Operator Manual RV Generator Set HGJAA HGJAB HGJAC English 1−2009 983−0101 (Issue 3)
! ! The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
Table of Contents SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions • Before working on the genset, disconnect the negative (−) battery cable at the battery to prevent accidental starting. Thoroughly read the OPERATOR’S MANUAL before operating the genset. Safe operation and top performance can only be obtained when equipment is operated and maintained properly. • Use caution when making adjustments while the genset is running—hot, moving or electrically live parts can cause severe personal injury or death.
ENGINE EXHAUST IS DEADLY! accumulate under hoods and inside housings and buildings. LPG sinks when released and can accumulate inside housings and basements and other below-grade spaces. Prevent leaks and the accumulation of gas. • Learn the symptoms of carbon monoxide poisoning in this manual and never sleep in the vehicle while the genset is running unless the vehicle is equipped with a working carbon monoxide detector.
Introduction ABOUT THIS MANUAL This manual covers the operation and maintenance of the HGJAA, HGJAB and HGJAC Series of generator sets (gensets). Each operator should study this manual carefully and observe all of its instructions and safety precautions. Keep this manual and the Installation Manual with the other vehicle manuals. Operation, Periodic Maintenance and Troubleshooting provide the instructions necessary for operating the genset and maintaining it at top performance.
TYPICAL GENSET If the cover pins and rubber grommets do not line up, check that the edging on the top edge of the base tray lies flat and is pushed down all the way. Figure 2 illustrates a typical self-enclosed genset with the maintenance access cover removed. If the cover feels loose, one of the rubber grommets probably pushed through. If so, remove the cover, insert the grommet back into its hole and try again. Removing the access cover: Pull the top of the cover outward and lift it away.
FUEL RECOMMENDATIONS ENGINE OIL RECOMMENDATIONS WARNING Gasoline and LPG are highly flammable and explosive and can cause severe personal injury or death. Do not smoke or turn electrical switches ON or OFF where fuel fumes, tanks or equipment are present or in areas sharing ventilation. Keep flames, sparks, pilot lights, arc-producing equipment and switches and all other sources of ignition well away. Keep a type ABC fire extinguisher in the vehicle.
GENSET CONTROL PANEL The genset control panel (Figure 3) is located behind the maintenance access cover (Figure 2) and has the following features: Control Switch − This switch is used to prime the fuel system, start and stop the genset and display the fault code. Hold the switch in its START position to crank and start the genset. Press the switch to its STOP position to stop the genset. Hold the switch in its STOP/PRIME position (starts in 2 seconds) to prime the fuel system (gasoline models only).
Operation WARNING EXHAUST GAS IS DEADLY! Exhaust gases contain carbon monoxide, an odorless, colorless gas. Carbon monoxide is poisonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning include: • • • Dizziness Muscular Twitching Weakness and Sleepiness • • • Throbbing in Temples Headache Inability to Think Clearly • • Nausea Vomiting IF YOU OR ANYONE ELSE EXPERIENCES ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY.
TABLE 2. TYPICAL APPLIANCE LOADS 5. See Troubleshooting (Page 22) if the engine shuts down and the status indicator light blinks. Appliance Air Conditioner Battery Charger DC Converter Refrigerator Microwave Oven Electric Frying Pan or Wok Electric Stove Element Electric Water Heater Electric Iron Electric Hair Dryer Coffee Percolator Television Radio Electric Drill Electric Broom Electric Blanket 6. Always secure the access cover after starting the genset at the genset control panel.
RESETTING CIRCUIT BREAKERS If a circuit breaker in the main power distribution panel of the vehicle or on the genset (Figure 7) trips, either a circuit shorted or too many appliances were running. Note that the genset may continue to run after a circuit breaker trips. If a circuit breaker trips, disconnect or turn off as many loads as possible and reset the circuit breaker. (Push the circuit breaker to OFF to reset it and then to ON to reconnect the circuit.
OPERATING IN COLD WEATHER Pay particular attention to the following items when operating the genset in cold weather: 1. Make sure engine oil viscosity is appropriate for the ambient temperatures. Change oil if there is a sudden drop in temperature. See ENGINE OIL RECOMMENDATIONS (Page 6). 2. Perform spark plug maintenance (Page 20). 3. Perform battery maintenance (Page 19). 4. If so equipped, reset the carburetor for altitude (Figure 8).
OPERATING IN DUSTY ENVIRONMENTS carburetor and removes oxides from electrical contacts and generator slip rings. The result is better starting, more reliable operation and longer engine life. Pay particular attention to the following items when operating the genset in dusty environments: 1. Do not let dirt and debris accumulate inside the genset compartment. Keep the genset clean. STORING THE GENSET 2. Perform air cleaner maintenance more often (Page 19).
