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CUMMINS
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HGJAC
Installation Manual
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Operator's Manual
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CUMMINS HGJAC, HGJAA, HGJAB Operator's Manual

OperatorOperator ManualManual
RV Generator Set
HGJAA (Spec A-E) HGJAB (Spec A-E) HGJAC (Spec A-D)
English Original Instructions 10-2014 983-0101 (Issue 6)

Table of Contents

1. SAFETY PRECAUTIONS .............................................................................................................. 1
1.3 Engine Exhaust is Deadly....................................................................................................... 2
1.4 Fuel is Flammable and Explosive ........................................................................................... 2
1.5 Battery Gas is Explosive......................................................................................................... 2
1.6 Moving Parts Can Cause Severe Personal Injury or Death ................................................... 3
2. INTRODUCTION............................................................................................................................ 5
2.4.1 Gasoline Models .......................................................................................................... 8
2.4.2 LPG Models ................................................................................................................. 8
2.5 Engine Oil Recommendations ................................................................................................ 8
2.7 Genset Control Panel.............................................................................................................. 9
2.8 Remote Control Panel............................................................................................................. 9
3. OPERATION ................................................................................................................................ 11
3.1 Conducting Pre-Start Checks ............................................................................................... 11
3.2 Priming Gasoline Fuel Systems............................................................................................ 11
3.3 Starting the Genset ............................................................................................................... 12
3.4 Stopping the Genset ............................................................................................................. 12
3.5 Restarting the Genset ........................................................................................................... 12
3.6 Loading the Genset............................................................................................................... 12
3.7 Resetting Circuit Breakers .................................................................................................... 14
3.8 Connecting Utility Power....................................................................................................... 14
3.9 Operating in Cold Weather ................................................................................................... 15
3.10 Operating in Hot Weather ................................................................................................... 15
3.11 Operating at High Altitude................................................................................................... 16
3.12 Operating in Dusty Environments ....................................................................................... 16
3.13 Breaking in a New Engine .................................................................................................. 17
3.14 Exercising the Genset......................................................................................................... 17
3.15 Storing the Genset .............................................................................................................. 17
3.15.1 Storing Genset ......................................................................................................... 17
3.15.2 Returning Genset to Service.................................................................................... 18
4. PERIODIC MAINTENANCE......................................................................................................... 19
4.1 Conducting General inspections ........................................................................................... 19
4.2 Oil Level ................................................................................................................................ 19
4.2.1 Exhaust System ......................................................................................................... 20
983-0101 (Issue 6) i
Table of Contents 10-2014
4.2.2 Fuel System ............................................................................................................... 20
4.2.3 Battery Connections................................................................................................... 20
4.2.4 Mechanical ................................................................................................................. 21
4.3 Checking Engine Oil Level.................................................................................................... 21
4.4 Changing Engine Oil and Oil Filter ....................................................................................... 22
4.5 Maintaining Battery and Battery Connections....................................................................... 23
4.6 Replacing the Air Filter Element ........................................................................................... 24
4.7 Replacing Spark Plugs.......................................................................................................... 24
4.8 Cleaning the Spark Arrestor ................................................................................................. 25
5. TROUBLESHOOTING ................................................................................................................. 27
5.1 Fault Codes........................................................................................................................... 27
6. SPECIFICATIONS ....................................................................................................................... 33
7. INFORMATION FOR CALIFORNIA GENSET USERS ............................................................... 37
8. HOW TO OBTAIN SERVICE ....................................................................................................... 39
9. MAINTENANCE RECORD........................................................................................................... 41
ii 983-0101 (Issue 6)

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 operated and maintained properly.
The following symbols in this manual alert you to potential hazards to the operator, service person and equipment.
alerts you to an immediate hazard which will result in severe personal injury or death.
WARNING
alerts you to a hazard or unsafe practice which can result in severe personal injury or death.
CAUTION
alerts you to a hazard or unsafe practice which can result in personal injury or equipment damage.

