Onan HGJAD, HGJAF, HGJAE Installation Manual

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Printed in U.S.A.

983-0601B

Installation Manual

Models

HGJAD, HGJAE, HGJAF

07-05

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth

defects or other reproductive harm.

!!

gasoline warnings

Table of Contents

SECTION PAGE

SAFETY PRECAUTIONS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Codes and Standards for Safety 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outline Drawings 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting and Handling Genset 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. LOCATION, MOUNTING AND VENTILATION 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heat, Fire and Exhaust Barriers 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilation 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. EXHAUST CONNECTIONS 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Muffler—Models HGJAD / HGJAE 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Muffler—Model HGJAF 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tailpipe 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. FUEL CONNECTIONS 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gasoline—Model HGJAD 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gasoline—Models HGJAE / HGJAF 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Pressure Propane Supply (Vapor Withdrawal) 4-4. . . . . . . . . . . . . . . . . . . . . . . .

High Pressure Propane Supply (Liquid Withdrawal) 4-5. . . . . . . . . . . . . . . . . . . . . . . .

5. ELECTRICAL CONNECTIONS 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Power Output Connections 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Control Connections 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Connections 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. HYDRAULIC PUMP CONNECTIONS 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i

SECTION PAGE

7. VOLTAGE ADJUSTMENTS 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Adjust Mode 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Voltage 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. INSTALLATION REVIEW AND STARTUP 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hot Air Recirculation Test 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Review 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Startup 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. SPECIFICATIONS 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OUTLINE DRAWING—HGJAD / HGJAE A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OUTLINE DRAWING—HGJAF A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM—HGJAD A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM—HGJAE / HGJAF A-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii

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

that will result in severe personal injury or
death.

WARNING

practice that can result in severe personal inju­ry or death.

CAUTION

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.

alerts you to an immediate hazard

alerts you to a hazard or unsafe

alerts you to a hazard or unsafe

• Learn the symptoms of carbon monoxide poi-

soning in the genset Operator’s Manual.

• Never sleep in 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 accor-

dance with the genset Installation Manual.

• Engine cooling air must not be used for heating

the vehicle.

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.

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, 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. 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 base­ments and other below-grade spaces. Prevent
leaks and the accumulation of gas.

ENGINE EXHAUST IS DEADLY

• Inspect for exhaust leaks at every startup and

after every eight hours of running.

• 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.

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.

iii

BATTERY GAS IS EXPLOSIVE

• Wear safety glasses.

• Do not smoke.

• To reduce arcing when disconnecting or recon-

necting battery cables, always disconnect the
negative (−) battery cable first and reconnect
it last.

• 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.

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. 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.

• Benzene and lead in some gasolines 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 readi-

ly 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.

MOBILE 6

iv

1-1

1. Introduction

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
HGJAD, HGJAE and HGJAF 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.

INSTALLATION CODES AND STANDARDS

FOR SAFETY

CAUTION

The Warranty applies only when

this genset is installed in a Commercial 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.

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 1-1 be obtained for reference.

TABLE 1-1. REFERENCE CODES AND STANDARDS

Code of Federal

Regulations,

Title 49: Chapter III

and Chapter V

Superintendent of Documents

P. O. Box 371954

Pittsburgh, PA 15250-7954

NFPA No 58, 70,

1192

National Fire Protection Association

470 Atlantic Avenue

Boston, MA 02210

ANSI/RVIA-EGS-1

Recreational Vehicle Industry Association

14650 Lee Road

Chantily, VA 22021

California Adminis-

trative Code—Title

25, Chapter 3

State of California Documents Section

P.O. Box 1015

North Highlands, CA 95660

CAN/CSA-Z240

Recreational Ve-

hicles

Bulletin 946

Canadian Standards Association

Housing and Construction Materials Section

178 Rexdale Blvd.

Rexdale, Ontario, Canada M9W 1R3

1-2

OUTLINE DRAWINGS

See the Outline Drawings (Pages A-1 and A-2) 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.

LIFTING AND HANDLING GENSET

Figure 1-1 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 (Page 9-1) 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.

LIFT HOOK

SLOTS

LIFT HOOK

SLOTS

THIS AREA CAN BE DAMAGED BY PRO-

TRUDING 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 TO

PREVENT THEM FROM PROTRUDING

INTO THIS COVER.

MOUNTING

BOLTS/

BOLT

HOLES

MOUNTING

BOLTS/

BOLT

HOLES

FIGURE 1-1. GENSET LIFT-HOOK SLOTS—MOUNTING BOLT HOLES—AREA THAT CAN BE DAMAGED

2-1

2. Location, Mounting and Ventilation

LOCATION

Typical genset locations on a recreational vehicle
are illustrated in Figures 2-1 and 2-2. 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 VENTILATION in this
section)

6. Ground clearance of at least 12 inches
(305 mm) (see VENTILATION in this section)

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 (Page 9-1) for minimum
compartment dimensions.

8. For a Model HGJAF genset, which does not
have an integral enclosure, protection from rain
and road splash.

FIGURE 2-1. TYPICAL GENSET LOCATIONS

GENSET

MOUNT ON RAILS AT LEAST 4 INCHES (102 MM)

HIGH SO OIL FILTER CAN BE CHANGED AND

COOLING AIR CAN ENTER AND EXIT

FIGURE 2-2. TYPICAL TRUCK APPLICATION

2-2

HEAT, FIRE AND EXHAUST BARRIERS

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.

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.

Thermal Insulation for Model
HGJAF—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/ft

3

(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.

Thermal Insulation for Model
HGJAF—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/ft

3

(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 Specifica-
tions (Page 9-1) regarding minimum compartment
dimensions.

MOUNTING

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

(Page 9-1) 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 1-1). 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.

Below-Floor Mounting

Below-floor mounting kits are available from Onan.
Carefully follow the instructions in the kit. Reinforce
a plywood or particle board floor with steel to resist
the dynamic weight of the genset. Do not mount the
genset within the approach or departure angles of
the vehicle or below the axle line (Figure 3-6).

2-3

VENTILATION

Unrestricted air flow into and out of the genset for
cooling and ventilation is essential for proper genset
performance and service life (Figure 2-3). See HOT
AIR RECIRCULATION TEST (Page 8-1).

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 on the
Outline Drawings (Pages A-1 and A-2)

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.

COOL AIR IN AROUND

FAN INLET BAFFLE

(ALL MODELS)

HOT AIR OUT AROUND

MUFFLER

(EXCEPT MODEL HGJAC)

HOT AIR OUT AROUND CYLINDERS

AND THROUGH GENERATOR

(MODEL HGJAF ONLY)

FIGURE 2-3. COOLING AIR FLOW INTO AND OUT OF GENSET

3-1

3. 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 3-5) or route it such that it is
likely to be damaged (Figure 3-6). 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.

