JuiceBoxt Operator’s Manual Printed in U.S.A. 914-0104 11−2006 Table of Contents TITLE PAGE SAFETY PRECAUTIONS. iii SECTION 1. INTRODUCTION. 1-1 About This Manual. 1-1 How to Obtain Service. 1-1 Overview. 1-2 SECTION 2. TRANSPORTATION AND OPERATION. 2-1 Hitch Requirements. 2-1 Transporting the JuiceBox. 2-1 Installing the Hitch Spline. 2-1 Installing the JuiceBox. 2-2 Removing the JuiceBox and Hitch Spline from the Vehicle/Trailer. 2-3 JuiceBox Setup. 2-4 Gasoline Fuel System. 2-4 Propane Fuel System. 2-6 Preparing the JuiceBox for Transportation (Pack-Up). 2-7 Gasoline Fuel System. 2-7 Propane Fuel System. 2-7 Operation. 2-8 Genset Control. 2-8 Remote Control. 2-8 Battery Charger. 2-8 SECTION 3. PARTS INFORMATION. 3-1 i THIS PAGE INTENTIONALLY BLANK ii Safety Precautions Thoroughly read this manual and the generator S Benzene and lead found in some gasolines set Operator’s Manual, Battery Charger Manu- have been identified by some state and federal als, and EC-15W Instruction Sheet before using agencies as causing cancer or reproductive the JuiceBox or operating the generator set. toxicity. Do not to ingest, inhale, or contact gas- Safe operation and top performance can be ob- oline or its vapors. tained only when equipment is operated and S Used engine oil has been identified by some maintained properly. state and federal agencies as causing cancer The following symbols in this manual alert you to po- or reproductive toxicity. Do not ingest, inhale, or tential hazards to the operator, service person and contact used oil or its vapors. equipment. S Do not store anything on the generator set, such as oil cans, oily rages, chains, or wooden DANGER alerts you to an immediate hazard bocks. A fire could result or operation could be which will result in severe personal injury or adversely affected. death. S Keep the genset and its compartment clean. WARNING alerts you to a hazard or unsafe Excess oil can catch fire. Dirt and gear stowed practice which can result in severe personal in- in the compartment can restrict cooling air. jury or death. S Do not work on the genset when mentally or CAUTION alerts you to a hazard or unsafe physically fatigued or after consuming alcohol practice which can result in personal injury or or drugs. equipment damage. ENGINE EXHAUST IS DEADLY! Electricity, fuel, exhaust, moving parts, and batter- S Operate the generator set outdoors only. Stay ies present hazards which precautions must be tak- away from the exhaust outlet. en to prevent severe personal injury or death. S Make sure the generator set exhaust will not GENERAL PRECAUTIONS enter windows, doors, vents, or air intakes of adjacent vehicles, buildings, or boats. S When used in conjunction with a recreational vehicle, a functional CO detector is strongly S NEVER USE THE GENERATOR SET INSIDE recommended. a home, garage, crawl space, barn, shed, cab- S in, boat, boat house, RV, or tent. Never use the Keep children away from the JuiceBox and the generator set in a confined outdoor space such generator set. as an alley, ditch, parking garage, or courtyard, S Keep multi-class ABC fire extinguishers handy. or in any other space where exhaust can accu- Class A fires involve ordinary combustible ma- mulate. Note that HAZARDOUS CARBON terials such as wood and cloth; Class B fires, MONOXIDE LEVELS FROM ENGINE EX- combustible and flammable liquid fuels and HAUST CAN ACCUMULATE INDOORS gaseous fuels; Class C fires, live electrical EVEN WHEN ALL WINDOWS AND DOORS equipment. (ref. NFPA No. 10). ARE OPEN AND FANS ARE RUNNING. iii FUEL IS FLAMMABLE AND EXPLOSIVE! must make electrical connections when the generator set is used for emergency power. S Gasoline and LPG are highly flammable and explosive and can cause severe personal inju- S Never operate the generator set in rain or snow ry or death. Do not smoke or turn electrical or when it is sitting on wet ground. switches ON or OFF where fuel fumes, tanks or S Make sure clothing, shoes, and skin are dry equipment are present. Keep flames, sparks, when handling electrical equipment. pilot lights, arc-producing equipment and switches and all other sources of ignition well S Use caution when working on live electrical away. Keep a type ABC fire extinguisher handy. equipment. Remove jewelry, make sure cloth- S ing and shoes are dry, stand on a dry wooden Refill the fuel tank outdoors only. platform or rubber insulating mat and use tools S Never fill the fuel tank while it is connected to with insulated handles. the generator set. MOVING PARTS CAN CAUSE SEVERE S DO NOT fill the fuel tank while the engine is run- ning. A hot engine can ignite the fuel. PERSONAL INJURY OR DEATH S S Static electric sparks caused by fuel flowing Before performing any maintenance on the