CUMMINS HGJAB, HGJAA Operator's Manual

OperatorOperator ManualManual

RV Generator Set

HGJAA (Spec J-K)
HGJAB (Spec J-L)

English
Original Instructions 7-2016 A035D009 (Issue 11)

Table of Contents

1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1

1.1 Overview ................................................................................................................................. 1

1.2 Warning, Caution, and Note Styles Used in This Manual ..................................................... 1

1.3 General Safety Precautions.................................................................................................... 1

1.4 Automatic Generator Start Control Hazards ........................................................................... 3

1.5 Electrical Shock and Arc Flash Can Cause Severe Personal Injury or Death ....................... 3

1.6 Generator Voltage Is Deadly .................................................................................................. 3

1.7 Engine Exhaust/Carbon Monoxide Is Deadly ......................................................................... 4

1.8 Fuel Is Flammable and Explosive........................................................................................... 5

1.9 Battery Gas Is Explosive......................................................................................................... 5

1.10 Moving Parts Can Cause Severe Personal Injury or Death ................................................. 5

1.11 CARB .................................................................................................................................... 6

1.12 Generator Set Warning Labels ............................................................................................. 6

2. INTRODUCTION............................................................................................................................ 9

2.1 About this Manual ................................................................................................................... 9

2.2 Related Literature ................................................................................................................... 9

2.3 Model Identification ............................................................................................................... 10

2.3.1 Nameplate Location ................................................................................................... 10

2.4 How to Obtain Service .......................................................................................................... 10

2.4.1 In North America ........................................................................................................ 10

2.4.2 Outside North America............................................................................................... 11

2.4.3 Information To Have Available................................................................................... 11

3. OVERVIEW .................................................................................................................................. 13

3.1 Electromagnetic Compatibility Compliance........................................................................... 13

3.2 Information for Generator Set Users (Spark-Ignited Exhaust Emissions) ............................ 13

3.3 Build Standards..................................................................................................................... 14

3.4 Specifications ........................................................................................................................ 15

3.4.1 Gasoline Model Specifications ................................................................................... 15

3.4.2 LPG Model Specifications .......................................................................................... 16

3.5 List of Acronyms ................................................................................................................... 18

4. OPERATION ................................................................................................................................ 21

4.1 Key Component Locations.................................................................................................... 21

4.2 Control Panel ........................................................................................................................ 23

4.2.1 Generator Set Control Panel...................................................................................... 23

4.2.2 Remote Control Panel................................................................................................ 23

4.3 Starting and Stopping the Generator Set ............................................................................. 25

4.3.1 Pre-start Checks ........................................................................................................ 25

4.3.2 Priming the Fuel System ........................................................................................... 25

4.3.3 Starting the Generator Set ......................................................................................... 26

4.3.4 Stopping the Generator Set ....................................................................................... 26

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Table of Contents 7-2016

4.3.5 Engine Run Only Operation ....................................................................................... 26

4.4 Loading the Generator Set ................................................................................................... 26

4.4.1 Power Versus Altitude................................................................................................ 28

4.4.2 Operating at High Altitude.......................................................................................... 29

4.5 Exercising the Generator Set................................................................................................ 29

4.6 Resetting Line Circuit Breakers ............................................................................................ 29

4.7 Connecting Shore Power...................................................................................................... 30

4.8 Operating in Weather Extremes ........................................................................................... 31

4.9 Operating in Dusty Environments ......................................................................................... 31

4.10 Care of New or Rebuilt Engine ........................................................................................... 31

5. MAINTENANCE ........................................................................................................................... 33

5.1 Periodic Maintenance ........................................................................................................... 33

5.1.1 Periodic Maintenance Schedule ................................................................................ 33

5.2 Consumable Parts ................................................................................................................ 34

5.3 General Inspection................................................................................................................ 34

5.4 Maintaining the Battery ......................................................................................................... 34

5.5 Maintaining the Lubrication System...................................................................................... 35

5.5.1 Oil Level ..................................................................................................................... 35