MUFFLER—MODELS HGJAD / HGJAE

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 3-1). Clamp the tail pipe to the adapt­er. See TAIL PIPE in this section 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 the Outline Drawing (Page A-1)
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 TAIL PIPE in this section regard­ing materials, clamps, support, routing and termina­tion. Do not route the tail pipe this way when the gen-

set is mounted on a combustible floor.

MUFFLER OUTLET FLANGE

AND ADAPTER

HOLE FOR TAIL PIPE

HANGER SCREW

FIGURE 3-1. OUTLET FLANGE AND ADAPTER ON MODELS WITH INTERNALLY MOUNTED MUFFLERS

3-2

MUFFLER—MODEL HGJAF

Figure 3-2 illustrates the exhaust outlet flange and
typical muffler kits 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.

EXHAUST OUTLET FLANGE

HEAT SHIELD

(BOTTOM-MOUNT MUFFLER

FIGURE 3-2. TYPICAL EXTERNAL MUFFLER KITS

3-3

TAILPIPE

1. Use 1-3/8 inch ID aluminized steel tubing or
equivalent for the tailpipe. (Do not use flexible
pipe. Flexible pipe is not gas tight or durable.)

2. Use U-bolt muffler clamps to connect sections
of tailpipe. It is recommended that the overlap­ping pipe be slotted as shown in Figure 3-3.

3. Use automotive-type tailpipe 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 tailpipe underneath the
vehicle. Extend it a minimum of 1 inch (25 mm)
beyond the perimeter of the vehicle (Fig­ure 3-4). Support the end of the tailpipe 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 tailpipe 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 tailpipe near fuel lines or fuel
tanks.

8. Do not terminate the tailpipe such that it is clos­er than 6 inches (153 mm) to any opening into
the vehicle interior (door, window, vent). See
Figure 3-5.

9. Do not connect the genset to the vehicle engine
exhaust system.

CAUTION

Interconnecting the engine ex­haust systems will allow exhaust conden­sates and soot to migrate into the engine
that is idle, causing engine damage.

3/4 INCH (19 MM)

MAXIMUM SLOT

(BOTH SIDES)

FIGURE 3-3. EXHAUST TAILPIPE CONNECTIONS

1 INCH (25 MM)

MINIMUM

LAST TAILPIPE HANGER AS

CLOSE TO END AS PRACTICAL

FIGURE 3-4. TERMINATING EXHAUST TAILPIPE

NO OPENING INTO THE VEHICLE INTERIOR MAY

BE CLOSER THAN 6 INCHES (153 MM) TO THE

END OF THE TAIL PIPE (WITHIN SHADED AREA)

6 in

153 mm

TAILPIPE

FIGURE 3-5. MINIMUM DISTANCES TO OPENINGS

3-4

10. Route the tailpipe such that it is not likely to be
struck when the vehicle is moving. Keep it out
of the approach and departure angles of the ve­hicle and above the axle clearance line (Fig­ure 3-6).

11. Make sure a tail pipe deflector will not cause ex­cessive back pressure or interfere with remov­ing a spark arresting screen, if so equipped.

CAUTION

Excessive back pressure can
cause loss of performance and engine dam­age.

12. Unless the muffler has an integral spark arres­tor, install a spark screen (Figure 3-7) or other
kind of approved add-on device to comply with
regulations for vehicles driven on federal lands.

13. To keep rain out, terminate a vertical tailpipe
(Figure 3-8) with a rain cap or bend that points
towards the rear of the vehicle. Provide guards
as necessary to prevent accidental contact with
the hot tailpipe during normal use of the vehicle.

DEPARTURE

ANGLE

APPROACH

ANGLE

AXLE CLEARANCE

LINE

FIGURE 3-6. VEHICLE CLEARANCES

FIGURE 3-7. TYPICAL SPARK ARRESTING

SCREEN

SUPPORT A VERTICAL TAILPIPE TO PRE-

VENT STRESS ON THE MUFFLER AND PRO-

VIDE GUARDS TO PREVENT ACCIDENTAL

CONTACT WITH THE HOT TAILPIPE

FIGURE 3-8. VERTICAL TAILPIPE

4-1

4. Fuel Connections

See the Operator’s Manual for recommended fuels
and Specifications (Page 9-1) for fuel consumption .

WARNING

Gasoline and Propane are flam­mable and explosive and can cause severe per­sonal injury or death — Do not smoke — Keep
flames, sparks, pilot lights, switches, arc-pro­ducing equipment and all other ignition sources
away from fuel, fuel components and areas
sharing ventilation — Keep an ABC fire extin­guisher handy.

CAUTION

Unauthorized modifications or re­placement of fuel, exhaust, air intake or speed
control system components that affect engine
emissions are prohibited by law in California.

GASOLINE—MODEL HGJAD

Note: The installer is responsible for meeting all
CARB and EPA evaporative emissions requirements
that may be applicable for the fuel system.

Remote Fuel Pump Kit

These gensets have an electronic fuel injection sys­tem supplied by a remote electric pump. Install only
the pump kit available for use in the make and model
of the vehicle in which the genset is installed. Follow
the installation instructions in the pump kit. Fig­ure 4-1 illustrates the wiring connector at the genset
for the remote pump.

Fuel Connections

Figure 4-2 illustrates the supply and return fuel fit­tings on the genset and Figure 4-3 the type of hose
clamps and hose beads required for fuel connec­tions. Use stainless steel stepless ear clamps,
Onan P/N 0503-1951-13 (Oetiker P/N 16700013).

CAUTION

When connecting fuel hoses, only
use soap-free lubricants such as WD40, which
runs through fuel without leaving residues that
can clog fuel jets.

REMOTE PUMP

WIRING CONNECTOR

FIGURE 4-1. REMOTE PUMP WIRING CONNECTOR

5/16 INCH

SUPPLY HOSE

FITTING

5/16 INCH

RETURN HOSE

FITTING

FIGURE 4-2. FUEL FITTINGS—LEFT END OF BASE

TYPE 1 HOSE BEADS

HOSE CLAMP AND TYPE 3 HOSE BEAD

FIGURE 4-3. DOUBLE-FLARE SAE J1231 HOSE

BEADS AND STEPLESS EAR CLAMP

4-2

Routing Fuel Lines

Route the supply and return lines side-by-side along
bulkheads and frame members such that they are
protected, and at or above the top of the fuel tank to

reduce siphoning if a line breaks or a hose comes
off. The entire length of a fuel line must be visible for

inspection and accessible for replacement.

Support fuel lines to restrain movement and prevent
chaffing or contact with sharp edges, electrical wir­ing and hot exhaust parts.

WARNING

Electric arcs can ignite gasoline
leading to severe personal injury or death. Do
not run wiring and fuel lines together.

