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HGJBB
Operator's Manual
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Table of contents
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CUMMINS HGJBB Operator's Manual

Operator Manual
RV Generator Set
HGJBB (Spec A)
English Original Instructions
06-2012 A031C171 (Issue 1)

Table of Contents

1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1
1.2 General Precautions ............................................................................................................... 1
1.3 Automatic Generator Start Control Hazards........................................................................... 2
1.4 Generator Voltage is Deadly................................................................................................... 2
1.6 Fuel is Flammable and Explosive........................................................................................... 4
2. INTRODUCTION............................................................................................................................ 5
2.1 About This Manual.................................................................................................................. 5
2.2 Nameplate............................................................................................................................... 5
2.3 Typical Genset ........................................................................................................................ 6
2.4 Fuel Recommendations .......................................................................................................... 8
2.4.1 Gasoline Models .......................................................................................................... 8
2.4.2 LPG Models ................................................................................................................. 8
2.6 Starting Batteries .................................................................................................................... 9
2.8 Remote Control Panel........................................................................................................... 10
3. OPERATION ................................................................................................................................ 13
3.1 Conducting the Pre-Start Checks ......................................................................................... 13
3.2 Priming Gasoline Fuel Systems............................................................................................ 13
3.3 Starting the Genset............................................................................................................... 14
3.4 Stopping the Genset ............................................................................................................. 14
3.5 Restarting the Genset........................................................................................................... 14
3.7 Resetting Circuit Breakers .................................................................................................... 16
3.8 Connecting Shore Power...................................................................................................... 17
3.9 Operating in Cold Weather ................................................................................................... 17
3.10 Operating in Hot Weather ................................................................................................... 18
3.11 Operating in Dusty Environments ....................................................................................... 18
3.12 Operating at a High Altitude................................................................................................ 18
3.13 Breaking in a New Engine .................................................................................................. 18
3.14 Exercising the Genset......................................................................................................... 18
3.15 Storing the Genset.............................................................................................................. 19
3.15.1 Gasoline Models ...................................................................................................... 19
3.15.2 Liquid Propane Models ............................................................................................ 19
3.15.3 Storing the Genset ................................................................................................... 19
3.15.4 Returning The Genset to Service ............................................................................ 20
A031C171 (Issue 1) i
Table of Contents 06-2012
4. PERIODIC MAINTENANCE......................................................................................................... 23
4.1 Conducting General inspections........................................................................................... 23
4.1.1 Oil Level ..................................................................................................................... 23
4.1.2 Exhaust System ......................................................................................................... 23
4.1.3 Fuel System ............................................................................................................... 24
4.1.4 Battery Connections................................................................................................... 24
4.1.5 Mechanical ................................................................................................................. 24
4.2 Checking Engine Oil Level.................................................................................................... 24
4.3 Changing Engine Oil............................................................................................................. 25
4.4 Replacing the Air Filter Element ........................................................................................... 26
4.5 Replacing the Spark Plug ..................................................................................................... 26
4.6 Cleaning the Spark Arrestor ................................................................................................. 27
4.7 Replacing the Fuel Filter....................................................................................................... 28
4.8 Maintaining Battery and Battery Connections....................................................................... 29
5. TROUBLESHOOTING ................................................................................................................. 31
5.1 Fault Codes........................................................................................................................... 31
6. SPECIFICATIONS ....................................................................................................................... 37
7. INFORMATION FOR CALIFORNIA GENSET USERS................................................................ 39
8. HOW TO OBTAIN SERVICE ....................................................................................................... 41
9. MAINTENANCE RECORD........................................................................................................... 43
ii A031C171 (Issue 1)

1 Important Safety Instructions

SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be
followed during installation and maintenance of the generator set and batteries.
Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and
precautions.

1.1 Warning, Caution and Note Styles Used In This Manual

The following safety styles and symbols found throughout this manual indicate potentially hazardous conditions to the operator, service personnel or the equipment.
DANGER: Warns of a hazard that will result in severe personal injury or death .
WARNING: Warns of a hazard that may result in severe personal injury or death .
CAUTION: Warns of a hazard or an unsafe practice that can result in product or property
damage .
NOTE: A short piece of text giving information that augments the current text .

