Redistribution or publication of this documentby any means, is strictly prohibited.
Thoroughly read the OPERATOR’S MANUAL
before operating the genset. Safe operation and
top performance can be obtained only 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
practice which can result in severe personal
injury or death.
CAUTION
practice which 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.
alerts you to a hazard or unsafe
alerts you to a hazard or unsafe
GENERAL PRECAUTIONS
• Keep children away from the genset.
• Do not use evaporative starting fluids. They are
highly explosive.
• 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. Dirt and
gear stowed in the compartment 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.
• 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
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.
• Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials such as wood and cloth; Class B fires,
combustible and flammable liquid fuels and
gaseous fuels; Class C fires, live electrical
equipment. (ref. NFPA No. 10)
• Genset installation and operation must comply
with all applicable local, state and federal codes
and regulations.
GENERATOR VOLTAGE IS DEADLY!
• 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 or to any other source of electrical
power. Back-feed to shore power can cause
electric shock resulting in severe personal injury or death 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.
2
ENGINE EXHAUST IS DEADLY!
Redistribution or publication of this documentby any means, is strictly prohibited.
• 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.
ments and other below-grade spaces. Prevent
leaks and the accumulation of gas.
BATTERY GAS IS EXPLOSIVE
• Wear safety glasses.
• Do not smoke.
• The exhaust system must be installed in accor-
dance 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.
• Make sure there is ample fresh air when operating the genset in a confined area.
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, arc-producing equipment and switches 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. Natural gas rises when released and can
accumulate under hoods and inside housings
and buildings. LPG sinks when released and
can accumulate inside housings and base-
• To reduce arcing when disconnecting or reconnecting battery cables, always disconnect the
negative (–) battery cable first and reconnect it
last.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
• 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.
HYDRAULIC FLUID UNDER PRESSURE
CAN CAUSE SEVERE PERSONAL INJURY
• Always shut down the engine that drives the hydraulic pump before loosening or tightening fittings.
• The high pressure spray from a leak or fitting in
a hydraulic line can penetrate the skin, leading
to possible blood poisoning. Wear safety
glasses. Do not delay getting proper medical
attention if exposed to spray.
Commercial Mobile-1
3
Introduction
Redistribution or publication of this documentby any means, is strictly prohibited.
ABOUT THIS MANUAL
This manual covers the operation and maintenance
of the HGJAD, HGJAE and HGJAF 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 (Page 15). This manual also includes genset specifications, information
on how to obtain service, and information for California users.
7HGJAD–1910A
D000012345
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.
NAMEPLATE
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.
[The engine family designation, engine displacement, statement of compliance with the applicable EPA and / or California
emissions regulations, including the compliance period or
category, appear in this block on the actual nameplate on the
genset.]
RECORD NUMBERS HERE
MODEL NUMBER:
SERIAL NUMBER:
FIGURE 1. TYPICAL NAMEPLATE
4
TYPICAL GENSET
Redistribution or publication of this documentby any means, is strictly prohibited.
Figure 2 illustrates a typical self-enclosed genset
with the maintenance access cover removed.
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
5
FUEL RECOMMENDATIONS
Redistribution or publication of this documentby any means, is strictly prohibited.
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.
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.
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 Specifica-tions.
WARNING
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.
High LPG supply pressure can
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 higher30
10° F to 100° F (–12° C to 38° C)
0° F to 80° F (–18° C to 27° C)
–20° F to 50° F (–28° C to 10° C)5W-30
SAE VISCOSITY
GRADE
15W-40
TM
(OnaMax
10W-30
10W-40
)
STARTING BATTERIES
The genset has a 12 volt, direct current (DC) engine
cranking and control system. See Specifications
(Page 29) regarding minimum battery ratings for
reliable genset cranking, especially in cold weather.
Also see PERIODIC MAINTENANCE SCHEDULE
(Page 15) 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.
The genset provides up to 10 amps of regulated battery charging current.
OnaMax is a trademark of Onan Corporation.
6
GENSET CONTROL PANEL
Redistribution or publication of this documentby any means, is strictly prohibited.
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 shutdown 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 Troubleshooting (Page 22) about dis-
playing shutdown 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 Troubleshooting (Page 22).
Line Circuit Breakers – The line circuit breakers
protect the AC power leads connected to the genset
from overloads and equipment short circuits.
Hour Meter – The hour meter records genset oper-
ating time in hours. It cannot be reset. See the Periodic Maintenance Schedule (Page 15).
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:
FIGURE 3. GENSET CONTROL PANEL
FIGURE 4. REMOTE SWITCH
• Remote switch / status lamp (Figure 4).
• Remote switch / status lamp and hour meter
(Figure 5).
• Remote switch / status lamp and DC voltmeter
(Figure 6).
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 (Page 19).
FIGURE 5. REMOTE SWITCH / HOUR METER
FIGURE 6. REMOTE SWITCH / DC VOLTMETER
7
Operation
Redistribution or publication of this documentby any means, is strictly prohibited.
WARNING
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•Throbbing in Temples•Nausea
•Muscular Twitching•Headache•Vomiting
•Weakness and Sleepiness•Inability to Think Clearly
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 sleep in 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.
CONDUCTING PRE-START CHECKS
Before the first start of the day and after every eight
hours of operation, inspect the genset as instructed
under CONDUCTING GENERAL INSPECTIONS
(Page 16). Keep a log of maintenance and the hours
run and perform any maintenance that may be due.