4-3

GASOLINE—MODELS HGJAE / HGJAF

Note: The installer is responsible for meeting all
CARB and EPA evaporative emissions requirements
that may be applicable for the fuel system.

Fuel Tank

Do not change or remove the fuel fill tube, fill limiter
vent, vapor canister, vapor lines, filler cap or any
other part of the fuel system without the express ap­proval of the vehicle chassis manufacturer. Modifi­cations must conform with applicable sections of the
Code of Federal Regulations, Titles 40 and 49, and
other standards.

Onan recommends a separate fuel pickup tube or a
separate fuel tank for the genset. The genset must
never be connected to the fuel supply line of the
vehicle engine—either to a high-pressure system
(pump in tank), which can overpressurize the gen­set fuel system, or to a vacuum system (pump on
engine), which can cause the genset to starve for
fuel. Some vehicle chassis manufacturers allow
connections to the fuel return line on high pressure
fuel systems. Contact the vehicle chassis manufac­turer for approval. Fuel line pressure at the point
where the genset is connected must not exceed
1-1/2 psi under any condition.

WARNING

Excessive fuel pressure can flood
the genset causing a fire. Genset fuel supply
line pressure must not exceed 1-1/2 psi under
any condition.

The maximum fuel pump lift is 36 inches (914 mm).

Terminate the genset fuel pickup above the vehicle
engine pickup in the supply tank to keep the genset
from running the vehicle out of fuel.

Fuel Lines

Figure 4-4 illustrates the fuel inlet fitting at the gen­set.

• Tubing: Use 1/4 inch O. D. (

± 0.003 inch)

welded and drawn Type 304L stainless or
AISI 1008−1010 low carbon steel tubing of

0.028 inch minimum wall thickness. The tubing
must meet requirements for 150 psi operating
pressure (Ref. ASTM A 539−99) and have cor-
rosion resistance equal to or better than hot­dipped zinc galvanization.

• Hose Beads: Use suitable tooling to form tub-

ing ends into SAE J1231 Type 1 or Type 3

double-flare hose beads (Figure 4-3). This is
recommended for all tubing and fittings.

• Flexible Hose: Use 1/4 in I. D. fuel hose that

meets applicable standards for evaporative
emissions.

CAUTION

When connecting fuel hoses,
only use soap-free lubricants such as
WD40, which runs through fuel without
leaving residues that can clog fuel jets.

• Hose Clamps: Use stainless steel stepless ear

clamps (Figure 4-3). Onan P/N 0503-1951-11,
Oetiker P/N 16700011 or equivalent are rec-
ommended.

Routing Fuel Lines

Route the fuel line along bulkheads and frame
members such that it is protected, and at or above

the top of the fuel tank to reduce siphoning if a line
breaks or a hose comes off. The entire length of a

fuel line must be visible for inspection and accessi­ble for replacement.

Support fuel lines to restrain movement and prevent
chaffing or contact with sharp edges, electrical wir­ing and hot exhaust parts.

WARNING

Electric arcs can ignite gasoline
leading to severe personal injury or death. Do
not run wiring and fuel lines together.

1/4 INCH

FUEL SUPPLY

HOSE FITTING

AND FUEL FILTER

FIGURE 4-4. FUEL FITTING—LEFT END OF BASE

4-4

LOW PRESSURE PROPANE SUPPLY

(VAPOR WITHDRAWAL)

Use the Standard for the Storage and Handling of
Liquified Petroleum Gases (NFPA No. 58) as a
guide for the installation of the propane fuel system.
Figure 4-5 illustrates the fuel fitting and regulator
vent screen.*

WARNING

Propane is flammable and explo­sive and can cause asphyxiation. NFPA 58, Sec­tion 1.6 requires all persons handling propane
to be trained in proper handling and operating
procedures.

The genset must be connected to the vapor with­drawal fitting on the propane tank. The tank must

have a manual shutoff valve and 2-stage pressure
regulator. Adjust the regulator to deliver
9 to 13 inches (229 to 330 mm) Water Column
(WC) pressure at the genset.

WARNING

High propane supply pressure can
cause gas leaks which can lead to fire and se­vere personal injury or death. Propane supply
pressure must be adjusted to Specifications by
qualified personnel.

Use approved fuel line materials of 3/8-inch I. D. for
runs up to 3 feet (0.9 m) and 1/2-inch I. D. for runs
up to 15 feet (4.6 m).

Do not connect the genset fuel supply line to any ap­pliance fuel supply line. The genset can draw fuel
away from other appliances and cause a flame out.
To prevent the possibility of flameout, the fuel supply
system must be designed to deliver sufficient fuel
for normal operation of the genset and other ap­pliances at the expected temperature conditions. It
may be necessary to use a separate fuel tank for the
genset if sufficient fuel cannot be supplied with a
single tank system.

WARNING

The flameout of an unvented pro­pane appliance can lead to explosive accumula­tions of gas inside the vehicle and the danger of
severe personal injury or death. Do not connect
the genset fuel supply line to any vehicle ap­pliance supply line.

Gas lines must be routed away from hot exhaust
parts and electrical wiring, be supported and pro­tected to prevent chaffing, kinking and pinching and
be accessible throughout for inspection and re­placement.

WARNING

Sparks can ignite propane, leading
to severe personal injury or death. Do not run
electrical wiring and fuel lines together.

Upon completing the installation, fill the propane
tank and test every joint and fitting in the propane
supply system using an approved method, such as
soap bubbles.

WARNING

Testing for gas leaks with a flame
can cause a fire or explosion that could lead to
severe personal injury or death. Use approved
methods only.

3/8−18 NPTF

FUEL SUPPLY

FITTING

PROPANE

REGULATOR

VENT BUG

SCREEN

FIGURE 4-5. FUEL FITTING—LEFT END OF BASE

* − The genset fuel regulator is vented to this location to prevent variations in compartment air pressure from affecting fueling and to vent pro­pane outside the genset compartment if the regulator diaphragm develops a leak.

4-5

HIGH PRESSURE PROPANE SUPPLY

(LIQUID WITHDRAWAL)

The Standard for the Storage and Handling of Liqui­fied Petroleum Gases (NFPA No. 58) should be
used as a guide for the installation of the propane
fuel system. Figure 4-6 illustrates the genset fuel fit­ting and Figure 4-7 the fuel handling parts of a typi­cal high pressure propane-fuel supply system.

WARNING

Propane is flammable and explo­sive and can cause asphyxiation. NFPA 58, Sec­tion 1.6 requires all persons handling propane
to be trained in proper handling and operating
procedures.

Connect the genset to the propane supply line with
flexible hose that is non-conductive between its end
fittings so that the fuel line cannot become an alter­native path for cranking currents. The hose must be
Listed for 350 psi working pressure and LP-Gas
or Propane.

