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7. vi
SAFETY PRECAUTIONS
Thoroughly read the OPERATOR’S MANUAL
before operating the Hybrid Quiet Diesel Pow-
er System (Hybrid Power System). Safe opera-
tion and top performance can only be obtained
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 genset Operator’s Manual.
Never sleep in the vehicle while the genset is
running unless the vehicle is equipped with a
working carbon monoxide detector.
Do not operate the genset when the vehicle
is parked in a confined space, such as a ga-
rage.
Disable the AGS feature of an inverter−char-
ger or other automatic starting device before
storing the vehicle or parking it in a garage or
other confined space.
The exhaust system must be installed in ac-
cordance with the genset Installation Manual.
Engine cooling air must not be used for heat-
ing the vehicle.
GENERATOR VOLTAGE IS DEADLY
Disable the automatic genset starting feature
(AGS) of an inverter−charger or other auto-
matic starting device before servicing the
genset to avoid electric shock from an unex-
pected start.
Generator electrical output connections must
be made by a trained and experienced elec-
trician in accordance with applicable codes.
The genset must not be connected to shore
power (utility). Back−feed to shore power can
cause electrocution and damage to equip-
ment. 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 genset starting feature
(AGS) of an inverter−charger or other auto-
matic starting device before servicing the
genset to avoid unexpected starting.
Do not wear loose clothing or jewelry near
moving parts such as PTO shafts, fans, belts
and pulleys.
Keep hands away from moving parts.
8. vii
Keep guards in place over fans, belts, pul-
leys, and other moving parts.
BATTERY GAS IS EXPLOSIVE
Before servicing the batteries, disconnect
Shore Power, push the Power Unit circuit
breaker OFF and turn the Coach DC Discon-
nect Switch to Disconnect (to power down the
Hybrid Power System).
Wear safety glasses.
Do not smoke.
Remove jewelry.
Observe proper battery cable connect/dis-
connect sequences.
Secure DC terminal protective covers to pre-
vent accidental shorting with metal tools.
IMPROPER CHARGING CAN OVERHEAT
COACH BATTERIES AND CAUSE FIRE
Do not mix old and new batteries or different types
of batteries. Reconfigure the Hybrid Power Sys-
tem for proper charging if battery type and bank
capacity have changed.
FLAMMABLE VAPORS CAN CAUSE
DIESEL ENGINES TO OVERSPEED
Do not operate the diesel-powered Hybrid Power
System where there are or can be flammable va-
pors created by fuel spills, gas leaks, etc. Flam-
mable vapors drawn into a diesel engine air intake
system can cause the engine to overspeed, which
can result in fire, explosion and equipment dam-
age. The owners and operators of the Hybrid
Power System are solely responsible for safe op-
eration.
COACH ELECTRICAL SYSTEMS CAN
IGNITE FLAMMABLE VAPORS
Disable AUTO and stop Generator Mode be-
fore fueling the coach to reduce the risk of ig-
niting flammable vapors.
Do not store liquid or gaseous fuel containers
in the same enclosures as the Inverter/Char-
gers, Transfer Switch, batteries or other
spark-producing equipment.
GENERAL PRECAUTIONS
Keep children away from Hybrid Power Sys-
tem components.
Do not use evaporative starting fluids. They
are highly explosive.
Let the engine cool down before removing
the coolant pressure cap or opening the cool-
ant drain. Releasing hot coolant under pres-
sure can lead to severe burns.
Keep the Hybrid Power System components
and their enclosures clean. Oil collects dirt
that can restrict cooling. Oily rags can catch
fire. Stowed gear can block cooling air.
Make sure all fasteners are secure and
torqued properly.
Do not perform Hybrid Power System mainte-
nance or service when mentally or physically
tired or after consuming alcohol or drugs.
You must be trained and experienced to
make adjustments while the Hybrid Power
System is in operation—hot, moving or elec-
trically 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.
Ethylene glycol, used as engine antifreeze, is
toxic to humans and animals. Clean up spills
and dispose of used engine coolant in accor-
dance with local environmental regulations.
Keep a multi-class ABC fire extinguisher in
the vehicle. 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. (ref. NFPA No. 10)
The Hybrid Power System installation must
comply with all applicable local, state and fed-
eral codes and regulations.
