehicle10ft-lbs (14 N-m)
TorqueGenerator set mounting bracket to vehicle14ft-lbs (19 N-m)
TorqueGenerator set mounting brackets and vibration isolators (Figure 4-1)10 ft-lbs (14 N-m)ft-lb
TorqueGenerator set mounting brackets and vibration isolators (Figure 4-1)14 ft-lbs (19 N-m)ft-lb
TorqueHousing screws27 in-lbs (3 N-m)in-lb
TorqueInverter isolator mounting screws8ft-lbs (11 N-m)
TorqueInverter isolator mounting screws8 ft-lbs (11 N-m)ft-lb
TorqueM10 1.5 Grade 8.852N.m (39 Ft-Lb)
TorqueM10 1.5 grade 8.8 fastener52 N.m (39 ft-lb)N.mgrade 8.8
TorqueM12 1.75 Grade 8.884N.m (62 Ft-Lb)
TorqueM12 1.75 grade 8.8 fastener84 N.m (62 ft-lb)N.mgrade 8.8
TorqueM6 1.0 Grade 8.811N.m (8 Ft-Lb)
TorqueM6 1.0 grade 8.8 fastener11 N.m (8 ft-lb)N.mgrade 8.8
TorqueM8 1.125 Grade 8.823N.m (17 Ft-Lb)
TorqueM8 1.125 grade 8.8 fastener23 N.m (17 ft-lb)N.mgrade 8.8
TorqueOuter housing screws27in-lbs (3 N-m)
TorqueOuter housing screws27 in-lbs (3 N-m)in-lb
Valve clearanceIntake & exhaust valve lash0.004 in (0.1 mm)incold
Valve clearanceValve Lash: Intake & Exhaust0.004in (0.1 mm)cold
VoltageBattery voltage below minimum to start9VDC

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Recommended fluids

FluidGradeStandardAmbientCapacityNotes
Engine oilSAE 15W-40 (multi-grade recommended for year-round use)API performance Class CH-4 or better1.1 literChoose viscosity grade appropriate for ambient temperatures expected until next scheduled oil change; see Figure 2-1 oil viscosity vs. temperature. Change oil after first 20 hours of operation.
Engine oilSAE 15W-40 multi-grade recommended; API performance Class CF or betterAPI CF1.1 literChoose viscosity grade per oil viscosity vs. temperature chart (Figure 2-1)
FuelGrade 2-D diesel; Grade 1-D when ambient temperatures are below freezingASTM D975 or EN 590; Cetane number at least 45Ultra Low Sulfur Diesel (ULSD) meeting ASTM D975 lubricity is suitable; B5 Bio-Diesel meeting industry specifications and quality is suitable.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Procedures

12
Accessing Service Screens diagnostic
  1. Press Gen OFF.
  2. Hold down the START button and Display ON together.
  3. Release both buttons when RV QD 3200 is displayed.
  4. IMMEDIATELY press the START button 3 times; GEN OFF should be displayed.
  5. Press the START button again to start the generator set.
  6. Once started, press the START button to view the service screens.
  7. Use the START button to navigate through the service screens.
Accessing the Service Screens diagnostic
  1. Press Gen OFF.
  2. Hold down the START button and Display ON together.
  3. Release both buttons when RV QD 3200 is displayed.
  4. Immediately press the START button 3 times; GEN OFF should be displayed.
  5. Press the START button again to start the generator set.
  6. Once started, press START to view the service screens and use START to navigate.
Measuring Fuel Transfer Pump Flow diagnostic

⚠ Diesel fuel is combustible.

Tools: 1 gallon (4 liter) container

  1. Disconnect the fuel supply line at the engine and direct the end into a 1 gallon (4 liter) container.
  2. Press the Display ON button on the Operator Panel to prime fuel (five minutes).
  3. Press the Gen OFF button to stop priming before the container fills up.
  4. Replace the pump if it does not provide a steady flow of fuel after air has been bled.
PMA Tests diagnostic

⚠ Hitting the rotor or prying against it to remove it can break the magnets inside.