Gas lines must be routed away from hot exhaust
parts and electrical wiring, be supported and pro­tected to prevent chaffing, kinking and pinching and
be accessible throughout for inspection and re­placement.

WARNING

Sparks can ignite propane, leading
to severe personal injury or death. Do not run
electrical wiring and fuel lines together.

Upon completing the installation, fill the propane
tank and test every joint and fitting in the propane
supply system using an approved method, such as
soap bubbles.

WARNING

Testing for gas leaks with a flame
can cause a fire or explosion that could lead to
severe personal injury or death. Use approved
methods only.

1/4−18 NPTF

FUEL SUPPLY FITTING

AND FUEL FILTER

FIGURE 4-6. FUEL FITTING—LEFT END OF BASE

APPROVED

HYDROSTATIC RELIEF

VALVE RATED TO

PROTECT GAS LINE

WHEN VALVES ON BOTH

ENDS ARE CLOSED

1/4−18 NPTF GENSET

CONNECTION—USE

APPROVED NON-CONDUCTIVE,

350 PSI (2.4 mPa) WORKING

PRESSURE PROPANE HOSE

APPROVED PRESSURE

RELIEF VALVE OF

APPROPRIATE RATING

IN TANK VAPOR SPACE

DIP

TUBE

APPROVED EXCESS
FLOW VALVE RATED

FOR 250 PSI (1.7mPa)

WORKING PRESSURE

APPROVED MANUAL

SHUTOFF VALVE RATED

FOR 250 PSI (1.7mPa)

WORKING PRESSURE

APPROVED DOT

OR ASME

PROPANE

SUPPLY TANK

APPROVED GAS LINES AND

FITTINGS FOR 250 PSI (1.7 mPa)

WORKING PRESSURE

FIGURE 4-7. TYPICAL HIGH PRESSURE PROPANE SUPPLY SYSTEM (LIQUID WITHDRAWAL)

5-1

5. Electrical Connections

To prevent accidental starting of the genset during
installation, do not connect the battery cables at the
battery until so instructed in STARTUP (Page 8-2).

WARNING

Accidental starting of the genset
can cause severe personal injury or death. Do
not connect the starting battery until so
instructed in STARTUP.

Also, when so equipped, the genset must not be
started before the hydraulic pump has been con­nected to the hydraulic system and filled with oil.

CAUTION

Running the genset without oil in

the hydraulic pump will destroy the pump.

AC POWER OUTPUT CONNECTIONS

The genset is equipped with circuit breakers and
120 inch (3 m) long, 12 AWG leads for AC power
output, which exit through a rain-tight 1/2 inch trade
size conduit connector. See Figure 5-1 for the con­nection diagrams and the location of the conduit
connector. For internal genset wiring see Page A-3
or A-4.

These gensets are not reconnectable for voltages
other than stated on the nameplate.

If the generator leads are replaced, their ampacity
must be equal to or greater than the ampere rating
marked on the genset circuit breakers. Unless
125° C rated wiring is available, heavier gauge wir­ing may be required to obtain the required ampacity.

Wiring Methods

Follow the National Electrical Code, especially not­ing the following:

1. Have a qualified electrician supervise and in­spect the installation of all AC wiring.

2. Install vibration-proof switches and controls
that won’t open and close circuits when the ve­hicle is in motion.

3. Provide ground fault circuit interrupters
(GFCIs)for all convenience power receptacles.

4. Route AC wiring, remote control wiring and fuel
lines separately.

5. Seal all conduit openings into the vehicle interi­or to keep out exhaust gas. Apply silicone rub­ber or equivalent sealant inside and outside
each conduit connector. (Flexible conduit is not
vapor-tight and will allow exhaust gas to enter
along the wires if not sealed.)

WARNING

EXHAUST GAS IS DEADLY!
Seal all wiring openings into the vehicle in­terior to keep out exhaust gas.

6. Bond the genset and all connected AC and DC
equipment and controls to a common ground­ing point in accordance with applicable codes.

WARNING

Faulty grounding can lead to
fire and electrocution, resulting in severe
personal injury or death. Grounding must
be in accordance with applicable codes.

Connecting Shore Power

A vehicle with provisions for connecting shore pow­er (utility) must have an approved device to keep the
genset and utility from being interconnected.

WARNING

Backfeed to shore power (utility)
can cause electrocution or damage to equip­ment. Use an approved device to prevent the
genset from being interconnected with shore
power.

5-2

1/2 INCH CONDUIT

CONNECTOR FOR AC

LEADS—BOTTOM,

LEFT END OF BASE

3-PHASE — 110/120V, 115/230V, 120/240V

1

“2-WIRE” — 100-120V

1, 2

STANDARD 3-WIRE— 100/200V, 115/230V, 120/240V

1

GENSET

GENSET

GENSET

WHT

GRN

BLK

WHT

GRN

BLK

WHT

GRN

BLK/YLW

BLK

BLK

GND

GND

GND

WHT

BLK

CB2−LOAD (L1)

CB2−LOAD (L2)

CB3−LOAD (L3)

NEUTRAL (L0)

NEUTRAL (L0)

CB1−LOAD (L1)

NEUTRAL (L0)

CB1−LOAD (L1)

CB1−LOAD (L1)

NEUTRAL (L0)

CB2−LOAD (L2)

1. These are not reconnectable
generators.

2. Because generator windings
T1-T2 and T3-T4 are in phase,
the “neutral” conductors in the
connected equipment, such as
between a transfer switch and
main distribution panel, must
be sized to carry the sum of the
currents.

BLK/YLW

FIGURE 5-1. CONNECTION DIAGRAMS AND AC LEAD OUTLET

5-3

REMOTE CONTROL CONNECTIONS

The genset has an 8-pin connector for remote con­trol connections (Figure 5-2). Wiring harnesses in
several lengths are available separately for connec­tions between the genset and a remote control pan­el. For internal genset control wiring see Page A-3
or A-4.

The 2-pin connector on Model HJGAD gensets is for
the remote fuel pump.

Onan offers a variety of three remote control panels,
as follows:

• Remote start/stop switch with status indicator

light only (Figure 5-3).

• Remote start/stop switch with status indicator

light and hour meter (Figure 5-4).

• Remote start/stop switch with status indicator

light and DC voltmeter (Figure 5-5).

To make connections to a remote control panel:

1. Push the genset remote control connector
through the entrance hole in the side of the gen­set housing and snap it together with the re­mote wiring harness connector mate.

2. Refer to Figure 5-6 to fabricate the remote con­trol panel and/or wiring harness when not using
the accessories available from Onan. Mark the
remote control end of each lead to identify the
connector pin number at the genset. Use insu­lated 18 AWG copper conductors for distances
up to 30 feet (9 meters) and heavier gauge con­ductors for greater distances. Protect the wiring
with full-length flexible sheathing.