4. Gasoline Models with Carburetor − Drain the carburetor float bowl (Figure 9) into a container and dispose of the fuel in accordance with local environmental regulations. Draining the float bowl prevents deposits of gum from clogging the tiny passages in the carburetor as the gasoline in the bowl evaporates during storage. 5. High Pressure LPG Models − Open the LPG oil drain valve (Figure 10) to drain the oil-like substance visible in the clear plastic drain hose.
7. Gasoline Models − Prime the genset fuel system by holding the control switch at STOP/ PRIME for 30 seconds. (The status indicator light will stay on solid while the pump is on.) Returning Genset to Service 1. Check the oil tag on the genset and change the oil if the viscosity indicated is not appropriate for the temperatures expected. See ENGINE OIL RECOMMENDATIONS (Page 6). 8. High Pressure LPG Models − Make sure the LPG oil drain valve (Figure 10, Page 13) is closed. 2.
Periodic Maintenance Periodic maintenance is essential for top performance and long genset life. Use Table 4 as a guide for normal periodic maintenance. In hot and dusty environments some maintenance procedures should be performed more frequently, as indicated by the footnotes in the table. Keeping a log of maintenance performed and hours run will help you keep genset maintenance regular and provide a basis for supporting warranty claims (Page 33).
CONDUCTING GENERAL INSPECTIONS WARNING Do not park the vehicle in high grass or brush. Contact with the exhaust system can cause a fire. Inspect the genset before the first start of the day and after every eight hours of operation. Fuel System Oil Level Check for leaks at the hose, tube and pipe fittings in the fuel supply and return systems while the genset is running and while it is stopped. Do not use a flame to check for LPG leaks. Check flexible fuel hose sections for cuts, cracks, and abrasions.
Mechanical Look for mechanical damage. Start the genset and look, listen and feel for any unusual noises and vibrations. Check the genset mounting bolts to make sure they are secure. Check to see that the genset air inlet and outlet openings are not clogged with debris or blocked. Clean accumulated dust and dirt from the genset. Do not clean the genset while it is running or still hot. Protect the generator, air cleaner, control panel, and electrical connections from water, soap and cleaning solvents.
CHANGING ENGINE OIL AND OIL FILTER 4. Spin off the old oil filter and thoroughly wipe off the filter mounting surface. Remove the old gasket if it does not come off with the filter. WARNING State and federal agencies have determined that contact with used engine oil can cause cancer or reproductive toxicity. Try to avoid skin contact and breathing of vapors. Use rubber gloves and wash exposed skin. 5.
MAINTAINING BATTERY AND BATTERY CONNECTIONS 2. Remove battery cables with a battery terminal puller. 3. Make sure which terminal is positive (+) and which is negative (−) before making battery connections, always removing the negative (−) cable first and reconnecting it last to reduce arcing.
REPLACING SPARK PLUGS plug that fouls frequently or has heavy soot deposits indicates the need for engine service. See Troubleshooting (Page 22). Refer to Table 4 for scheduled spark plug replacement. (The genset has two spark plugs, Figure 14.) The spark plugs must be in good condition for proper engine starting and performance. A spark To prevent cross threading, always thread a spark plug in by hand until it seats and then torque to 10 lbs-ft (13 N-m). SPARK PLUGS FIGURE 14.
CLEANING THE SPARK ARRESTOR Refer to Table 4 for scheduled cleaning of the spark arrestor muffler. Cleaning is required for maximum genset performance. Park the vehicle away from grass, brush or debris that could be ignited by sparks expelled during this procedure. WARNING A hot muffler can cause severe burns. Let the muffler cool down before removing or installing cleanout plugs or screens. CLEANOUT PLUG Series HGJAA: A double-drum muffler is mounted inside the genset.
Troubleshooting Hot engine parts can cause severe burns. Always allow the engine time to cool before performing any maintenance or service. fault shutdown, the indicator light will repeatedly blink 2, 3 or 4 blinks at a time. TABLE 5. TROUBLESHOOTING lists the Fault Codes in numerical order along with step-by-step corrective actions. If you are unable to resolve the problem after taking the corrective actions suggested, contact an authorized Onan dealer. See How to Obtain Service (Page 32).
TABLE 5. TROUBLESHOOTING (CONT.) WARNING Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. STARTING BATTERIES RUN DOWN (Marginal batteries, connections, or charging system or, parasitic loads) Corrective Action: 1.