1.1 General Precautions

DANGER
• Keep ABC fire extinguishers handy.
• Keep children away from the genset.
• Make sure all fasteners are secure and torqued properly.
• 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.
• Before working on the genset, disconnect the negative (-) battery cable at the battery to prevent accidental starting.
• Use caution when making 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 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 gasolines have been identified by some state and federal agencies as causing cancer or reproductive toxicity. Do not to ingest, inhale or contact gasoline or its vapors.
• Do not work on the genset when mentally or physically fatigued or after consuming alcohol or drugs.
• Carefully follow all applicable local, state and federal codes.
983-0101 (Issue 6) 1
1. Safety Precautions 10-2014

1.2 Generator Voltage is Deadly

• Disable the automatic genset starting feature(AGS) of an inverter-charger or other automatic starting device before servicing the genset to avoid electric shock from an unexpected start.
• Generator output connections must be made by a qualified electrician in accordance with applicable codes.
• The genset must not be connected to the public utility or any other source of electrical power. Connection could lead to electrocution of utility personnel 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 and stand on a dry wooden platform.

1.3 Engine Exhaust is Deadly

• Learn the symptoms of carbon monoxide poisoning in this manual and never occupy the vehicle while the genset is running unless the vehicle is equipped with a working carbon monoxide detector.
• The exhaust system must be installed in accordance with the genset Installation Manual. Engine cooling air must not be used for heating the working or living space or compartment.
• Inspect for exhaust leaks at every startup and after every eight hours of running.
• Disable the automatic genset starting feature of an inverter-charger or other automatic starting device before storing the vehicle or parking it in a garage or other confined space.
• Make sure there is ample fresh air when operating the genset in a confined area.

1.4 Fuel is 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 flame, sparks, pilot lights, arc­producing 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.

1.5 Battery Gas is Explosive

• Wear safety glasses and do not smoke while servicing batteries.
• When disconnecting or reconnecting battery cables, always disconnect the negative (-) battery cable first and reconnect it last to reduce arcing.
2 983-0101 (Issue 6)
10-2014 1. Safety Precautions

1.6 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 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.
• Keep guards in place over fans, belts, pulleys, etc.
983-0101 (Issue 6) 3
1. Safety Precautions 10-2014
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4 983-0101 (Issue 6)

2 Introduction

2.1 About This Manual

This manual covers the operation and maintenance of the HGJAA and HGJAB 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. The owner is responsible for performing maintenance in accordance with the PERIODIC MAINTENANCE SCHEDULE (See Periodic Maintenance Section). This manual also includes genset specifications, information on how to obtain service, and information for California users.
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.

2.2 Nameplate

WARNING
Model and Serial Numbers: Have the model and serial numbers handy (gray boxes, Figure 1 ) when contacting an Onan dealer for parts, service or product information. Each character is significant. (The last character of the model number is the specification letter, which is important for obtaining the right parts.) Record these numbers in the boxes in Figure 1 so that they are handy when you need them.
Genuine Onan replacement parts are recommended for best performance and safety.
Federal Emissions Compliance Period: The Federal Emissions Compliance Period referred to on the nameplate indicates the number of operating hours for which the engine has been shown to meet Federal emissions requirements. Category C = 250 hrs, B = 500 hrs, A = 1000 hrs.
983-0101 (Issue 6) 5
2. Introduction 10-2014
FIGURE 1. TYPICAL NAMEPLATE

2.3 Typical Genset

Figure 2 illustrates a typical self-enclosed genset with the maintenance access cover removed.
Removing the access cover: Pull the top of the cover outward and lift it away.
Securing the access cover: Catch the bottom lip of the cover on the top edge of the base tray
and firmly push it into place.
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.
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.
6 983-0101 (Issue 6)
10-2014 2. Introduction
CAUTION
Operating the genset with the access cover off can lead to overheating of components. Always secure the cover after starting the genset.
FIGURE 2. TYPICAL SELF-ENCLOSED GENSET

2.4 Fuel 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.
983-0101 (Issue 6) 7
2. Introduction 10-2014

2.4.1 Gasoline Models

Use clean, fresh unleaded gasoline having a minimum octane rating (Anti-Knock Index) of 87.
• Ethanol Blend - Not more than 10% ethanol.
• Methanol Blend - Not more than 5% methanol and the fuel must also contain solvents and corrosion inhibitors.
CAUTION
Do not use gasoline or gasoline additives containing methanol because methanol can be corrosive to fuel system components.
Avoid using leaded gasoline because of the extra engine maintenance that will be required.

2.4.2 LPG Models

Use clean, fresh HD-5 grade liquified petroleum gas (LPG) or equivalent product consisting of at least 90 percent propane. Commercial liquified petroleum gas fuels may contain more than 2.5 percent butane which can result in poor fuel vaporization and poor engine starting in low ambient temperatures (below 32° F (0° C).
Satisfactory performance on low-pressure LPG models requires that the LPG vapor be supplied at a pressure within the range indicated in Specifications.
WARNING
High LPG supply pressure can cause gas leaks which can lead to fire and severe personal injury or death. LPG supply pressure must be adjusted to Specifications by trained and experienced personnel.