3. A “continuous stop” switch located in the cab
and/or boom bucket can be installed in the re­mote control circuit to prevent unauthorized op­eration of the genset by not allowing cranking
(Figure 5-6).

4. Route control leads separately from AC power
leads to reduce the possibility of erratic opera­tion due to false induced signals.

5. Seal the opening where the leads enter the ve­hicle interior with silicone rubber or equivalent
sealant to keep out exhaust gas.

WARNING

EXHAUST GAS IS DEADLY!
Seal all wiring openings into the vehicle in­terior to keep out exhaust gas.

REMOTE PUMP

WIRING CONNECTOR

REMOTE

CONTROL

CONNECTOR

FIGURE 5-2. REMOTE CONNECTORS

FIGURE 5-3. REMOTE SWITCH

FIGURE 5-4. REMOTE SWITCH / HOUR METER

FIGURE 5-5. REMOTE SWITCH / DC VOLTMETER

5-4

+

−

+

−

REMOTE CONTROL

CONNECTOR P2

REMOTE CONTROL

PANEL

START

B−

REMOTE RUN

STOP

START/STOP SWITCH

DC

VOLTMETER

+

−

HOUR METER

OPTIONAL

OPTIONAL

A
B

C

F

GENSET

CONNECTOR J2

E

F
GH

WIRE END

CONNECTOR END

WIRE END

CONNECTOR END

A

B

C

D

E

F

G

H

A

A

B

B

WIRE END (VIEW B−B) CONNECTOR END (VIEW A−A)

LAMP

STATUS LAMP

REMOTE CONTINUOUS STOP SWITCH

(Closing P2-D to P2-A [B−] Prevents Start)

B−

SWITCH

E

D

SWITCH

FIGURE 5-6. SCHEMATIC OF TYPICAL REMOTE CONTROL CONNECTIONS

5-5

BATTERY CONNECTIONS

The genset has a 12 VDC, negative-ground engine
control and cranking system. See Specifications
(Page 9-1) for the requirements for cranking batter­ies.

To prevent accidental starting of the genset during
installation, do not connect the battery cables at the
battery until so instructed in STARTUP (Page 8-2).

WARNING

Accidental starting of the genset
can cause severe personal injury or death. Do
not connect the starting battery until so
instructed in STARTUP.

Also, when so equipped, the genset must not be
started before the hydraulic pump has been con­nected to the hydraulic system and filled with oil.

CAUTION

Running the genset without oil in

the hydraulic pump will destroy the pump.

Battery Charging

The genset provides up to 10 amps of regulated bat­tery charging current.

Battery Compartment

Batteries must be mounted in a compartment sepa­rate from that of the genset and away from spark­producing equipment. A compartment must have
openings of at least 1.7 square inches (11 square
centimeters) at the top and bottom for ventilation of
battery gasses. It should be located such that spills
and leaks will not drip acid on fuel lines, wiring and
other equipment that could be damaged.

WARNING

Arcing can ignite the explosive hy­drogen gas given off by the battery, causing se­vere personal injury. The battery compartment
must be ventilated and must isolate the battery
from spark-producing equipment.

Battery Cables

Size battery cables according to Table 5-1. The cur­rent path between the genset and the negative (−)
battery terminal must also be able to carry full crank­ing current without causing excessive voltage drop.
It is highly recommended that a full-length cable be
used to connect the genset to the negative (−) bat-
tery terminal (Figure 5-7). Note also that codes may
require a bonding conductor between the genset

and vehicle frame and between the battery and ve­hicle frame.

If the vehicle frame is used as the path between the
negative (−) battery terminal and the genset (Fig­ure 5-8), all frame members in the path of battery
cranking currents must have substantial crossec­tions. The electrical resistance of riveted or bolted
frame joints must also be carefully considered, es­pecially if the joints will be exposed to corrosive con­ditions. A cable sized according to Table 5-1 must
be used to connect the frame to the designated neg­ative (−) terminal on the genset (Figure 5-8). The

genset mounting bolts are not considered ade­quate means for bonding the genset to the ve­hicle frame, either for the purpose of carrying
cranking currents or for complying with require­ments for genset/system grounding.

TABLE 5-1. BATTERY CABLE SIZES FOR

TEMPERATURES DOWN TO −20° F (−29° C)

TOTAL CABLE LENGTH*

FEET (METERS)

CABLE SIZE

AWG

0 to 10 (0 to 3) 2**

11 to 15 (3 to 4.5) 0

16 to 20 (4.5 to 6) 000

* − Add the negative battery cable lengths with the positive
battery cable lengths for the total.

** − A total length of up to 20 feet (6 meters) may be used
in warmer climates or when battery capacity totals at least
1000 CCA (Cold Cranking Amps).

GENSET

BAT

− +

−

+

#8 AWG

MINIMUM

VEHICLE FRAME

GND

SIZE PER

TABLE 5-1

FIGURE 5-7. FULL-LENGTH CABLE FROM

BATTERY NEGATIVE (−) TERMINAL

GENSET

BAT

− +

−

VEHICLE FRAME

+

SIZE PER

TABLE 5-1

FIGURE 5-8. VEHICLE FRAME AS PATH FROM

BATTERY NEGATIVE (−) TERMINAL

5-6

Route battery cables away from fuel lines and hot
engine exhaust components. Battery cables should
be accessible for inspection and replacement, pro­tected from damage and secured to prevent chafing
due to vibration.

WARNING

Routing battery cables with fuel
lines can lead to fire and severe personal injury
or death. Keep battery cables away from fuel
lines.

Battery Cable Connections at Genset

Terminate the battery cables with ring terminals
sized for 5/16 inch screws and connect them to the
genset as shown in Figures 5-9 and 5-10. Secure
the insulating boot on the positive (+) terminal and
tie it to the battery cable with the tie-wrap in the bag
with the manuals.

Torque the positive (+) cable terminal to 4.5 lb-ft
(6 N-m).

Torque the negative (−) cable screw to 8 lb-ft
(11 N-m).

Genset (Equipment) Grounding Screw

When required (see Figure 5-7) connect the genset
grounding screw (Figure 5-9) to the vehicle frame
with a No. 8 AWG or larger stranded cable having a
ring terminal sized for a 3/8 inch screw.

Torque the grounding screw to 8 lb-ft (11 N-m).

POSITIVE (+) CABLE

TERMINAL NUTS AND

INSULATING BOOT

POSITIVE (+)

CABLE

TERMINAL

GENSET

GROUNDING

SCREW

FIGURE 5-9. POSITIVE (+) CABLE TERMINAL &

GENSET GROUNDING SCREW

BOTTOM, LEFT END OF BASE

FIGURE 5-10. NEGATIVE (−) CABLE SCREW

6-1

6. Hydraulic Pump Connections

Figure 6-1 illustrates the hydraulic pump mounted
atop the genset. See Specifications (Page 9-1) re­garding hose fittings, fluid specifications and inlet
conditions.