Engine exhaust gases include CARBON MON-
OXIDE (CO), an odorless, colorless, poisonous
gas that can cause severe personal injury or
death. Symptoms of CO poisoning include:
Mobile-9
9. 1-1
1. Introduction
ABOUT THIS MANUAL
This is the Service Manual for the Model HQDSB
Hybrid Quiet Diesel Power System (Hybrid Power
System), comprised of the following major compo-
nents:
Model HQDPB Power Unit
Model HQDVA Inverter/Charger (Primary)
Model HQDVB Inverter/Charger (Secondary)
Model HQDTA Transfer Switch
For specific information about the system and its
components, see Appendix F. Specifications.
Note: The Hybrid Power System will not work without
these components, nor with substitutes.
Read and carefully observe all of the instructions
and precautions in this manual.
To operate the Hybrid Power System, see Sec-
tion 2. Operating the Hybrid Power System.
The operator is responsible for Power Unit mainte-
nance in accordance with the PERIODIC MAINTE-
NANCE SCHEDULE (p. 3-7) and for battery main-
tenance in accordance with Section 7. Coach Bat-
teries.
To understand and use the Operator Panel and nav-
igate its menus, see Appendix A. Operator Panel.
For steps that can be taken to diagnose and correct
a problem that causes a warning or shutdown, see
Appendix B. Troubleshooting Symptoms and Ap-
pendix C. Troubleshooting Fault Codes.
WARNING The Hybrid Power System is not for
life support. 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 power system
operation is critical.
HYBRID POWER SYSTEM COMPONENT
NAMEPLATES
WARNING Improper service or replacement of
parts can lead to severe personal injury or death
and to damage to equipment and property. Ser-
vice personnel must be qualified to perform
electrical and mechanical service.
CAUTION Unauthorized modifications or re-
placement of fuel, exhaust, air intake or speed
control system components that affect engine
emissions are prohibited by law in the State of
California.
Be ready to provide the model, spec and serial num-
bers on the component nameplates when contact-
ing Cummins Onan for information, parts and ser-
vice. Figure 1-1 illustrates the nameplates and their
locations.
11. 1-3
ENGINE EMISSIONS COMPLIANCE
The label that states compliance with applicable en-
gine emissions regulations is located on the side of
the Power Unit, as shown circled in Figure 1-2. Re-
fer also to the FEDERAL EMISSION DESIGN AND
DEFECT LIMITED WARRANTY FOR C. I. EN-
GINES (DIESELS) that is part of the same package
as this manual.
FIGURE 1-2. EMISSIONS LABEL LOCATION
12. 1-4
FEATURES
The Hybrid Power System components are inte-
grated with Shore Power and the Coach Batteries to
comprise a complete Coach AC power supply sys-
tem. The Operator Panel is used to monitor, control
and configure the integrated power supply system.
The Hybrid Power System has the following fea-
tures:
Automatic Power Unit operation
Battery boost when transients or short term
loads (air conditioners) exceed Power Unit ca-
pacity
Battery charge shedding under high AC load
conditions
Accurate battery state of charge (SOC) moni-
toring based on battery temperature, current
and voltage
Battery charging at up to 140 amps DC in Model
1215 HQDSB systems, or up to 280 amps DC
in Model 1218 HQDSB systems
Power factor correction when charging
Shore power quality monitoring
Built-in system diagnostics
13. 1-5
MODES OF OPERATION
Modes of Operation
The Hybrid Power System has three modes of op-
eration:
Generator Mode
Inverter Mode
Shore Power Mode
Generator Mode
Power flows from the Power Unit to the two Inverter/
Chargers (one shown). The Inverter/Chargers con-
vert the dual 3-phase, variable-voltage, variable-
frequency output of the Power Unit into single-
phase, 120/240 volt, 60 Hertz AC power. During
power boost to start loads such as air conditioners,
the Inverter/Chargers also convert 12 volt DC from
the coach batteries into single-phase, 120/240 volt,
60 Hertz AC power to supplement output from the
Power Unit. The Transfer Switch connects the in-
coming power from the Inverter/Chargers to the
main AC distribution panel to supply all coach ap-
pliances, lights, power outlets and air conditioners.
While supplying the AC loads, the Inverter/Char-
gers also recharge the coach batteries with any
power still available from the Power Unit.
