CUMMINS HGJAC, HGJAA, HGJAB Installation Manual
Installation Manual
RV Generator Set
HGJAA (Spec A-E)
English
Original Instructions
HGJAB (Spec A-E)
HGJAC (Spec A-D)
7-2011 983-0600 (Issue 10)
Table of Contents
1. SAFETY PRECAUTIONS .............................................................................................................. 1
1.1 Gasoline and Propane Are Flammable and Explosive ........................................................... 1
1.2 Engine Exhaust is Deadly....................................................................................................... 1
1.3 Generator Voltage is Deadly................................................................................................... 2
1.4 Moving Parts Can Cause Severe Personal Injury or Death ................................................... 2
1.5 Battery Gas is Explosive......................................................................................................... 2
1.6 General Precautions ............................................................................................................... 2
2. INTRODUCTION............................................................................................................................ 5
2.1 About this Manual................................................................................................................... 5
2.2 Installation Codes and Standards for Safety .......................................................................... 5
2.3 Outline Drawings..................................................................................................................... 6
2.4 Lifting and Handling Genset ................................................................................................... 6
3. LOCATION, MOUNTING AND VENTILATION .............................................................................. 9
3.1 Location .................................................................................................................................. 9
3.2 Heat, Fire and Exhaust Barriers ........................................................................................... 10
3.2.1 Insulating Materials ...................................................................................................... 10
3.2.2 Fire and Exhaust Barriers ............................................................................................ 10
3.2.3 Thermal Insulation for Model HGJAC—Below-Floor Mounted .................................... 10
3.2.4 Thermal Insulation for Model HGJAC—Above-Floor Mounted .................................... 10
3.3 Mounting ............................................................................................................................... 10
3.3.1 Mounting Structure and Hardware ............................................................................... 10
3.3.2 Below-Floor Mounting .................................................................................................. 11
3.4 Ventilation ............................................................................................................................. 11
4. EXHAUST CONNECTIONS......................................................................................................... 13
4.1 Muffler—Models HGJAA / HGJAB........................................................................................ 13
4.2 Muffler—Model HGJAC ........................................................................................................ 14
4.3 Tail Pipe ................................................................................................................................ 15
5. FUEL CONNECTIONS................................................................................................................. 19
5.1 Gasoline—Model HGJAA (EFI) ............................................................................................ 19
5.1.1 Remote Fuel Pump Kit................................................................................................. 19
5.1.2 Fuel Tank ..................................................................................................................... 20
5.1.3 Fuel Supply Line Pump to Genset ............................................................................... 20
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Table of Contents 7-2011
5.1.4 Vapor and Fuel Return Line Requirements ................................................................. 21
5.1.5 Routing Fuel Lines....................................................................................................... 22
5.2 Gasoline—Models HGJAB/HGJAC ...................................................................................... 22
5.2.1 Fuel Tank ..................................................................................................................... 22
5.2.2 Fuel Lines .................................................................................................................... 23
5.2.3 Routing Fuel Lines....................................................................................................... 24
5.3 Evaporative system installation ............................................................................................ 24
5.3.1 System Components.................................................................................................... 25
5.3.2 Fuel Tank ..................................................................................................................... 25
5.3.3 Carbon Canister........................................................................................................... 26
5.3.4 Carburetor Fuel System Generator Sets ..................................................................... 29
5.3.5 Fuel Injection (EFI) System Generator Sets ................................................................ 29
5.3.6 Fuel Hoses................................................................................................................... 31
5.4 Low Pressure Propane Supply (Vapor Withdrawal) ............................................................. 31
5.5 High Pressure Propane Supply (Liquid Withdrawal) ............................................................ 33
6. ELECTRICAL CONNECTIONS.................................................................................................... 35
6.1 AC Power Output Connections............................................................................................. 35
6.1.1 Wiring Methods ............................................................................................................ 35
6.1.2 Connecting Shore Power............................................................................................. 36
6.2 Remote Control Connections................................................................................................ 37
6.3 Battery Connections.............................................................................................................. 40
6.3.1 Battery Compartment................................................................................................... 40
6.3.2 Battery Cables ............................................................................................................. 41
6.3.3 Battery Cable Connections at Genset ......................................................................... 42
6.3.4 Genset (Equipment) Grounding Screw ........................................................................ 42
7. INSTALLATION REVIEW AND STARTUP .................................................................................. 45
7.1 Hot Air Recirculation Test ..................................................................................................... 45
7.1.1 Test Method ................................................................................................................. 45
7.1.2 Test Requirement ........................................................................................................ 46
7.2 Installation Review ................................................................................................................ 46
7.3 Startup .................................................................................................................................. 47
8. SPECIFICATIONS ....................................................................................................................... 49
APPENDIX A. WIRING DIAGRAMS................................................................................................. 53
Wiring Diagrams.......................................................................................................................... 55
APPENDIX B. OUTLINE DRAWINGS .............................................................................................. 57
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7-2011 Table of Contents
Outline Drawings ......................................................................................................................... 59
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iv 983-0600 (Issue 10)
1 Safety Precautions
Thoroughly read the OPERATOR'S MANUAL before operating the genset. Safe operation
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
injury or death.