Tools: Ohmmeter

  1. Disconnect the 9-pin connector on the inverter and measure main winding resistance between pins 1 and 2, 2 and 3, 3 and 1. Replace the stator if any winding is grounded or open or does not measure 1.1
  2. With the 9-pin connector disconnected, measure auxiliary winding resistance between pins 4 and 9. Replace the stator if grounded, open or not 0.3 ohms within 10 percent.
  3. Disconnect the 6-pin connector from the internal control panel and measure auxiliary winding resistance between pins 2 and 3. Replace the stator if grounded, open or not 0.3 ohms within 10 percent.
Testing the Fuel Transfer Pump diagnostic

Tools: 1 gallon (4 liter) container

  1. Disconnect the fuel supply line at the engine and direct the end into a 1 gallon (4 liter) container.
  2. Press the Display ON button on the Operator Panel to prime fuel (five minutes).
  3. Press the Gen OFF button to stop priming before the container fills up.
  4. Replace the pump if it does not provide a steady flow of fuel after air has been bled from the system.
Changing Engine Oil maintenance

⚠ Push the Stop Switch Off and disconnect the battery cables (negative first) before servicing.

  1. Place a pail under the oil drain plug.
  2. Remove the maintenance access door and oil fill cap, unscrew the oil drain cap and drain all oil from the engine. Reinstall the oil drain cap securely.
  3. Refill with approximately 0.7 quarts of oil, check oil level and secure the front access door.
  4. Dispose of the used oil according to local environmental regulations.
Checking Engine Oil Level maintenance

⚠ Contact with used engine oil can cause cancer or reproductive toxicity.

Tools: Rubber gloves

  1. Park the vehicle on level ground, shut down the generator set and remove the front access door.
  2. Pull out the oil dipstick, wipe it clean, reinsert it and pull it out again to check the oil level.
  3. Add or drain oil as necessary; keep the oil level between the MIN / MAX marks.
  4. Reinsert the dipstick and secure the oil fill cap and front access door.
Cleaning the Engine Oil Strainer maintenance

⚠ Wear safety glasses when using compressed air to clean the oil strainer.

Tools: Compressed air

  1. Remove the maintenance access door.
  2. Loosen the center screw of the strainer about five turns and withdraw the strainer from the engine block.
  3. Use compressed air to clean the strainer, blowing debris from inside out.
  4. Replace the O-rings or strainer if damaged.
  5. Lubricate the O-rings with clean oil and insert the strainer until it stops.
  6. Check for spring tension against the strainer and tighten the center screw.
  7. Secure the front access door.
Cleaning the Spark Arrester maintenance

⚠ A hot muffler can cause severe burns. Let the muffler cool down before removing or installing the cleanout plug.

  1. Remove the cleanout plug on the bottom of the muffler.
  2. Start the generator set and load it nearly to full power; let it run about five minutes to expel the soot.
  3. Stop the generator set, allow the muffler to cool down and reinstall the cleanout plug.
Cleaning the Spark Arrestor maintenance

⚠ A hot muffler can cause severe burns. Let the muffler cool down before removing or installing the cleanout plug.

  1. Remove the cleanout plug on the side of the spark arrestor canister.
  2. Start the generator set and load it nearly to full power. Let it run about five minutes to expel the soot.
  3. Stop the generator set, allow the muffler to cool down, and reinstall the cleanout plug.
Maintaining the Battery and Battery Connections maintenance

⚠ Flames, sparks and arcing at battery terminals can ignite battery gas causing severe personal injury.

Tools: Battery terminal puller

  1. Keep the battery case and terminals clean and dry and the terminals tight.
  2. Use a battery terminal puller to remove cable clamps on post-type battery terminals.
  3. Tighten threaded-stud battery terminals as recommended by the battery manufacturer.
  4. Determine positive (+) and negative (-) terminals before making connections; always remove negative (-) cable first and reconnect it last.
Replacing the Air Filter Element maintenance
  1. Remove the filter cover.
  2. Unscrew the knurled nut and remove the old filter element.
  3. Clean dust and debris from the filter housing and install the new filter element.
  4. Secure the front access door.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Common questions

Is the Cummins/Onan HDZAA diesel or gas?