TRANSFER SWITCH
INVERTER / CHARGER
COACH
BATTERIES
3-PH
VARIABLE
HZ
/
V
120
V,
60
Hz
AC
12
V
DC
120 V, 60 Hz AC TO 30 AMP SUB-DISTRIBUTION PANEL
TO MAIN AC DISTRIBUTION PANEL
POWER UNIT
FIGURE 1-3. GENERATOR MODE
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15. 1-6
Inverter Mode
Power flows from the coach batteries to the two In-
verter/Chargers (one shown). The Inverter/Char-
gers convert 12 volt DC into 120 volt, 60 Hertz AC
power, which is distributed by two AC sub-distribu-
tion panels to most of the coach appliances, lights
and power outlets. (In Model 1215 HQDSB systems
only the Primary Inverter/Charger inverts battery
power.)
Inverting stops when battery charge is drawn down
to a preset low battery level.
TRANSFER SWITCH
12
V
DC
INVERTER / CHARGER
COACH
BATTERIES
120 V, 60 Hz AC TO 30 AMP SUB-DISTRIBUTION PANEL
POWER UNIT
FIGURE 1-4. INVERTER MODE
16. 1-7
Shore Power Mode
The Transfer Switch senses when the coach is con-
nected to shore power. Unless the Hybrid Power
System is in Generator Mode, the Transfer Switch
connects the incoming shore power to the main AC
distribution panel to supply all coach appliances,
lights, power outlets and air conditioners.
While shore power is supplying the AC loads, the
two Inverter/Chargers also recharge the coach bat-
teries with any power still available from Shore Pow-
er.(In Model 1215 HQDSB systems only the Primary
Inverter/Charger charges the batteries.)
TRANSFER SWITCH
INVERTER / CHARGER
COACH
BATTERIES
120 V, 60 Hz AC TO 30 AMP SUB-DISTRIBUTION PANEL
SHORE POWER TO MAIN AC DISTRIBUTION PANEL
120 V, 60 Hz AC FROM MAIN DISTRIBUTION PANEL
12
V
DC
POWER UNIT
FIGURE 1-5. SHORE POWER MODE
17. 2-1
2. Operating the Hybrid Power System
WARNING ENGINE EXHAUST IS DEADLY. En-
gine exhaust gases include CARBON MON-
OXIDE (CO), an odorless, colorless, poisonous
gas that can cause severe personal injury or
death. Symptoms of CO poisoning include:
Dizziness, Headache or Throbbing Temples
Weakness or Muscular Twitching
Sleepiness or Confusion
Nausea or Vomiting
IF YOU OR ANYONE ELSE EXPERIENCES ANY
OF THESE SYMPTOMS, GET OUT INTO FRESH
AIR IMMEDIATELY.
Get advice from 911, poison control or a medi-
cal center.
Do not enable AUTO or start Generator Mode
until the exhaust system has been repaired. Ex-
haust system installation must be in accor-
dance with the Hybrid Power System Installa-
tion Manual.
Do not enable AUTO or start Generator Mode
before going to sleep unless the coach has
working CO detectors.
Do not enable AUTO or start Generator Mode
unless the coach is out in fresh, open air.
Disable AUTO and stop Generator Mode when
parking the coach in a garage or other confined
space.
WARNING Disable AUTO and stop Generator
Mode before fueling the coach to prevent igni-
tion of flammable vapors.
PRE-START CHECKS
Before the first start of the day and after every eight
hours of operation in Generator Mode, inspect the
Power Unit as instructed under GENERAL IN-
SPECTIONS (p. 3-8). Also make sure that all car-
bon monoxide (CO) detectors are working.
EVERYDAY OPERATION
The Hybrid Power System is designed for AUTO op-
eration. When AUTO is enabled, power is suppled
in Generator, Inverter or Shore Power Mode, as ap-
propriate. AUTO is disabled each time you park or
move the coach. This gives YOU the opportunity to
confirm that AUTO operation is safe under the con-
ditions.
When you park the coach at a new site you will have
to decide about:
Enabling AUTO (p. 2-2)
Manually controlling Inverter Mode (p. 2-4)
Manually controlling Generator Mode (p. 2-5)
Connecting Shore Power (p. 2-6)
18. 2-2
ENABLING AUTO
To enable AUTO confirm that it is safe to do so and
then press Auto (Figure 2-1).
Note: See Page A-27 if either of these two prompts
appear: “Auto Mode Expires in (5, 4, 3, 2, or 1) days”
or “Safety Input Expired.”
Quiet Time
Note the Quiet Times displayed on the CONFIRM
AUTO screen. Reset and enable/disable as neces-
sary (p. A-5). Then select CONFIRM AUTO and
press OK.
Current Time
If the time zone has changed, press Clock to reset
(p. A-6). Otherwise, Quiet Time will start and end
earlier or later than expected.