1.2 General Precautions

WARNING: The generator set produces carbon monoxide, has dangerous moving parts
and may be hot at times. Keep children away from the generator set.
WARNING: Evaporative starting fluids are highly explosive and may cause personal
injury or death if ignited. Do not use evaporative starting fluids.
WARNING: Alcohol, drugs and mental or physical fatigue may cause impairment which
may result in personal injury to the affected person or others. Do not operate, service, or install a generator set after consuming alcohol or drugs, or when mentally or physically fatigued.
WARNING: Hot, moving, or electrically charged parts can cause severe injury or death.
Only trained and experienced personnel should make adjustments while the generator set is running.
WARNING: Operating the genset with the access cover off can result in severe personal
injury or equipment damage. Hot components are exposed when the access cover is removed and genset cooling air does not circulate properly. Do not operate the genset with the access cover removed.
WARNING: Improper installation may cause product damage, severe injury, or death.
Comply with all applicable local, state and federal codes and regulations to verify proper generator set installation.
A031C171 (Issue 1) 1
1. Important Safety Instructions 06-2012
WARNING: When equipped with an integral or add-on Auto-matic Generator Starting
System (AGS) control, carbon monoxide exhaust inhalation (CO), electric shock, and moving parts hazards are possible due to unexpected starting. Turn off AGS whenever performing maintenance or service, when the vehicle is stored between uses, is awaiting service, or is parked in a garage or other confined area to avoid these hazards.
WARNING: Electricity, fuel, exhaust, moving parts and batteries present hazards which
can result in severe personal injury or death. Read and adhere to all cautions and warnings found in this manual to avoid personal injury.
CAUTION: Improper battery cable disconnection may cause accidental or remote starting
which may result in injury to the person servicing the generator set. Disconnect the negative (–) battery cable at the battery to prevent starting while servicing the generator set.
CAUTION: The generator set requires ample air flow to run without overheating. Keep the
generator set and its compartment clean and free from obstructions at all times.
CAUTION: Restricted air flow may cause a fire. Do not store oil, rags or other gear in the
generator set or generator set compartment to prevent starting a fire.
CAUTION: Operation of the generator set may loosen fasteners. Operating a generator set
with loose fasteners may cause damage to the generator set. Make sure all fasteners are secured and torqued properly.

1.3 Automatic Generator Start Control Hazards

WARNING: Accidental starting can cause severe personal injury or death. Turn off the
AGS whenever performing maintenance or service, when the vehicle is stored between uses, is awaiting service, or is parked in a garage or other confined area.
Unexpected starting may occur if the generator set is equipped with an inverter-charge or other Automatic Generator Start (AGS) control. This may cause exposure to:
· Unexpected generator starting.
· Moving parts hazards.
· Electric shock.
· Exhaust carbon monoxide (CO).

1.4 Generator Voltage is Deadly

WARNING: Imporperly connected generator electrical output connections can cause
equipment damage, severe personal injury, or death and therefore must be made by a trained and experienced electrician in accordance with applicable codes.
WARNING: Imporper installations can cause equipment damage, severe personal injury,
or death and therefore all installations must be conducted by a trained and experienced person in accordance with the installation instructions and all applicable codes.
2 A031C171 (Issue 1)
06-2012 1. Important Safety Instructions
WARNING: When equipped with an integral or add-on Auto-matic Generator Starting
System (AGS) control, carbon monoxide exhaust inhalation (CO), electric shock, and moving parts hazards are possible due to unexpected starting. Turn off AGS whenever performing maintenance o rservice, when the vehicle is stored between uses, is awaiting service, or is parked in a garage or other confined area to avoid these hazards.
WARNING: Back feed to shore power can cause electrocution and damage to equipment.
The generator set must not be connected to shore power or to any other source of electrical power. An approved switching device must be used to prevent interconnections.
WARNING: Live electrical equipment can cause electricution. 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.

1.5 Engine Exhaust is Deadly

WARNING: When equipped with an integral or add-on Auto-matic Generator Starting
System (AGS) control, carbon monoxide exhaust inhalation (CO), electric shock, and moving parts hazards are possible due to unexpected starting. Turn off AGS whenever performing maintenance o rservice, when the vehicle is stored between uses, is awaiting service, or is parked in a garage or other confined area to avoid these hazards.
WARNING: Carbon monoxide is a posionus gas. Inhalation of this gas can cause severe
personal injury or death. Adhere to the following bullet points to make sure carbon monoxide is not being inhaled by occupants of the vehicle as well as others working on or around the generator set.
··
Inspect for exhaust leaks at every startup and after every eight hours of running.
··
Never occupy the vehicle while the generator set is running unless the vehicle is equipped with a working carbon monoxide detector.
··
Never operate the generator set when the vehicle is in a confined space, such as a garage, basement, or building of any kind.
··
Make sure the exhaust system is installed in accordance with the generator set installation manual.
··
Never use engine cooling air for heating a working or living space compartment.
Carbon monoxide poisioning symptoms include:
· headache
· dizziness
· weakness
· nausea
· vomiting
· chest pain
· confusion
· loss of consciousness
A031C171 (Issue 1) 3
1. Important Safety Instructions 06-2012

1.6 Fuel is Flammable and Explosive

WARNING: Fuel and fuel vapor is highly explosive. Adhere to the following bullets to
avoid igniting fuel and fuel vapors.
··
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, arc-producing equipment and all other sources of ignition well away from fuel lines and sources.
··
Fuel lines must be secured, free of leaks and separated or shielded from electrical wiring.
Leaks can lead to explosive accumulations of gas.
· Natural gas rises when released and can accumulate inside housings and buildings.
· LPG sinks when released and can accumulate inside housings and basements and other
below-grade spaces.
NOTE: Propane (LPG) is identifiable by the rotten egg smell it emits.

1.7 Battery Gas is Explosive

WARNING: Battery gas is highly explosive and may cause personal injury or death if
ignited. Take the proper precautions to avoid personal injury.
··
For personal safety, wear appropriate PPE when working on or around the generator set.
··
To make sure battery gas is not ignited, do not smoke around the generator set.
··
To reduce arcing when disconnecting or reconnecting battery cables, always disconnect the negative (-) battery cable first and reconnect it last.