2.5 Engine Oil Recommendations

Use API (American Petroleum Institute) performance Class SJ, SH or SG engine oil, which may be in combination with performance Class CH-4, CG-4 or CF-4 (for example: SJ/CH-4). Also look for the SAE (Society of Automotive Engineers) viscosity grade. Referring to Table 1, choose the viscosity grade appropriate for the ambient temperatures expected until the next scheduled oil change.
Single-grade SAE 30 oil is preferable when temperatures are consistently above freezing. Multigrade oils are better when wide temperature variations are expected.
TABLE 1. OIL VISCOSITY VS. TEMPERATURE
EXPECTED AMBIENT
TEMPERATURES
32° F (0° C) and higher 30
10° F to 100° F (-12° C to 38° C) 15W-40 (OnaMaxTM)
0° F to 80° F (-18° C to 27° C) 10W-30 10W-40
-20° F to 50° F (-28° C to 10° C) 5W-30
SAE VISCOSITY GRADE
OnaMax is a trademark of Onan Corporation.
8 983-0101 (Issue 6)
10-2014 2. Introduction

2.6 Starting Batteries

The genset has a 12 volt, direct current (DC) engine cranking and control system. See Specifications regarding minimum battery ratings for reliable genset cranking, especially in cold weather. Also see Periodic Maintenance Schedule and the battery manufacturer's instructions regarding battery maintenance. Reliable genset starting and starter service life depend upon adequate battery system capacity and proper maintenance.

2.7 Genset Control Panel

The genset control panel ( Figure 3 ) is located behind the maintenance access cover ( Figure
4 ) 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). See Chapter 5 on page
27 about displaying fault codes.
Status Indicator Light - This light is an LED (light emitting diode) in the control switch which
blinks rapidly during cranking and comes on solid when the starter disconnects, indicating that the genset is running. If the genset shuts down abnormally, the light will blink a code to indicate the cause of the shutdown. See Chapter 5 on page 27.
Line Circuit Breaker -The line circuit breaker protects the AC power leads connected to the genset from overloads and equipment short circuits.

2.8 Remote Control Panel

The vehicle probably has a control panel inside the vehicle for remote control of the genset. Onan offers three remote control kits as follows:
• Remote switch with status indicator light only ( Figure 4 ).
• Remote switch with status indicator light and hour meter ( Figure 5 ).
• Remote switch with status indicator light and DC voltmeter ( Figure 6 ).
The hour meter (time totalizing meter) records genset operating time in hours. It cannot be reset. See the Periodic Maintenance Schedule Chapter 4 on page 19.
The DC voltmeter indicates whether voltage across the 12 VDC control system and battery is normal. If the indicator consistently stays above or below the normal zone, see Section 4.5 on
page 23.
983-0101 (Issue 6) 9
2. Introduction 10-2014
FIGURE 3. GENSET CONTROL PANEL
FIGURE 4. REMOTE SWITCH
FIGURE 5. REMOTE SWITCH / HOUR METER
FIGURE 6. REMOTE SWITCH / DC VOLTMETER
10 983-0101 (Issue 6)

3 Operation

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. If symptoms persist, seek medical attention. Shut down the genset and do not operate it until it has been inspected and repaired.
Never occupy the vehicle with the genset running unless the vehicle is equipped with a working carbon monoxide detector. Primary protection against inhaling carbon monoxide, however, is proper installation of the exhaust system, daily (every eight hour) inspection for visible and audible exhaust system leaks.
WARNING

3.1 Conducting Pre-Start Checks

Before the first start of the day and after every eight hours of operation, inspect the genset as instructed under Section 4.1 on page 19. Keep a log of maintenance and the hours run and perform any maintenance that may be due. See Section 4.1 on page 19 if the vehicle has been in storage.
Before each start:
1. Make sure all vehicle CO detectors are working.
2. Check for signs of fuel and exhaust leaks and for damage to the exhaust system.
3. Turn off the air conditioner and other large appliances.

3.2 Priming Gasoline Fuel Systems

If a gasoline genset ran out of fuel, prime the 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.)
983-0101 (Issue 6) 11
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