Normal Operation
When you press OK the Auto and Inverter lights
come on and power becomes available right away
for most coach appliances, lights and power outlets.
From time to time the Inverter light will go out and
the Generator light will come on, indicating that
AUTO has switched to Generator Mode to recharge
the coach batteries or power the air conditioners.
You should hear the Power Unit engine crank, start
and run.
Once the batteries have been recharged and the air
conditioners have cycle off, AUTO switches
operation back to Inverter Mode. AUTO switching
from Inverter Mode to Generator Mode and back
again takes place without power interruption.
If Quiet Time has been enabled, AUTO will switch to
Generator Mode as far ahead of time as necessary
(could be several hours) to fully charge the batteries
for the upcoming Quiet Time.
See Page 7-1 about battery charging and go to Bat-
tery Status (p. A-9) to find out how many hours it will
take.
QUIET TIMES:
10:00 PM − 07:00 AM
11:00 AM − 03:00 PM
SET QUIET TIMES
CONFIRM AUTO
FIGURE 2-1. CONFIRM AUTO SCREEN
19. 2-3
Generator Mode Screen
When the Generator light comes on, the home
screen displays AC voltage, the current in each line
and the state of charge of the coach batteries (Fig-
ure 2-2). The arrow in the battery icon points up
when the coach batteries are being charged and
down when they are being discharged to provide
boost for starting loads such as the air conditioners.
Inverter Mode Screen
When the Inverter light comes on, the Inverter Mode
screen displays AC voltage and current output from
each Inverter/Charger (Line 1 and Line 2) and the
state of charge of the coach batteries (Figure 2-3).
The arrow in the battery icon points down because
the coach batteries are being discharged as power
flows from them.
Press Menu for more information about the status of
the Hybrid Power System. See Page A-8.
Moving the Coach
To prevent disruption of Generator Mode when it is
time to move the coach (turning the ignition key or
releasing the parking brake disables AUTO), first
exit AUTO. To do this, press Manual, select EXIT
AUTO MODE (Figure 2-4) and press OK.
Generator Mode will stay on while driving until
manually turned OFF.
Voltage 119V
Line 1 25A
Line 2 15A
Batt 85%
AUTO 1:23 PM
FIGURE 2-2. TYPICAL GENERATOR MODE
SCREEN
Voltage 119V
Line 1 25A
Batt 85%
AUTO 1:23 PM
Line 2 15A
FIGURE 2-3. TYPICAL INVERTER MODE SCREEN
TURN INVERTER ON
TURN GENSET ON
TURN ALL ON
MANUAL CONTROL
TURN INVERTER ON
EXIT AUTO MODE
FIGURE 2-4. EXIT AUTO MODE SCREEN
20. 2-4
INVERTER MODE—MANUAL CONTROL
You may want to start Inverter Mode if the coach
batteries have been recharged but shore power is
not available and engine noise or the possible
hazard of CO is a concern.
Starting Inverter Mode
To start Inverter Mode, press Manual, select
TURN INVERTER ON (Figure 2-5) and press OK.
Normal Operation
When you press OK, the Inverter light comes on and
power becomes available right away for most coach
appliances, lights and power outlets. If the Low
Battery light comes on, power will be available for a
limited time. Go to the Battery Status screen (p. A-9)
to find out how many hours are left at current usage.
You may have to reduce the number of appliances
being used during the time Generator Mode and
Shore Power Mode are not available.
Inverter Mode Screen
When the Inverter light comes on, the Inverter Mode
screen displays AC voltage and current output from
each Inverter/Charger (Line 1 and Line 2) and the
state of charge of the coach batteries (Figure 2-3).
The arrow in the battery icon points down because
the coach batteries are being discharged as power
flows from them.
Press Menu for more information about the status of
the Hybrid Power System. See Page A-8.
Stopping Inverter Mode
To stop Inverter Mode, press Manual, select
TURN INVERTER OFF and press OK.
When Generator or Shore Power Mode
Becomes Available
Switching to Generator Mode or to Shore Power
Mode from Inverter Mode takes place without power
interruption.
TURN INVERTER ON
TURN GENSET ON
EXIT AUTO MODE
TURN ALL ON
MANUAL CONTROL
TURN INVERTER ON
FIGURE 2-5. MANUAL CONTROL SCREEN
Voltage 119V
Line 1 25A
Batt 85%
MANUAL 2:13 PM
Line 1 15A
FIGURE 2-6. MANUAL INVERTER MODE SCREEN