The Cummins/Onan HDZAA runs on diesel.

How much oil does the Cummins/Onan HDZAA take?

The Cummins/Onan HDZAA has an engine oil capacity of 1.1 liters (1.2 US quarts), per the manufacturer specification sheet.

What is the sound level of the Cummins/Onan HDZAA?

The Cummins/Onan HDZAA is rated at 68.0 dBA at 3 m, per the manufacturer specification sheet.

What voltage does the Cummins/Onan HDZAA produce?

The Cummins/Onan HDZAA is offered in 120 V, 1-phase.

How many cold cranking amps does the Cummins/Onan HDZAA require?

The Cummins/Onan HDZAA uses 12 V each, 475 CCA, per the manufacturer specification sheet. The starting system is 12 V DC.

Which alternator is fitted to the Cummins/Onan HDZAA?

The Cummins/Onan HDZAA uses a PMA (Permanent Magnet Alternator) alternator.

What oil filter does the Cummins/Onan HDZAA use?

The Cummins/Onan HDZAA uses oil filter part number 140-4151I.

What fuel filter fits the Cummins/Onan HDZAA?

The Cummins/Onan HDZAA uses fuel filter part number F102-1004.

What air filter fits the Cummins/Onan HDZAA?

The Cummins/Onan HDZAA uses air filter part number 149-2834I.

Troubleshooting

6

Symptoms & remedies

SymptomCauseRemedy
The Operator Panel in the vehicle must be able to communicate with the inverter in the generator set. If communication is interrupted this fault will likely occur when attempting to start the generator set.1. The Operator Panel in the vehicle must be able to communicate with the inverter in the generator set. If communication is interrupted this fault will likely occur when attempting to start the generator set. 2. Without power from the PMA auxiliary windings AC3 and AC4, the inverter will not be able to communicate with the Operator Panel. If the output frequency detected by the inverter is too high (engine speed greater than 4200rpm) the inverter will shut down the generator set. See PMA information in section 4−9 for engine speed calculation. 3. Faulty inverter.1. Disconnect the vehicle AC wiring from the generator set and connect the generator set to a load bank. If the problem goes away check the vehicle AC wiring for shorts. Shorts to ground can cause an inverter communications fault. 2. Check for open wiring, shorts to ground, and bad crimps at the 2-pin connector on the inverter and at Pins 1 and 6 of the 6-pin connector on the internal control board. 3. Check for open wiring to ground and bad crimps at Pin 5 of the 6-pin connector on the internal control board. 4. Check for open wiring, shorts to ground, and bad crimps at Pins 1 and 4 of the 12-pin connector on the Operator Panel and for good connections at pins 7 and 10 of the 10-pin connector on the internal control board. 5. Check for open wiring, shorts to ground, and bad crimps at Pins 4 and 9 of the 9-pin connector on the inverter. 6. Check PMA winding connections to the internal control board and inverter. Refer to PMA tests (p. 4-9) and replace PMA stator if necessary. 7. Replace a faulty inverter.
Inverter temperature detected to be over 70 C.1. Reduce loads. 2. Verify that the inverter heat sink is clean and that there is no air flow restriction or hot air recirculation. 3. After allowing generator and inverter too cool, start and run the generator set with no load. If it still shuts down on OVER TEMPERATURE, replace the inverter.
Too many applications are connected, or the inverter is defective.1. Measure current draw. If it is greater than 32 amps, reduce the number of appliances connected in the coach and wait a few minutes for generator set to cool down. Press STOP to stop engine and restart the generator set. 2. If the generator set shuts down on ’Overload’ condition, disconnect it from the coach and bench-test with a load-bank. If the generator set runs fine without shutting down, then the problem likely exists within vehicle wiring and/or appliances. In the event that it shuts down with no load connected, perform checks in Step 3. 3. Ensure stator is not damaged and has no shorts internally or to Ground on all Main and Auxiliary Windings. Test winding insulation resistance with a Megger. Replace state if necessary. If the stator is good, replace the inverter.
Engine speed is below 2300 rpm1. Check that the engine stop lever is in its vertical (run) position (Figure 5-1). Refer to Engine Workshop Manual 983−0504 if the lever does not return to the run position after it has been pushed to stop the engine. 2. Reduce Loads: Disconnect AC output leads and connect to load bank. Test performance. 3. Check Fuel Flow: Verify fuel flow from lift pump it should be approximately 0.4 pints/min (200 ml/minute) If flow is low check for kinked hoses and replace fuel filter as needed. 4. Check air flow (intake, exhaust) for restrictions: Remove exhaust and test, (spark arrestor clean out may be needed). 5. Verify that the stop solenoid is operating correctly. Replace the solenoid if it does not pull in when 12 VDC is applied to its terminals. 6. Check the PMA winding connections at the internal control board and inverter. Refer to PMA tests (p. 4-9). Replace PMA stator if necessary. 7. The engine “wet-stacked” when run under no load. Run under approximately 3/4 rated load for approximately 30 minutes. If the problem persists, go to Step 8. 8. The injector is partially blocked. Check the spray pattern and replace as necessary. Refer to Engine Workshop Manual 983−0504. 9. The injector popping pressure is too Low. Check the popping pressure and replace as necessary. Refer to Engine Workshop Manual 983−0504. 10. The engine is worn. Refer to Engine Workshop Manual 983−0504.
Gen Wait should appear on the display.Clear the Gen Wait message from the Operator Panel by cycling it off and on. Try starting again.
Engine cranks but does not start.Possible Cause/Diagnosis/Repair1. Clear the Gen Wait message from the Operator Panel by cycling it off and on. Try starting again. 2. Check the fuel level and fill as necessary. 3. Press the stop switch (p. 2-2) if it is not in its “1” position. 4. Replace the fuel if it is not of the specified grade or suitable for the ambient temperature (p 2-1). 5. Check Fuel flow from lift pump, should be approximately 0.4 pints/minute (200 ml/minute). Look for kinked hoses and replace fuel filter as need. 6. Verify that the fuel solenoid is getting 12V DC and clicks open when energized. 7. The cam to crank timing is off. Check Timing. Refer to Engine Workshop Manual 983−0504. 8. Valves not set properly: Check Valve lash. Refer to Engine Workshop Manual 983−0504. 9. The injector nozzle is blocked or locked. Remove the injector and check popping pressure and spray pattern. Refer to Engine Workshop Manual 983−0504. 10. The injection pump is stuck. Remove the high pressure injector line and crank the engine. Watch for fuel at delivery valve. Refer to Engine Workshop Manual 983−0504 11. Engine compression is low—blown head gasket, bad injector seal, worn engine. Refer to Engine Workshop Manual 983−0504.

Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing. Full Cummins/Onan HDZAA troubleshooting guide (41 entries) →

Parts

5
Part #DescriptionQtySystem
140-4151IOil Filter.11 quartsOil filter Amazon eBay
149-2834IAir FilterAir filter Amazon eBay
F102-1004Fuel Filter1Fuel filter Amazon eBay
F102-1005Air Filter1Air filter Amazon eBay
500-4709OUTLINE DRAWING—SHEET 1 OF 2Service part / kit Amazon eBay

Service, wear & replacement parts referenced for this model and its engine — confirm the exact part for your serial number. See the full parts catalog to search and cross-reference.

Fuel consumption

RatingLoadL/hgal/h
0.760.2
Full_load100%1.510.4
Half_load50%0.790.21
No_load0.490.13
Prime1.440.38
Prime25%1.30.3425
Prime50%2.590.685
Prime100%5.191.37
Standby0.760.2

Available documents

Service manual — 0983-0602 (Cummins/Onan)Service manual — 983-0103 Onan HDZAA Quiet Diesel Genset Operator's manual (09-2009)Service manual — 983-0502 Onan HDZAA (spec A-B) Diesel Genset Service manual (06-2010) (Cummins/Onan)Service manual — 983-0602 Onan HDZAA Installation Manual (7-2007) (Cummins/Onan)Service manual — A066T111-I1-202103 (Cummins/Onan)Service manual — Cummins Onan Service Manual HDZAA Spec A-E (Cummins/Onan)

This page was generated from the 6 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.