5.5.2 Engine Oil Recommendations ................................................................................... 36

5.5.3 Changing Engine Oil and Oil Filter ............................................................................ 36

5.6 Maintaining the Fuel System ................................................................................................ 38

5.6.1 Fuel System ............................................................................................................... 39

5.6.2 Fuel Recommendations ............................................................................................. 39

5.6.3 Replacing the Fuel Filter ............................................................................................ 40

5.7 Exhaust System .................................................................................................................... 41

5.8 Mechanical System............................................................................................................... 42

5.9 Replacing the Air Filter Element ........................................................................................... 42

5.10 Replacing the Spark Plug(s) ............................................................................................... 43

5.11 Cleaning the Spark Arrester ............................................................................................... 44

5.12 Storing the Generator Set................................................................................................... 45

5.12.1 Carburetor Float Bowl Drain Valve .......................................................................... 48

5.13 Returning the Generator Set to Service ............................................................................. 49

6. TROUBLESHOOTING ................................................................................................................. 51

6.1 Overview ............................................................................................................................... 51

6.2 Fault Codes........................................................................................................................... 51

6.2.1 Code 2 - Low Oil Pressure......................................................................................... 52

6.2.2 Code 3 - Service Check............................................................................................. 52

6.2.3 Code 4 - Over Crank.................................................................................................. 52

6.2.4 Code 12 - Over Voltage ............................................................................................. 53

6.2.5 Code 13 - Under Voltage ........................................................................................... 53

6.2.6 Code 14 - Over Frequency ........................................................................................ 53

6.2.7 Code 15 - Under Frequency ...................................................................................... 53

6.2.8 Code 19 - Governor Actuator..................................................................................... 53

6.2.9 Code 22 - Governor Actuator Overload ..................................................................... 54

6.2.10 Code 27 - Voltage Sense......................................................................................... 54

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6.2.11 Code 29 - High Battery Voltage ............................................................................... 54

6.2.12 Code 31 - Over Speed............................................................................................. 54

6.2.13 Code 32 - Low Cranking Speed............................................................................... 54

6.2.14 Code 35 - Control Card Failure................................................................................ 55

6.2.15 Code 36 - Engine Stopped ...................................................................................... 55

6.2.16 Code 37 - Invalid Generator Set Configuration........................................................ 55

6.2.17 Code 38 - Over Current (Field Overload) ................................................................ 56

6.2.18 Code 41 - Generator Rotor ...................................................................................... 56

6.2.19 Code 42 - Processor ................................................................................................ 56

6.2.20 Code 43 - Processor ................................................................................................ 56

6.2.21 Code 45 - Speed Sense .......................................................................................... 56

6.2.22 Code 47 - Ignition..................................................................................................... 56

6.2.23 Code 48 - Generator Field Sense............................................................................ 56

6.2.24 Code 51 - Processor ................................................................................................ 56

6.2.25 Code 52 - Fuel Injector ............................................................................................ 57

6.2.26 Code 54 - MAT Sender............................................................................................ 57

6.2.27 Code 56 - MAP Sender............................................................................................ 57

6.2.28 Code 57 - Over Prime.............................................................................................. 57

6.2.29 Code 58 - Exhaust Gas Temperature Shutdown..................................................... 57

6.2.30 Code 81 - Exhaust Gas Temperature Sensor Open ............................................... 57

6.2.31 Code 82 - Exhaust Gas Temperature Sensor Shorted............................................ 57

6.3 Symptom Based.................................................................................................................... 57

6.3.1 Status Indicator Not Working ..................................................................................... 58

6.3.2 Starting Batteries Run Down...................................................................................... 58

6.3.3 Starter Engages-Disengages ..................................................................................... 58

6.3.4 No Power—Generator Set Running, Status Light On................................................ 58

6.3.5 No AC Power—Generator Set Running, Status Light Flashing Rapidly.................... 59

7. MAINTENANCE RECORD........................................................................................................... 61

iiiA035D009 (Issue 11) Copyright © 2016 Cummins Inc.

Table of Contents 7-2016

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iv A035D009 (Issue 11)Copyright © 2016 Cummins Inc.