1.8 Moving Parts Can Cause Severe Personal Injury or Death

WARNING: When equipped with an integral or add-on Auto-matic Generator Starting
System (AGS) control, carbon monoxide exhaust inhalation (CO), electric shock, and moving parts hazards are possible due to unexpected starting. Turn off AGS whenever performing maintenance o rservice, when the vehicle is stored between uses, is awaiting service, or is parked in a garage or other confined area to avoid these hazards.
WARNING: Moving parts can catch on loose items such as clothing or jewelry. Do not
wear loose clothing or jewelry near moving parts such as PTO (power take- off) shafts, fans, belts, and pulleys.
WARNING: Moving parts can entangle appendages such as fingers. Keep the protective
guards in place over fans, belts, pulleys, and other moving parts and keep hands away from all moving parts.
4 A031C171 (Issue 1)

2 Introduction

WARNING: Imporperly connected generator electrical output connections can cause
equipment damage, severe personal injury, or death and therefore must be made by a trained and experienced electrician in accordance with applicable codes.
WARNING: Imporper installations can cause equipment damage, severe personal injury,
or death and therefore all installations must be conducted by a trained and experienced person in accordance with the installation instructions and all applicable codes.

2.1 About This Manual

This manual covers the operation and maintenance of the generator set or sets listed on the front cover. Each operator should study this manual carefully and adhere to all instructions and safety precautions therein. Keep this manual readily available for reference.
This manual provides the operator-level instructions necessary for operating the genset and maintaining it at top performance.
WARNING: This generator set 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

Nameplate information is very useful in identifying a product. Have the model and serial numbers available when contacting a Cummins/Onan dealer for parts, service or product information.
A031C171 (Issue 1) 5
2. Introduction 06-2012
FIGURE 1. NAMEPLATE LOCATION

2.3 Typical Genset

The control panel and the components requiring attention during periodic maintenance (see Periodic Maintenance) are located behind a removable access cover. See Figure 2.
Removing the access cover: Unlock the access cover, using a flat-end tool. Pull the access cover down and out to remove the access cover.
Securing the access cover: Slide the access cover up and into the opening in the housing. Hold the base of the cover flush with the housing. Use a flat-end tool to secure the access cover.
6 A031C171 (Issue 1)
06-2012 2. Introduction
WARNING: Operating the genset with the access cover off can result in severe personal
injury or equipment damage. Hot components are exposed when the access cover is removed and genset cooling air does not circulate properly. Do not operate the genset with the access cover removed.
The genset itself is usually located behind a door in a compartment somewhere around the perimeter of the vehicle.
No. Description No. Description
1 Removable Access Cover 5 Control Panel
2 Muffler (inside cover) 6 Fuel Filter (gasoline models only)
3 Air Filter Cover 7 Oil Fill Cap and Dipstick
4 Oil Drain (bottom) 8 Spark Plug Access
FIGURE 2. TYPICAL GENSET
A031C171 (Issue 1) 7
2. Introduction 06-2012

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.

2.4.1 Gasoline Models

Use clean, fresh unleaded gasoline having a minimum octane rating (Anti-Knock Index) of 87.
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.
The use of synthetic oils with recommended viscosity grade is acceptable. However, oil change intervals found in Chapter 4 must still be followed.
TABLE 1. OIL VISCOSITY VS. TEMPERATURE
EXPECTED AMBIENT TEMPERATURES SAE VISCOSITY GRADE
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
8 A031C171 (Issue 1)
06-2012 2. Introduction
EXPECTED AMBIENT TEMPERATURES SAE VISCOSITY GRADE
-20° F to 50° F (-28° C to 10° C) 5W-30

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 on the genset (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.
· START position - Hold the switch in this position to crank and start the genset.
· STOP/PRIME position - Press the switch to this position to stop the generator set.
· STOP/PRIME position - Hold the switch in this position to prime the fuel system (gasoline
models only).
Status Indicator Light - This light is an LED (light emitting diode) in the control switch that blinks rapidly during cranking and stays on continuously when the genset is running. If the genset shuts down abnormally, the light will blink a numerical code to indicate the cause of the shutdown. See Troubleshooting about display fault codes.
Line Circuit Breaker -The line circuit breaker protects the AC power leads connected to the genset from overloads and equipment short circuits.
A031C171 (Issue 1) 9
2. Introduction 06-2012
No. Description No. Description
1 Status Indicator Light 3 AC Circuit Breaker
2 Control Switch
FIGURE 3. GENSET CONTROL PANEL

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 records genset operating time in hours. It cannot be reset.
FIGURE 4. REMOTE SWITCH
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 MAINTAINING THE BATTERY AND BATTERY CONNECTIONS.
10 A031C171 (Issue 1)
06-2012 2. Introduction
FIGURE 5. REMOTE SWITCH / HOUR METER
FIGURE 6. REMOTE SWITCH / DC VOLTMETER
A031C171 (Issue 1) 11
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