WARNING

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 — Shut down the genset
before loosening or tightening fittings — Do not
delay getting proper medical attention if ex­posed to high pressure oil spray.

CAUTION

Running the genset without oil in

the hydraulic pump will destroy the pump.

The genset must not be started before the hydraulic
pump has been connected to the hydraulic system
and filled with oil.

CAUTION

The slightest amount of dirt in an
hydraulic system can damage precisely ma­chined internal components. Keep dirt out:

• Thoroughly clean the outside of a fitting or

cap before disconnecting or removing it.

• Keep all openings in components and

hoses capped with proper JIC caps until
just before making connections.

• Thoroughly flush hoses before connecting.

• Regularly replace the oil filter.

• Never reuse hydraulic fluid that has been

drained from a system.

When connecting hoses and starting up the system:

1. Consider that hoses shrink slightly in length
and expand slightly in diameter under pres­sure.

2. There must be enough slack in the connected
hoses to prevent strain due to movement of the
pump.

3. Support, restrain and protect hydraulic hose as
necessary to prevent chaffing.

4. Do not bend hose tighter than the hose
manufacturer recommends.

5. Use wide-sweep 90-degree fittings.

6. Always use two wrenches when tightening hy­draulic fittings.

7. Install an SAE Class 4 filter (10 micron) in the
system.

8. The system oil reservoir should be above the
pump and the hose from the pump should slope
up to the reservoir.

9. To fill the pump, first fill the reservoir and crank
the engine with the spark plug cables discon­nected from the spark plugs to prevent the en­gine from starting. Replenish oil in the reservoir
as necessary.

10. The installed system must not cause pump inlet
conditions to exceed Specifications.

CAUTION

Continuing to run or load a
noisy pump can destroy it. Purge the air be­fore continuing.

11. The hydraulic system has air in it as long as
there continues to be sharp metallic noise.
While filling the system, run the genset only for
a few seconds at a time until all air has been
purged.

HYDRAULIC

PUMP

FIGURE 6-1. HYDRAULIC PUMP

7-1

7. Voltage Adjustments

VOLTAGE ADJUST MODE

Voltage is adjusted by means of the control switch.
Rapidly pressing the switch to START 6 times dur-
ing the first minute after startup puts the genset con­troller into voltage set mode. The amber status indi­cator lamp will begin blinking once every second to
confirm voltage set mode. The green status indica­tor lamp will remain on. The controller resumes nor­mal operating mode 20 seconds after the last ad­justment.

Note: If a fault shutdown occurs or the control switch
is pressed to STOP during voltage set mode, voltage
adjustments will not be stored in controller memory.

ADJUSTING VOLTAGE

To adjust voltage:

1. Make sure that proper fuel, exhaust and battery
connections have been made and that the en­gine has the proper level of oil. See the Opera­tor’s Manual. Complete INSTALLATION RE­VIEW (Page 8-2).

2. Disconnect all generator loads and connect ac­curate meters to measure AC volts and fre­quency.

WARNING

HAZARDOUS VOLTAGE!
Touching uninsulated live parts inside the
genset or connected equipment can result
in severe personal injury or death. For your
protection, stand on a dry wooden platform
or rubber insulating mat, make sure your
clothing and shoes are dry, remove jewelry
from your hands and use tools with insu­lated handles.

3. Start the genset and let voltage and frequency
stabilize for 5 to 10 seconds.

4. Rapidly press the control switch to START
6 times within 10 seconds.

5. To adjust voltage up, press the control switch
to START and release quickly. Each time the
switch is released, voltage will rise approxi­mately 0.6 volt.

6. To adjust voltage down, press the control
switch to START and release in approximately
2 seconds. Each time the switch is released,
voltage will drop approximately 0.6 volt.

7. Normal operation will resume in 20 seconds af­ter the last adjustment.

8-1

8. Installation Review and Startup

HOT AIR RECIRCULATION TEST

A representative installation of the genset must be
tested to determine that the genset will not overheat
due to recirculation of hot air back into the genset.

Test Method

1. Complete a representative installation.

2. Set up a load bank to run the genset at rated
full-load.

3. Conduct the test at a location where the ambi­ent air temperature will remain between 60° F
and 100° F (16° C and 38° C).

WARNING

EXHAUST GAS IS DEADLY! Do
not operate the genset when the vehicle is
parked indoors or where exhaust can accu­mulate.

4. Measure temperatures with thermocouples not
heavier than No. 24 AWG (0.21 mm

2

).

A. Measure genset inlet air temperature with

one thermocouple tied in the middle of the
inlet air grille (Figure 8-1).

B. Measure ambient air temperature with a

shielded thermocouple within 4 feet
(1.2 meters) of the genset and at approxi­mately the same height. Make sure the
thermocouple will not be affected by warm
air discharged from the genset or by sun­light. Use 2 inch diameter white PVC pip-

ing at least 6 inches long as a thermocou­ple shield.

5. Close all compartment doors and run the gen­set at full-load for at least an hour. Record tem­peratures at 15 minute intervals until they sta­bilize. Temperature is considered stable when
there is no change in three consecutive read­ings. Table 8-1 illustrates how the data can be
arranged for recording and analysis.

TABLE 8-1. TEMPERATURE DATA

TEMPERATURE C° (F°)

THERMOCOUPLE

Time Of Reading

LOCATION

AMBIENT AIR

INLET AIR

Test Requirement

The rise in inlet air temperature over ambient air
temperature must not exceed 25° F (14° C). A rise
in inlet air temperature indicates hot air recircula­tion. If the rise exceeds the requirement, steps must
be taken to reduce recirculation to an acceptable
level. Review VENTILATION (Page 2-3).

CAUTION

High ambient operating tempera­tures could reduce maximum genset power out­put if the air temperature rise measured in this
test is on the high end of the acceptable range.

INLET AIR

AMBIENT AIR

FIGURE 8-1. THERMOCOUPLE LOCATIONS FOR HOT AIR RECIRCULATION TEST

8-2

INSTALLATION REVIEW

Before starting the genset inspect the installation
and check (

√) each of the following questions if it can

be answered “YES”. If an item cannot be checked,
provision must be made to satisfy the requirement.

Is the control panel on the genset easily acces­sible for starting and stopping the genset and
resetting the circuit breaker?

Is there easy access for checking and adding
engine oil, replacing the spark plugs and
changing the air filter?

Is the genset securely bolted in place?

Are all specified clearances provided?

Are the air inlet and outlet openings free of ob­structions?

Is there access for draining engine oil?

Are all tail pipe connections tight and all hang­ers and support straps secure?