CAUTION: alerts you to a hazard or unsafe practice that can result in personal injury or
equipment damage.
Electricity, fuel, exhaust, moving parts and batteries present hazards which can result in severe
personal injury or death.
1.1 Gasoline and Propane Are Flammable and Explosive
· 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.
· Leaks can lead to explosive accumulations of gas. LPG sinks when released and can
accumulate inside housings and basements and other below-grade spaces. Prevent leaks
and the accumulation of gas.
1.2 Engine Exhaust is Deadly
· Inspect for exhaust leaks at every startup and after every eight hours of running.
· Prior to every startup and after every eight hours of running, all carbon monoxide detectors
must be tested and confirmed to be working in accordance with the manufacture's
instructions or owners manual.
· Learn the symptoms of carbon monoxide poisoning in the genset Operator's Manual.
· Never occupy 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
garage.
· Disable the automatic genset starting feature (AGS) of an inverter-charger 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 accordance with the genset Installation Manual.
983-0600 (Issue 10) 1
1. Safety Precautions 7-2011
· Engine cooling air must not be used for heating the vehicle.
1.3 Generator Voltage is Deadly
· Disable the automatic genset starting feature (AGS) of an inverter-charger or other
automatic starting device before servicing the genset.
· Generator electrical output connections must be made by a trained and experienced
electrician 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 equipment. 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.
1.4 Moving Parts Can Cause Severe Personal Injury or Death
· Disable the automatic genset starting feature (AGS) of an inverter-charger or other
automatic starting device before servicing the genset.
· Do not wear loose clothing or jewelry near moving parts such as PTO shafts, fans, belts
and pulleys.
· Keep hands away from moving parts.
· Keep guards in place over fans, belts, pulleys, and other moving parts.
1.5 Battery Gas is Explosive
· Wear safety glasses.
· Do not smoke.
· To reduce arcing when disconnecting or reconnecting battery cables, always disconnect
the negative (-) battery cable first and reconnect it last.
1.6 General Precautions
· Keep children away from the genset.
· To prevent accidental or remote starting while working on the genset, disconnect the
negative (-) battery cable at the battery.
· Keep the genset and its compartment clean. Excess oil and oily rags can catch fire. Do not
store gear in the compartment it can restrict cooling air.
· Make sure all fasteners are secure and torqued properly.
· Do not work on the genset when mentally or physically fatigued or after consuming alcohol
or drugs.
2 983-0600 (Issue 10)
7-2011 1. Safety Precautions
· You must be trained and experienced to make adjustments while the genset is
running—hot, moving or electrically 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.
· Benzene and lead in some gasoline have been identified by some state and federal
agencies as causing cancer or reproductive toxicity. Do not ingest, inhale or contact
gasoline or its vapors.
· Keep multi-class ABC fire extinguishers readily at hand. 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 equipment. (ref.
NFPA No. 10)
· Genset installation and operation must comply with all applicable local, state and federal
codes and regulations.
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4 983-0600 (Issue 10)
2 Introduction
2.1 About this Manual
WARNING: Improper installation can result in severe personal injury, death and
equipment damage. The installer must be trained and experienced in the
installation of electrical, mechanical, fuel and exhaust equipment.
WARNING: This genset is not a life support system. It can stop without warning.
Children, persons with physical or mental limitations, and pets could suffer
personal injury or death. A personal attendant, redundant power or an alarm
system must be used if genset operation is critical.
CAUTION: Unauthorized modifications or replacement of fuel, exhaust, air intake or speed
control system components that affect engine emissions are prohibited by law in
the State of California.
This manual is a guide for the installation of the HGJAA and HGJAB Series of generator sets
(gensets). Proper installation is essential for top performance. Read through this manual before
starting the installation. Leave this manual with the vehicle.
This manual addresses the following aspects of the installation:
· Location, Mounting and Ventilation
· Exhaust Connections
· Fuel Connections
· Electrical Connections
· Startup
See the Operator's Manual for operation and maintenance instructions.
