Service parts for the HDZAA
Grouped by system, with how many of each the parts manual calls for.
Air intake
1 requiredFuel system
1 requiredOil system
1 requiredPrices captured from merchant listings; some links are affiliate links. Confirm against your serial number before ordering.
Specifications
| Fuel | diesel |
|---|---|
| Frequency | 60.0 Hz |
| Controller | Integrated Microprocessor-Based Engine and Generator Controller and AC Output Inverter |
| Oil capacity | 1.1 L |
| Alternator | PMA (Permanent Magnet Alternator) |
| Voltage options | 120 V |
| Phase | 1 |
| Rated current | 26.7 A |
| Power factor | 1.0 |
| Battery cranking | 475 CCA |
| Battery voltage | 12 V |
| Starting system | 12 V DC |
| Dimensions (L×W×H) | 766×439×457 mm |
| Wet weight | 93 kg |
| Sound level | 68.0 dBA @ 3 m |
Maintenance & consumables
| Item | Spec | Capacity | Part # | Interval | |
|---|---|---|---|---|---|
| Air filter | Air Filter | 149-2834I | Amazon eBay | ||
| Fuel filter | Fuel Filter | F102-1004 | Amazon eBay | ||
| Oil filter | Oil Filter | 140-4151I | Amazon eBay | ||
| Battery | Cranking batteries | — | |||
| Belt | — | ||||
| Coolant | — | ||||
| Fuel | High quality Grade 2-D diesel fuel is necessary for good performance and long engine life. Diesel fuels specified by ASTM D975 or EN 590 are recommended. Use Grade 1-D diesel fuel when ambient temperatures are below freezing. The fuel should have a Cetane number of at least 45 for reliable starting. | — | |||
| Oil | Change after first 50 hours and then every 250 hours | 1.2 liter | — | 250 hr | |
| Spark plug | — |
Service intervals
11| Item | Action | Hours | Months | Notes |
|---|---|---|---|---|
| Engine oil level | Check | 8 hr | ||
| General Inspection | Inspect | 8 hr | Inspect before the first start of the day and after every eight hours of operation | |
| Generator set | Inspect | 8 hr | Before first start of the day and after every 8 hours of operation | |
| Engine oil | Change | 250 hr | First service — Perform more often when operating in hot weather; perform at least once a year | |
| Oil filter (engine oil strainer) | Clean | 250 hr | ||
| Engine air filter | Replace | 500 hr | Perform more often in dusty conditions; perform at least once a year | |
| Fuel filter | Replace | 500 hr | Perform at least once a year | |
| Engine valve lash | Adjust | 1000 hr | Must be performed by trained and experienced personnel (authorized Cummins service representatives) | |
| Fuel injector pressure | Check | 1000 hr | EPA requirement; must be performed by trained and experienced personnel | |
| Battery & battery connections | Check | 1 mo | Perform more often when operating in hot weather | |
| Battery and battery connections | Check | 1 mo | Table 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| Type | Item | Value | Unit | Condition |
|---|---|---|---|---|
| Injection timing | Fuel injection timing (BTDC) | 16 | degrees | BTDC |
| Other | Fuel transfer pump flow | at least 0.4 pints (200 mL)/minute | pints/minute | |
| Other | Internal control panel control circuit fuse | 30 | amp | automotive-type |
| Pressure | Cylinder Compression Test | 290 to 319 | psi (20 to 22 bar) | |
| Pressure | Cylinder compression test | 290 to 319 psi (20 to 22 bar) | psi | |
| Pressure | Fuel Nozzle Injection Pressure | 2900±174 | psi (200±12 bar) | |
| Pressure | Fuel nozzle injection pressure | 2900 +/- 174 psi (200 +/- 12 bar) | psi | |
| Pressure | Normal engine oil pressure | 36 | psi | at 3100 RPM |
| Pressure | Normal oil pressure | 36 | psi | at 3000 RPM |
| Pressure | Oil pressure switch closes | 2.5 to 3.6 | psi | normally closed; closes between 2.5 and 3.6 psi |
| Pressure | Oil pressure switch closing pressure | 2.5 and 3.6 | psi | normally closed |
| Resistance | PMA auxiliary winding resistance (6-pin connector pins 2 and 3) | 0.3 ohms within 10 percent | ohms | 6-pin connector disconnected from internal control panel |
| Resistance | PMA auxiliary winding resistance (9-pin connector pins 4 and 9) | 0.3 ohms within 10 percent | ohms | 9-pin connector disconnected from inverter |
| Resistance | PMA auxiliary winding resistance (pins 2-3 on 6-pin) | 0.3 within 10 percent | ohms | |
| Resistance | PMA auxiliary winding resistance (pins 4-9 on 9-pin) | 0.3 within 10 percent | ohms | |