See Returning the Genset to Service (Page 14) 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. To prevent overheating and to reduce fouling
with dust and debris, make sure the genset’s
normal ground clearance is not being reduced
by sloping ground, curbs, logs or other objects.
Repark the vehicle if necessary and/or remove
any objects blocking the air inlet or air outlet.
4. Turn off air conditioners and other large loads.
5. If the genset is equipped with an hydraulic
pump, check and refill the oil reservoir as necessary.
PRIMING GASOLINE FUEL SYSTEMS
If a gasoline genset ran out of fuel prime the fuel system by holding the control switch at STOP/PRIME
EXHAUST GAS IS DEADLY!
for 30 seconds. (The status indicator light will stay
on solid while the pump is on.)
STARTING THE GENSET
Start the genset from the genset control panel or remote control panel inside the vehicle (Page 7).
1. Push and hold the switch at START until the
genset starts. The status indicator light on the
switch flashes while cranking. It will come on
solid when the starter disconnects, indicating
that the genset is running. (Because the genset
control has to “wake up,” a slight delay might be
noticed before anything seems to happen. On
models with fuel injection, the delay could be up
to 3 seconds to pressurize the fuel injectors.)
2. The genset control will discontinue cranking if
the genset does not start within 30 seconds and
will cause the status indicator light to blink shutdown code No. 4. Wait 5 seconds for the control to reset before trying again. See Trouble-shooting (Page 22) if the genset does not start
after two or three tries.
CAUTION
starter motor by continued attempts to
start. Find out why the genset is not starting
and repair as necessary.
3. For top performance and engine life, especially
in colder weather, let the engine warm up for
two minutes before connecting appliances.
Do not risk burning out the
8
4. Check for fuel and exhaust leaks. Stop the gen-
Redistribution or publication of this documentby any means, is strictly prohibited.
set immediately if there is a fuel or exhaust leak
and have it repaired.
5. See Troubleshooting (Page 22) if the engine
shuts down and the status indicator light blinks.
6. Always secure the access cover after starting
the genset at the genset control panel.
WARNING
Operating the genset with the
access cover off can lead to severe burns
and overheating of components. Always
secure the cover after starting the genset.
STOPPING THE GENSET
Turn off air conditioners and other large loads and
let the genset run for two minutes to cool down before stopping. This reduces backfiring and run-on.
Then press the switch to STOP to stop the genset.
can be powered depends upon the genset power
rating. The genset will shut down or its circuit breakers will trip if the sum of the loads exceeds genset
power.
To avoid overloading the genset and causing shutdowns, compare the sum of the loads that are likely
to be used at the same time with the power rating of
the genset. It may be necessary to run fewer
loads at the same time—the sum of the loads
must not be greater than genset rating.
Note that the genset may shut down due to overload—even though the sum of the loads is less than
genset rating—when a large motor or air conditioner
is started last or cycles off and then on again. The
reason for this is that a motor’s startup load is much
larger than its running load. It may be necessary to
run fewer loads when large motors and air conditioners are cycling on and off.
RESTARTING THE GENSET
See Troubleshooting (Page 22) if the genset shuts
down abnormally.
ENGINE ONLY OPERATION
Shutdowns due to generator failure are bypassed
when the genset is restarted within one (1) minute.
While operating in this mode, the status indicator
lamp flashes at a high frequency. This feature allows the engine to run so that hydraulic systems
powered by the engine can be operated though AC
output has failed.
GENSET LOCKOUT SWITCH
The vehicle may be equipped with a genset lockout
switch in the cab and/or boom bucket that can be
used to prevent unauthorized starting of the genset.
The switch(s) must be in their unlocked positions to
start the genset.
LOADING THE GENSET
The genset can power AC motors, air conditioners,
AC/DC converters and other loads. How much load*
Note also that air density decreases as altitude increases, causing rated genset engine power to decrease—approximately 3.5 percent each increase
of 1000 feet (305 m) above the maximum elevation
at which the engine can maintain rated power
(Table 2). It may be necessary to run fewer loads
at higher altitudes.
De-rating for temperature usually is not necessary
because the engine can maintain rated power in
ambient air temperatures of up to 120° F (49° C).
TABLE 2. POWER VS. ALTITUDE
Genset Rated
7000 watts up to
3000 ft (914 m)
6755 watts @
4000 ft (1219 m)
6510 watts @
5000 ft (1524 m)
Subtract 245 watts
each additional
1000 ft (305 m)
1. – This table does not take into account the effect circuit
breakers may have in limiting maximum genset power. Also,
power decreases even though the altitude adjust knob is set
correctly (Page 11).
7.0 kW
1
Genset Rated
6500 watts up to
3000 ft (914 m)
6272 watts @
4000 ft (1219 m)
6044 watts @
5000 ft (1524 m)
Subtract 228 watts
each additional
1000 ft (305 m)
6.5 kW
1
Genset Rated
5500 watts up to
5000 ft (1524 m)
5307 watts @
6000 ft (1829 m)
5114 watts @
7000 ft (2134 m)
Subtract 193 watts
each additional
1000 ft (305 m)
5.5 kW
1
* Load and genset power are measured in terms of watts (W) or kilowatts (kW), where 1 kilowatt (kW) = 1000 watts (W).
9
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