NOTE: Manuals are updated from time to time to reflect changes in the equipment
and its specifications. For this reason, only the copy of the installation
manual supplied with the genset should be used as a guide for the
installation.
2.2 Installation Codes and Standards for Safety
CAUTION: The Warranty applies only when this genset is installed in a Recreational Vehicle.
The installer bears sole responsibility for the selection of the appropriate genset, for its proper
installation and for obtaining approvals from the authorities (if any) having jurisdiction over the
installation. These sets meet the basic requirements of the Standard for Safety for Engine
Generator Sets for Recreational Vehicles, ANSI/RVIA EGS-1. They are suitable for installation
in accordance with:
· NFPA No. 1192—Recreational Vehicles
· NFPA No. 70, Article 551—Recreational Vehicles and RV Parks
· NFPA No. 58—Liquefied Petroleum Gas Code
983-0600 (Issue 10) 5
2. Introduction 7-2011
· CSA Electrical Bulletin 946—Requirements for Internal Combustion Engine-Driven Electric
Generators for Use in Recreational Vehicles
Federal, State and local codes, such as the California Administrative Code—Title 25 (RV
installation), might also be applicable. Installation codes and recommendations can change from
time-to-time and are different in different countries, states and municipalities. It is recommended
that the standards in Table 1 be obtained for reference.
TABLE 1. REFERENCE CODES AND STANDARDS
Code of Federal
Regulations, Title
49: Chapter III
and Chapter V
NFPA No 58, 70,
1192
ANSI/RVIA-EGS-
1
California
Administrative
Code—Title 25,
Chapter 3
CAN/CSA-Z240
Recreational Canadian Standards Association Housing and Construction Materials Section 178 Rexdale Blvd.
Vehicles Bulletin Rexdale, Ontario, Canada M9W 1R3
946
Superintendent of Documents P. O. Box 371954 Pittsburgh, PA 15250-7954
National Fire Protection Association 470 Atlantic Avenue Boston, MA 02210
Recreational Vehicle Industry Association 14650 Lee Road Chantily, VA 22021
State of California Documents Section P.O. Box 1015 North Highlands, CA 95660
2.3 Outline Drawings
See the Appendix B on page 57 at the end of the manual for installation details: mounting bolt
hole locations, connection points (fuel, battery, exhaust, remote control, AC output), sizes and
types of fittings, cooling air openings, weight, and overall dimensions. See your Onan dealer for
a large-scale Outline Drawing and full-size floor cutout template.
2.4 Lifting and Handling Genset
Figure 1 illustrates the four lift hook slots for genset lifting. A lifting rig must spread the hook
straps such that they do not crush or bend parts such as the control box, air filter and fuel lines
while lifting. See Specifications (Chapter 8) for the weight of the genset and make provisions
accordingly for safe handling.
CAUTION: Avoid tipping the front (service side) down while handling the genset. Engine oil
could drain into and soak the air filter to cause hard starting and poor operation.
The underside of the genset can be damaged by protruding objects — Always rest
the genset on a flat surface that has been cleared off — Always extend the lifting
arms of a forklift beyond the base of the genset to prevent them from protruding
into the underside cover.
6 983-0600 (Issue 10)
7-2011 2. Introduction
FIGURE 1. GENSET LIFT-HOOK SLOTS—MOUNTING BOLT HOLES—AREA THAT CAN BE
DAMAGED
FIGURE 2. LIFTING HOOK SLING - EXAMPLE ONLY
Contact local sling or rigging supplier for specifications
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2. Introduction 7-2011
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8 983-0600 (Issue 10)
3 Location, Mounting and Ventilation
3.1 Location
Typical genset locations are illustrated in Figure 3. The location must provide:
1. Ready access for starting and stopping the genset and performing all periodic maintenance
2. Separation from sources of flammable vapors, such as batteries and fuel tanks, which the
genset can ignite
3. Access for connecting and disconnecting fuel lines, battery cables, remote control wiring
and AC wiring
4. Access from below for draining engine oil and changing the oil filter
5. Unobstructed space below the genset for proper cooling air flow (see Section 3.4 ).
6. Ground clearance of at least 12 inches (305 mm) (see Section 3.4 ).
7. Space to mount the genset with at least 1/2 inch (12.7 mm) clearance at the top and any
side of the genset. These minimum clearances apply to any thermal or acoustic insulation
with which a compartment may be lined. See Specifications (Chapter 8) for minimum
compartment dimensions.