| Resistance | PMA main winding resistance (9-pin connector pins 1 and 2; 2 and 3; 3 and 1) | 1.1 ohms within 10 percent | ohms | 9-pin connector disconnected from inverter |
| Resistance | PMA main winding resistance (pins 1-2, 2-3, 3-1) | 1.1 within 10 percent | ohms | |
| Speed | Engine speed calculation from PMA frequency | (HZ x 60) / 9 = Engine RPM | rpm | |
| Speed | Engine speed shutdown limit (PMA frequency high) | 4200 | rpm | greater than |
| Speed | Inverter shutdown limit for high output frequency | 4200 | rpm | engine speed greater than 4200 rpm |
| Speed | Low engine power condition | 2300 | rpm | below |
| Speed | Low engine power threshold | 2300 | rpm | engine speed below 2300 rpm |
| Temperature | Inverter over-temperature threshold | 70 | C | inverter temperature detected to be over 70 C |
| Temperature | Maximum inverter temperature | 70 | °C | |
| Temperature | Oil temperature switch closes | 220 C (428 F) | C | normally open (cold); closes at 220 C |
| Temperature | Oil temperature switch closing temperature | 220 | °C (428 °F) | normally open (cold) |
| Temperature | Rise over ambient (oil temperature) | 15 | °F | |
| Torque | DC cable terminal nuts | 10 | ft-lbs (14 N-m) | |
| Torque | DC cable terminal nuts | 10 ft-lbs (14 N-m) | ft-lb | |
| Torque | Engine harness connector screws | 10.6 | in-lbs (1.2 N-m) | |
| Torque | Engine harness connector screws | 10.6 in-lbs (1.2 N-m) | in-lb | |
| Torque | Engine mounting bracket bolts (to engine) | 14 | ft-lbs (19 N-m) | |
| Torque | Engine mounting bracket bolts (to engine) | 14 ft-lbs (19 N-m) | ft-lb | |
| Torque | Engine mounting isolator bolts (to generator set base) | 10 | ft-lbs (14 N-m) | |
| Torque | Engine mounting isolator bolts (to generator set base) | 10 ft-lbs (14 N-m) | ft-lb | |
| Torque | Exhaust clamp screws | 7.4 | ft-lbs (10 N-m) | |
| Torque | Exhaust clamp screws | 7.4 ft-lbs (10 N-m) | ft-lb | |
| Torque | Exhaust flange nuts at the engine | 18-22 ft-lbs (25-30 N-m) | ft-lb | use a new flange gasket |
| Torque | Exhaust isolator screws | 13 | ft-lbs (18 N-m) | |
| Torque | Exhaust isolator screws | 13 ft-lbs (18 N-m) | ft-lb | |
| Torque | Generator set mounting bracket to vehicle | 10 | ft-lbs (14 N-m) | |
| Torque | Generator set mounting bracket to vehicle | 14 | ft-lbs (19 N-m) | |
| Torque | Generator set mounting brackets and vibration isolators (Figure 4-1) | 10 ft-lbs (14 N-m) | ft-lb | |
| Torque | Generator set mounting brackets and vibration isolators (Figure 4-1) | 14 ft-lbs (19 N-m) | ft-lb | |
| Torque | Housing screws | 27 in-lbs (3 N-m) | in-lb | |
| Torque | Inverter isolator mounting screws | 8 | ft-lbs (11 N-m) | |
| Torque | Inverter isolator mounting screws | 8 ft-lbs (11 N-m) | ft-lb | |
| Torque | M10 1.5 Grade 8.8 | 52 | N.m (39 Ft-Lb) | |
| Torque | M10 1.5 grade 8.8 fastener | 52 N.m (39 ft-lb) | N.m | grade 8.8 |
| Torque | M12 1.75 Grade 8.8 | 84 | N.m (62 Ft-Lb) | |
| Torque | M12 1.75 grade 8.8 fastener | 84 N.m (62 ft-lb) | N.m | grade 8.8 |
| Torque | M6 1.0 Grade 8.8 | 11 | N.m (8 Ft-Lb) | |
| Torque | M6 1.0 grade 8.8 fastener | 11 N.m (8 ft-lb) | N.m | grade 8.8 |
| Torque | M8 1.125 Grade 8.8 | 23 | N.m (17 Ft-Lb) | |
| Torque | M8 1.125 grade 8.8 fastener | 23 N.m (17 ft-lb) | N.m | grade 8.8 |
| Torque | Outer housing screws | 27 | in-lbs (3 N-m) | |
| Torque | Outer housing screws | 27 in-lbs (3 N-m) | in-lb | |
| Valve clearance | Intake & exhaust valve lash | 0.004 in (0.1 mm) | in | cold |
| Valve clearance | Valve Lash: Intake & Exhaust | 0.004 | in (0.1 mm) | cold |
| Voltage | Battery voltage below minimum to start | 9 | VDC |
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
| Fluid | Grade | Standard | Ambient | Capacity | Notes |
|---|---|---|---|---|---|
| Engine oil | SAE 15W-40 (multi-grade recommended for year-round use) | API performance Class CH-4 or better | 1.1 liter | Choose 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 oil | SAE 15W-40 multi-grade recommended; API performance Class CF or better | API CF | 1.1 liter | Choose viscosity grade per oil viscosity vs. temperature chart (Figure 2-1) | |
| Fuel | Grade 2-D diesel; Grade 1-D when ambient temperatures are below freezing | ASTM D975 or EN 590; Cetane number at least 45 | Ultra 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
12Accessing Service Screens diagnostic
- Press Gen OFF.