TABLE 5. TROUBLESHOOTING (CONT.) WARNING Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. OVERCRANK FAULT—CODE NO. 4 (First-level fault code—Cranking exceeded 30 seconds without engine starting) Corrective Action: 1. Gasoline Models − Check and fill the fuel tank, as necessary.
TABLE 5. TROUBLESHOOTING (CONT.) WARNING Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. GOVERNOR ACTUATOR FAULT—CODE NO. 19 (Controller sensed open or shorted circuit) Corrective Action: See an authorized Onan dealer. GOVERNOR ACTUATOR OVERLOAD FAULT—CODE NO.
TABLE 5. TROUBLESHOOTING (CONT.) WARNING Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. LOW CRANKING SPEED FAULT—CODE NO. 32 (Cranking speed less than 180 rpm for more than 2 seconds) Corrective Action: 1.
TABLE 5. TROUBLESHOOTING (CONT.) WARNING Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. OVERCURRENT (FIELD OVERLOAD) FAULT—CODE NO. 38 (Low power factor loads) Corrective Action: 1.
TABLE 5. TROUBLESHOOTING (CONT.) WARNING Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform genset service. See Safety Precautions. PROCESSOR FAULT—CODE NO. 51 (Microprocessor malfunction) Corrective Action: See an authorized Onan dealer. FUEL INJECTOR FAULT—CODE NO.
Specifications GASOLINE MODELS 7.0 HGJAA 7.0 HGJAB 7.0 HGJAC 5.5 HGJAA 5.5 HGJAB 5.5 HGJAC GENERATOR: 2-Pole Revolving Field, 2-Bearing, Self-Excited, 1-Phase, Vertical Shaft, Capped Digital Voltage Regulation Power 7000 watts 5500 watts Frequency 60 Hertz 60 Hertz Voltage 120 volts 120 volts Current 58.3 amp 45.8 amp Speed 3600 rpm 3600 rpm FUEL CONSUMPTION: No load 0.43 gph (1.6 l/h) 0.43 gph (1.6 l/h) 0.43 gph (1.6 l/h) 0.34 gph (1.3 l/h) 0.35 gph (1.3 l/h) 0.35 gph (1.
LPG MODELS 6.5 HGJAA 6.5 HGJAB 6.5 HGJAC 5.5 HGJAA 5.5 HGJAB 5.5 HGJAC GENERATOR: 2-Pole Revolving Field, 2-Bearing, Self-Excited, 1-Phase, Vertical Shaft, Capped Digital Voltage Regulation Power 6500 watts 5500 watts Frequency 60 Hertz 60 Hertz Voltage 120 volts 120 volts Current 54.2 amp 45.8 amp Speed 3600 rpm 3600 rpm FUEL CONSUMPTION: No load 2.2 lbs/h (1.0 kg/h) 2.2 lbs/h (1.0 kg/h) 2.2 lbs/h (1.0 kg/h) 1.8 lbs/h (0.8 kg/h) 1.8 lbs/h (0.8 kg/h) 1.8 lbs/h (0.
Information for California Genset Users This genset meets the requirements of California’s Exhaust Emissions Standards as stated on the nameplate. Figure 1 (Page 4) illustrates where this information appears on the nameplate. You should carefully review Operator (Owner), Installation and other manuals and information you receive with your genset. If you are unsure that the installation, use, maintenance or service of your genset is authorized, you should seek assistance from an approved Onan dealer.
How to Obtain Service When you need service, parts, or product literature (such as the Service Manual) for your genset, contact the nearest authorized distributor. Onan has factory-trained representatives to handle your needs for genset parts and service. 4:00 PM, Central Standard Time, Monday through Friday, or fax 1−763−528−7229. Call 1-800-888-ONAN to contact the nearest Cummins/Onan or Onan-only distributor in the United States or Canada. (This automated service utilizes touch-tone phones only).
Maintenance Record Record all periodic and unscheduled maintenance and service. See Periodic Maintenance (Page 15). DATE HOUR METER READING MAINTENANCE OR SERVICE PERFORMED Record the name, address, and phone number of your authorized Onan service center.
Cummins Power Generation 1400 73rd Ave. NE Minneapolis, MN 55432 USA Phone 1 763 574 5000 Toll-free 1 800 888 6626 Fax 1 763 574 5298 Email www.cumminsonan.com/contact www.cumminsonan.com CumminsR, OnanR, the “C” logo, and “Performance you rely on.” are trademarks of Cummins Inc. E2009 Cummins Power Generation, Inc. All rights reserved.