FIGURE 3. TYPICAL GENSET LOCATIONS
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3. Location, Mounting and Ventilation 7-2011
3.2 Heat, Fire and Exhaust Barriers
3.2.1 Insulating Materials
Acoustic/thermal insulation and adhesive must be Classified as “Self-Extinguishing" at not less
than 200°F (90°C). Do not line the bottom of a compartment with insulation, which absorbs fuel
and oil.
3.2.2 Fire and Exhaust Barriers
Barriers to provide vapor and fire resistance must be installed between the genset and the
interior of the vehicle if the genset is mounted below the floor. If the genset is mounted in a
compartment on the floor of the vehicle, the entire compartment (except the floor) must be lined
with vapor and fire resistive materials. All seams and openings in the barriers for wiring,
mounting screws and so forth must be sealed. Use approved materials (26 gauge galvanized
steel or equivalent). See NFPA 1192 for details.
WARNING: EXHAUST GAS AND FIRE ARE DEADLY! Construct a suitable vapor and fire
barrier of approved materials between the genset and vehicle interior.
3.2.3 Thermal Insulation for Model HGJAC—Below-Floor
Mounted
If the floor is of combustible material, such as plywood, cover the floor above the genset and
any side wall around the genset with 1/4 to 1/2 inch (6.4 to 12.7 mm) thick, 4 lb/ft3(0.0167
kg/m3) density fiberglass thermal insulation with aluminum foil facing at least 0.001 inch (0.025
mm) thick. Secure the insulation every 12 inches (304 mm) to the surfaces being protected by
means of mechanical fasteners and washers as least 1 inch (25 mm) in diameter.
3.2.4 Thermal Insulation for Model HGJAC—Above-Floor
Mounted
If of combustible material, such as plywood, line the compartment and door, but not the floor,
with 1/4 to 1/2 inch (6.4 to 12.7 mm) thick, 4 lb/ft3(0.0167 kg/m3) density fiberglass thermal
insulation with aluminum foil facing at least 0.001 inch (0.025 mm) thick. Secure the insulation
every 12 inches (304 mm) to the surfaces being protected by means of mechanical fasteners
and washers as least 1 inch (25 mm) in diameter. See Specifications (Page Chapter 8)
regarding minimum compartment dimensions.
3.3 Mounting
3.3.1 Mounting Structure and Hardware
Support the genset on a structure able to resist the dynamic weight of the genset: ±3 g-force
vertical and ±1 g-force horizontal. See Specifications (Chapter 8) for the weight of the specific
model being installed. Secure the genset with four 3/8 inch thread-forming bolts in the ends or
bottom of the base (Figure 1). Torque the bolts to 31 lb-ft (42 N-m).
WARNING: The genset support structure must be designed and installed to support and
restrain the dynamic weight of the genset. Failure to do so can result in the
genset dropping onto the roadway causing property damage, severe
personal injury and death.
10 983-0600 (Issue 10)
7-2011 3. Location, Mounting and Ventilation
3.3.2 Below-Floor Mounting
Below-floor mounting kits are available from Onan. Carefully follow the instructions in the kit.
Reinforce generator set with steel to resist the dynamic weight. Do not mount the genset within
the approach or departure angles of the vehicle or below the axle line (Figure 10).
3.4 Ventilation
Unrestricted air flow into and out of the genset for cooling and ventilation is essential for proper
genset performance and service life (Figure 4). See Section 7.1 .
1. See your Onan dealer for a full-size floor template to accurately locate the air inlet and
outlet openings when installing the genset on the floor of the vehicle. The template is
illustrated in Section 2.3.
2. At least 6 inches (152 mm) of unobstructed space below the genset that is open on at least
three sides is required for proper cooling air flow.
3. A ground clearance of at least 12 inches (305 mm) is recommended to reduce the amount
of dust pulled in by the cooling fan and the likelihood of blocking air flow by parking curbs
or logs.
4. Shield the air inlet in the bottom of the genset from direct road splash when the genset is
located in line with the road wheels.
5. Do not duct genset cooling air into the vehicle for heating.
WARNING: EXHAUST GAS IS DEADLY! Do not duct genset cooling air into the vehicle
for heating.
FIGURE 4. COOLING AIR FLOW INTO AND OUT OF GENSET
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12 983-0600 (Issue 10)
4 Exhaust Connections
The exhaust system must be gas-tight and designed to limit entry of exhaust gases into the
vehicle.
WARNING: EXHAUST GAS IS DEADLY! To keep exhaust gases from entering the vehicle
do not terminate the exhaust tailpipe underneath the vehicle or closer than
specified to openings into the vehicle (Figure 9) or route it such that it is
likely to be damaged (Figure 10). Use approved materials and parts only.