- Hold down the START button and Display ON together.
- Release both buttons when RV QD 3200 is displayed.
- IMMEDIATELY press the START button 3 times; GEN OFF should be displayed.
- Press the START button again to start the generator set.
- Once started, press the START button to view the service screens.
- Use the START button to navigate through the service screens.
Accessing the Service Screens diagnostic
- Press Gen OFF.
- Hold down the START button and Display ON together.
- Release both buttons when RV QD 3200 is displayed.
- Immediately press the START button 3 times; GEN OFF should be displayed.
- Press the START button again to start the generator set.
- 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
- Disconnect the fuel supply line at the engine and direct the end into a 1 gallon (4 liter) container.
- Press the Display ON button on the Operator Panel to prime fuel (five minutes).
- Press the Gen OFF button to stop priming before the container fills up.
- 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
- 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
- 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.
- 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
- Disconnect the fuel supply line at the engine and direct the end into a 1 gallon (4 liter) container.
- Press the Display ON button on the Operator Panel to prime fuel (five minutes).
- Press the Gen OFF button to stop priming before the container fills up.
- 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.
- Place a pail under the oil drain plug.
- 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.
- Refill with approximately 0.7 quarts of oil, check oil level and secure the front access door.
- 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
- Park the vehicle on level ground, shut down the generator set and remove the front access door.
- Pull out the oil dipstick, wipe it clean, reinsert it and pull it out again to check the oil level.
- Add or drain oil as necessary; keep the oil level between the MIN / MAX marks.
- 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
- Remove the maintenance access door.
- Loosen the center screw of the strainer about five turns and withdraw the strainer from the engine block.
- Use compressed air to clean the strainer, blowing debris from inside out.
- Replace the O-rings or strainer if damaged.
- Lubricate the O-rings with clean oil and insert the strainer until it stops.
- Check for spring tension against the strainer and tighten the center screw.
- 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.
- Remove the cleanout plug on the bottom of the muffler.
- Start the generator set and load it nearly to full power; let it run about five minutes to expel the soot.
- 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.
- Remove the cleanout plug on the side of the spark arrestor canister.
- Start the generator set and load it nearly to full power. Let it run about five minutes to expel the soot.
- 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
- Keep the battery case and terminals clean and dry and the terminals tight.
- Use a battery terminal puller to remove cable clamps on post-type battery terminals.
- Tighten threaded-stud battery terminals as recommended by the battery manufacturer.
- Determine positive (+) and negative (-) terminals before making connections; always remove negative (-) cable first and reconnect it last.
Replacing the Air Filter Element maintenance
- Remove the filter cover.
- Unscrew the knurled nut and remove the old filter element.
- Clean dust and debris from the filter housing and install the new filter element.
- 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
6Symptoms & remedies
| Symptom | Cause | Remedy |
|---|---|---|
| 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 rpm | 1. 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/Repair | 1. Clear the Gen Wait message from the Operator Panel by cycling it off and on. Try starting again. 2. Check the fuel level and fill as necessary. 3. Press the stop switch (p. 2-2) if it is not in its “1” position. 4. Replace the fuel if it is not of the specified grade or suitable for the ambient temperature (p 2-1). 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) →
Repair guides
21- Accessing Service Screens
- Accessing the Service Screens
- Changing Engine Oil
- Checking Engine Oil Level
- Cleaning the Engine Oil Strainer
- Cleaning the Engine Oil Strainer
- Cleaning the Spark Arrestor
- Measuring Fuel Transfer Pump Flow
- PMA Tests
- Reassembling Engine/PMA Assembly
- Removing and Reinstalling the Engine/PMA Assembly
- Removing Engine/PMA Assembly
- Removing Generator Set — Disconnections
- Removing the Generator Set - Disconnections
- Replacing the Air Filter Element
- Replacing the Fuel Filter
- Returning the Generator Set to Service
- Starting the Generator Set
- Starting the Generator Set
- Storing the Generator Set
Step-by-step procedures compiled from the Cummins/Onan service manual for this model.
Parts
5| Part # | Description | Qty | System | |
|---|---|---|---|---|
| 140-4151I | Oil Filter | .11 quarts | Oil filter | Amazon eBay |
| 149-2834I | Air Filter | Air filter | Amazon eBay | |
| F102-1004 | Fuel Filter | 1 | Fuel filter | Amazon eBay |
| F102-1005 | Air Filter | 1 | Air filter | Amazon eBay |
| 500-4709 | OUTLINE DRAWING—SHEET 1 OF 2 | Service 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
| Rating | Load | L/h | gal/h |
|---|---|---|---|
| 0.76 | 0.2 | ||
| Full_load | 100% | 1.51 | 0.4 |
| Half_load | 50% | 0.79 | 0.21 |
| No_load | 0.49 | 0.13 | |
| Prime | 1.44 | 0.38 | |
| Prime | 25% | 1.3 | 0.3425 |
| Prime | 50% | 2.59 | 0.685 |
| Prime | 100% | 5.19 | 1.37 |
| Standby | 0.76 | 0.2 |
Available documents
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.