Does the tail pipe terminate at least 1 inch
(25 mm) beyond the perimeter of the vehicle
and at least 6 inches (153 mm) away from any
opening into the vehicle?

Is the genset located outside the vehicle interior
or separated by approved vapor- and fire-resis­tive materials?

Are all openings into the vehicle, such as for AC
wiring, sealed to keep out engine exhaust? Are
AC conduit connectors sealed inside and out­side?

Have all AC connections been inspected and
approved?

Has a properly sized battery been installed in a
ventilated compartment isolated from the gen­set?

Have properly sized battery cables been
installed and secured at sufficient intervals to
prevent chaffing and contact with sharp edges,
fuel lines and hot exhaust parts?

Are all fuel connections tight?

Have the fuel lines been secured at sufficiently
close intervals to prevent chaffing and contact

with sharp edges, electrical wiring and hot ex­haust parts?

Fuel Injected Models − Has the fuel pump
been installed in accordance with the instruc­tions in the kit? Has a fuel return line been pro-

vided?

Has the HOT AIR RECIRCULATION TEST
been conducted on a representative installa­tion with acceptable results?

STARTUP

WARNING

EXHAUST GAS IS DEADLY! Do not
operate the genset when the vehicle is parked
indoors or where exhaust can accumulate.

When all the items on the Installation Review check
list have been checked, connect the battery cables
to the battery, positive (+) cable first.

WARNING

Batteries give off explosive gases
that can cause severe personal injury — Do not
smoke — Keep flames, sparks, pilot lights,
switches, arc-producing equipment and all oth­er ignition sources away.

Read the Operator’s Manual and perform the main­tenance and pre-start checks instructed. Check the

oil level and fill as necessary.

Recheck all fuel connections for tightness. On gaso-

line models check for leaks by priming the fuel sys­tem in accordance with the genset Operator’s
Manual. Fix all leaks before starting the genset.

WARNING

Gasoline is flammable and explo­sive and can cause severe personal injury or
death. Stop priming immediately if you smell
gasoline or see fuel leaking. Clean up spilled
fuel and ventilate the area before starting the
genset or vehicle.

Start and operate the genset, following all the in­structions and safety precautions in the Operator’s
Manual. Check for fuel and exhaust leaks and un­usual noises while the genset is running under full
and intermediate loads. Do not place the genset in
service until all fuel and exhaust leaks have been
fixed and operation is satisfactory.

9-1

9. Specifications

GASOLINE MODELS

7.0 HGJAD 7.0 HGJAE 7.0 HGJAF 5.5 HGJAD 5.5 HGJAE 5.5 HGJAF

GENERATOR: 2-Pole Revolving Field, 2-Bearing, Self-Excited, 1-Phase, Vertical Shaft, Capped Digital Voltage Regulation

Power (1.0 PF) 7000 watts 5500 watts

Frequency 60 Hertz 60 Hertz

1-Ph, 4-Wire V/A 120 / 240 Volts, 29.2 Amps 120 / 240 Volts, 22.9 Amps

1-Ph, 2-Wire V/A 120 Volts, 58.3 Amps 120 Volts, 45.8 Amps

3-Ph V/A 120 / 240 Volts, 16.8 Amps 120 / 240 Volts, 12 Amps

Speed 3600 rpm 3600 rpm

FUEL CONSUMPTION:

No load 0.43 gph (1.6 l/h) 0.43 gph (1.6 l/h) 0.43 gph (1.6 l/h) 0.34 gph (1.3 l/h) 0.35 gph (1.3 l/h) 0.35 gph (1.3 l/h)

Half load 0.70 gph (2.7 l/h) 0.73 gph (2.8 l/h) 0.73 gph (2.8 l/h) 0.58 gph (2.2 l/h) 0.60 gph (2.3 l/h) 0.60 gph (2.3 l/h)

Full load 1.13 gph (4.3 l/h) 1.22 gph (4.6 l/h) 1.22 gph (4.6 l/h) 0.89 gph (3.4 l/h) 0.95 gph (3.6 l/h) 0.95 gph (3.6 l/h)
ENGINE: Air-Cooled, 4-Cycle Spark-Ignited, OHV, 90° V Twin Cyl, Vertical Shaft

Fueling Method SFI

1

Carburetor Carburetor SFI

1

Carburetor Carburetor

Governor Digital Mechanical Mechanical Digital Mechanical Mechanical

Speed 2880 rpm 2400 rpm

Bore 3.15 in (80 mm) 3.15 in (80 mm)

Stroke 2.56 in (65 mm) 2.56 in (65 mm)

Displacement 39.8 in3 (653 cc) 39.8 in3 (653 cc)

Comp. Ratio 8.0 : 1 8.0 : 1

Oil Capacity 2.0 quart (1.8 l) 2.0 quart (1.8 l)

Valve Lash (Cold) 0.004 in (0.10 mm), Intake & Exhaust 0.004 in (0.10 mm), Intake & Exhaust

Spark Plug 18−25 lbs-ft (23−32 N-m) 18−25 lbs-ft (23−32 N-m)
Ignition Timing 20° BTDC, non-adjustable magneto 20° BTDC, non-adjustable magneto

Magneto Air Gap 0.012 in (0.3 mm) 0.012 in (0.3 mm)

Spark Plug Gap 0.025 in (6-7 mm) 0.025 in (6-7 mm)

HYDRAULIC PUMP: Fixed-displacement gear pump—1.8 gpm @ 2500 psi Fixed-displacement gear pump—1.6 gpm @ 2500 psi

DC SYSTEM:

Battery Voltage 12 volts 12 volts

Battery Charging 10 amps regulated 10 amps regulated
Min. Battery CCA 450 @ 0° F (−18° C) 450 @ 0° F (−18° C)

INSTALLATION:

Exhaust O. D. 1-1/4 in 1-1/4 in

Max. Exhaust Back
Pressure

− − 35 in (889 mm) WC − − 35 in (889 mm) WC

Fuel Supply
Connection

5/16 in. SAE J1231

Type 1

1/4 in. SAE J1231

Type 1

1/4 in. SAE J1231

Type 1

5/16 in. SAE J1231

Type 1

1/4 in. SAE J1231

Type 1

1/4 in. SAE J1231

Type 1

Fuel Return
Connection

5/16 in. SAE J1231

Type 1

− −

5/16 in. SAE J1231

Type 1

− −

Hydraulic Fluid

Transmission or Petroleum-Based Hydraulic Fluid—Operating

Viscosity: 80-1000 SSU—Maximum Start-Up Viscosity: 4000 SSU

Transmission or Petroleum-Based Hydraulic Fluid—Operating

Viscosity: 80-1000 SSU—Maximum Start-Up Viscosity: 4000 SSU

Hydraulic Pump Inlet
Conditions

Not to exceed 5 in Hg Vacuum or 20 psi Pressure Not to exceed 5 in Hg Vacuum or 20 psi Pressure