through a service station pump nozzle can ig- generator set, disconnect the negative (−) nite gasoline. Set the fuel tank on the ground cable from the battery and disconnect the re- and slowly fill it. mote harness cable at the genset to prevent ac- cidental starting. S Do not smoke or allow an open flame near the S generator set. Keep flame, sparks, pilot lights, Do not wear loose clothing or jewelry while ser- arc-producing equipment and switches and all vicing the generator set. Loose clothing and other sources of ignition well away. jewelry can become caught in moving parts. Jewelry can short out electrical contacts, caus- S Fuel lines must be secured, free of leaks, and ing sparks, flame, and electrical shock. separated or shielded from electrical wiring. S Keep hands away from moving parts. S Leaks can lead to explosive accumulations of S gas. LPG sinks when released and can accu- Keep guards in place over fans, belts, pulleys, mulate inside housings and basements and and other moving parts. other below-grade spaces. Prevent leaks and S Make sure that fasteners and clamps on the the accumulation of gas. generator set are tight. Keep guards in position over fans, rotors, etc. GENERATOR VOLTAGE IS DEADLY! S DO NOT CONNECT THE GENERATOR SET BATTERY GAS IS EXPLOSIVE DIRECTLY TO ANY BUILDING ELECTRICAL S Wear safety glasses when servicing batteries. SYSTEM OR ANY OTHER SOURCE OF S ELECTRICAL POWER. Back-feed could Do not smoke. cause electrocution of utility line workers and S To reduce arcing when disconnecting or recon- damage to equipment. An approved switching necting battery cables, always disconnect the device must be used to prevent interconnec- negative (−) battery cable first and reconnect it tions. A trained and experienced electrician last. iv Section 1. Introduction ABOUT THIS MANUAL NOTE: When checking the oil level in the generator, make sure the generator is level to get the This manual provides information for operating and most accurate reading. Checking the oil lev- maintaining the JuiceBoxt. el when the JuiceBox is setting on an un- even surface or when it is connected to the A separate genset Operator’s Manual is included vehicle’s hitch and lifted off of the ground will with each unit. It contains information on operating not give an accurate reading and may result and maintaining the generator set. Separate docu- in oil running out of the dipstick hole. If the ments are also included for the Energy Command JuiceBox is connected to the vehicle’s hitch ED-15W wireless remote control and the battery and lifted off of the ground, move the vehicle charger. Study all manuals carefully and comply to a location with the appropriate incline so with all warnings and cautions before disconnect- that the generator is level before checking ing/connecting the JuiceBox from/to the vehicle’s the oil level. hitch or operating the equipment inside of the Juice- Box. See Section 3 of this manual for parts identification numbers and required quantities and for exploded Because the JuiceBox includes an installed gener- views of the JuiceBox subassemblies. Genuine ator set, this manual supersedes the installation in- Onan® replacement parts are recommended for structions included in the genset Installation Manu- best results. al. HOW TO OBTAIN SERVICE When the JuiceBox or the generator set requires service, contact your nearest dealer or distributor. Factory-trained Parts and Service representatives are ready to handle all your service needs. A copy of the warranty form is in the literature pack- age included with each unit. A generator service manual is available on special order through an Onan dealer or distributor. When contacting an authorized service center con- cerning genset parts or service issues, supply the complete model number and serial number listed on the nameplate (Figure 1-1). 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. [THE ENGINE FAMILY DESIGNATION, ENGINE DISPLACEMENT, STATEMENT OF COMPLIANCE WITH THE APPLICABLE EPA AND / OR CALIFORNIA EMISSIONS REGULATIONS, INCLUDING THE COMPLIANCE PERIOD OR CATEGORY, APPEAR IN THIS BLOCK ON THE ACTUAL NAMEPLATE ON THE GENSET.] FIGURE 1-1. TYPICAL NAMEPLATE CopyrightE 2006 Cummins Power Generation. All rights reserved. Onan is a registered trademark of Cummins Inc. JuiceBox is a trademark of Cummins Inc. 1-1 OVERVIEW • Control Panel − Includes the following (see Figure 1-3). The JuiceBox (see Figure 1-2) is a self-contained, hitch-mounted towable portable power source that − 30 amp receptacle includes the following. − Two 20 amp 120 volt GFI protected out- lets • MicroQuiet 4000 KY (gasoline) or 3600 KY (LP) Generator Set − Refer to the separate − Two 20 amp 120 volt outlets generator set Owner’s Manual for details.