CAUTION: Unauthorized modifications or replacement of fuel, exhaust, air intake or speed
control system components that affect engine emissions are prohibited by law in
the State of California.
4.1 Muffler—Models HGJAA / HGJAB
The muffler is mounted inside the genset enclosure. It has a USDA (Forest Service) spark
arrestor and meets RVIA EGS-1 construction requirements.
A genset without a properly installed and maintained spark arresting exhaust system can cause
a forest fire. It is illegal on federal lands. Liability for damage, injury and warranty expense due
to the modification of the exhaust system or to the use of unapproved parts is the responsibility
of the person performing the modification or installing the unapproved parts.
The muffler has a short adapter bolted to its outlet flange (Figure 5). Clamp the tail pipe to the
adapter. See Section 4.3 regarding materials, clamps, support, routing and termination.
Alternatively, a tail pipe with elbow and flange can be bolted to the muffler flange to run straight
out the tunnel in the front or the tunnel in the back of the genset base. See ( Section 2.3 ) for
muffler flange dimensions. Make sure to use a suitable flange gasket. Use the hole shown on
the drawing for the tail pipe hanger if the tail pipe runs out the front. See Section 4.3 regarding
materials, clamps, support, routing and termination. Do not route the tail pipe this way when the
genset is mounted on a combustible floor.
983-0600 (Issue 10) 13
4. Exhaust Connections 7-2011
FIGURE 5. OUTLET FLANGE AND ADAPTER ON MODELS WITH INTERNALLY MOUNTED
MUFFLERS
4.2 Muffler—Model HGJAC
Figure 6 illustrates the exhaust outlet flange and a side-mount muffler kit available from Onan.
The muffler must have a USDA (Forest Service) spark arrestor, meet RVIA EGS-1
requirements, be constructed of aluminized steel or material of equivalent corrosion resistance
and be of welded or crimped construction. The spark arrestor may be integral to the muffler or
an add-on.
A genset without a properly installed and maintained spark arresting exhaust system can cause
a forest fire. It is illegal on federal lands. Liability for damage, injury and warranty expense due
to the modification of the exhaust system or to the use of unapproved parts is the responsibility
of the person performing the modification or installing the unapproved parts.
We recommend that you contact an Onan dealer for spark arresting mufflers that meet RVIA
and USDA requirements. Side-mount and bottom-mount muffler kits are available from Onan,
with front or back exhaust outlets. The kits include a USDA (Forest Service) spark screen for
mounting in the end of the tail pipe.
Follow the instructions in the Onan kit when mounting the muffler. See TAIL PIPE regarding
materials, clamps, support, routing and termination. Install the spark screen in accordance with
the instructions in the kit.
14 983-0600 (Issue 10)
7-2011 4. Exhaust Connections
FIGURE 6. TYPICAL EXTERNAL MUFFLER KIT INSTALLATION
4.3 Tail Pipe
WARNING: Beginning with Spec J, EPA Phase 3 and CARB Tier 3 product incorporates a
catalyst which leads to subsequent higher exhaust gas temperatures. Due to
higher exhaust gas temperatures, the installer must review and follow all
guidelines for tail pipe installations, shielding and surrounding material
requirements for compatibility.
1. Use 1-3/8 inch ID aluminized steel tubing or equivalent for the tail pipe. (Do not use flexible
pipe. Flexible pipe is not gas tight or durable.)
2. Use U-bolt muffler clamps to connect sections of tail pipe. It is recommended that the
overlapping pipe be slotted as shown in Figure 7.
3. Use automotive-type tail pipe hangers every 2 to 3 feet (0.6 to 0.9 m). Attach the hangers
to steel framework, not to wood or other combustible material.
4. Do not terminate the tail pipe underneath the vehicle. Extend it a minimum of 1 inch (25
mm) beyond the perimeter of the vehicle (Figure 8). Support the end of the tail pipe such
that it cannot be pushed inward and up under the skirt of the vehicle.
5. Do not route the tail pipe underneath the oil drain or cooling air inlet.
WARNING: A hot exhaust tail pipe can ignite oil drain spills causing severe personal
injury or death. Do not route the exhaust tail pipe underneath the oil drain.
6. Do not route the tail pipe closer than 3 inches (76 mm) to combustible material (wood, felt,
cotton, organic fibers, etc.) unless it is insulated or shielded. The temperature rise (above
ambient) on adjacent combustible material must not exceed 117°F (65°C).
7. Do not route the tail pipe near fuel lines or fuel tanks.
983-0600 (Issue 10) 15
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