Hydraulic Pump Con­nections

Outlet
Inlet

3/4-16 UNF-2B SAE
7/8-14 UNF-2B SAE

3/4-16 UNF-2B SAE
7/8-14 UNF-2B SAE

Noise dB(A)

2

66 67 75 66 67 75

Weight 290 lb (132 Kg) 290 lb (132 Kg) 239 lb (107 Kg) 279 lb (127 Kg) 279 lb (127 Kg) 228 lb (104 Kg)

Compartment
(H x D x W)

3

HGJAD/HGJAE: 17.2 in x 23.2 in x 34.6 in (438 mm x 589 mm x 879 mm)

HGJAF: 16.5 in x 22.8 in x 27.9 in (420 mm x 579 mm x 709 mm)

1. Sequential Multiport Fuel Injection

2. Measurements @ 10 ft (3 m) in a typical installation, under an 4 kW load.

3. With 1/2 in. clearances. See the Installation Manual for additional considerations when sizing the genset compartment.

9-2

LPG MODELS

6.5 HGJAE 6.5 HGJAF 5.5 HGJAE 5.5 HGJAF

GENERATOR: 2-Pole Revolving Field, 2-Bearing, Self-Excited, 1-Phase, Vertical Shaft, Capped Digital Voltage Regulation

Power (1.0 PF) 6500 watts 5500 watts

Frequency 60 Hertz 60 Hertz

1-Ph, 4-Wire V/A 120 / 240 Volts, 27 Amps 120 / 240 Volts, 22.9 Amps

Speed 3600 rpm 3600 rpm

FUEL CONSUMPTION:

No load

2.2 lbs/h (1.0 kg/h) 2.2 lbs/h (1.0 kg/h) 1.8 lbs/h (0.8 kg/h) 1.8 lbs/h (0.8 kg/h)

Half load

3.9 lbs/h (1.8 kg/h) 3.9 lbs/h (1.8 kg/h) 3.3 lbs/h (1.5 kg/h) 3.3 lbs/h (1.5 kg/h)

Full load

5.3 lbs/h (2.4 kg/h) 5.3 lbs/h (2.4 kg/h) 4.6 lbs/h (2.1 kg/h) 4.6 lbs/h (2.1 kg/h)

ENGINE: Air-Cooled, 4-Cycle Spark-Ignited, OHV, 90° V Twin Cyl, Vertical Shaft

Fueling Method Air/Fuel Mixer Air/Fuel Mixer

Governor Mechanical Mechanical

Speed 2880 rpm 2400 rpm

Bore 3.15 in (80 mm) 3.15 in (80 mm)

Stroke 2.56 in (65 mm) 2.56 in (65 mm)

Displacement 39.8 in3 (653 cc) 39.8 in3 (653 cc)

Comp. Ratio 8.0 : 1 8.0 : 1

Oil Capacity 2.0 quart (1.8 l) 2.0 quart (1.8 l)

Valve Lash (Cold) 0.004 in (0.10 mm), Intake & Exhaust 0.004 in (0.10 mm), Intake & Exhaust

Spark Plug 18−25 lbs-ft (23−32 N-m) 18−25 lbs-ft (23−32 N-m)
Ignition Timing 20° BTDC, non-adjustable magneto 20° BTDC, non-adjustable magneto

Magneto Air Gap 0.012 in (0.3 mm) 0.012 in (0.3 mm)

Spark Plug Gap 0.025 in (6-7 mm) 0.025 in (6-7 mm)

HYDRAULIC PUMP: Fixed-displacement gear pump—1.8 gpm @ 2500 psi Fixed-displacement gear pump—1.6 gpm @ 2500 psi

DC SYSTEM:

Battery Voltage 12 volts 12 volts

Battery Charging 10 amps regulated 10 amps regulated
Min. Battery CCA 450 @ 0° F (−18° C) 450 @ 0° F (−18° C)

INSTALLATION:

Exhaust O. D. 1-1/4 in 1-1/4 in

Max. Exhaust Back
Pressure

− 35 in (889 mm) WC − 35 in (889 mm) WC

LPG Vapor:

Connection
Pressure

3/8−18 NPTF

9-13 in (228-330 mm) WC

3/8−18 NPTF

9-13 in (228-330 mm) WC

LPG Liquid:

Connection
Pressure

1/4−18 NPTF

Tank Pressure

1/4−18 NPTF

Tank Pressure

Hydraulic Fluid

Transmission or Petroleum-Based Hydraulic Fluid—Operating

Viscosity: 80-1000 SSU—Maximum Start-Up Viscosity: 4000 SSU

Transmission or Petroleum-Based Hydraulic Fluid—Operating

Viscosity: 80-1000 SSU—Maximum Start-Up Viscosity: 4000 SSU

Hydraulic Pump Inlet
Conditions

Not to exceed 5 in Hg Vacuum or 20 psi Pressure Not to exceed 5 in Hg Vacuum or 20 psi Pressure

Hydraulic Pump Con­nections

Outlet
Inlet

3/4-16 UNF-2B SAE
7/8-14 UNF-2B SAE

3/4-16 UNF-2B SAE
7/8-14 UNF-2B SAE

Noise dB(A)

1

67 75 67 75

Weight 290 lb (132 Kg) 239 lb (107 Kg) 279 lb (127 Kg) 228 lb (104 Kg)

Compartment
(H x D x W)

2

HGJAD/HGJAE: 17.2 in x 23.2 in x 34.6 in (438 mm x 589 mm x 879 mm)

HGJAF: 16.5 in x 22.8 in x 27.9 in (420 mm x 579 mm x 709 mm)

1. Measurements @ 10 ft (3 m) in a typical installation, under an 4 kW load.

2. With 1/2 in. clearances. See the Installation Manual for additional considerations when sizing the genset compartment.

A-1

500-3449

OUTLINE DRAWING—HGJAD / HGJAE

A-2

500-3450

OUTLINE DRAWING—HGJAF

A-3

611-1274

NORMALLY CLOSED

FREQUENCY SELECT

P1.29

J1.29

AC SENSE 1 (LINE)

(SEE NOTE 5)

NOTES:

1. TO ADJUST OUTPUT VOLTAGE: WITHIN 1 MINUTE OF START DISCONNECT,
PRESS AND RELEASE THE START SWITCH 6 TIMES WITHIN 10 SECONDS.

THE STATUS LIGHT WILL BEGIN BLINKING AT 1 HZ. EACH PRESS AND
RELEASE OF THE START SWITCH WILL INCREASE THE VOLTAGE BY
APPROXIMATELY 0.5 VOLTS. VOLTAGE IS DECREASED (0.5 V / SECOND)

BY HOLDING THE START SWITCH ON CONTINUOUSLY.

2.

3. GROUND J2.D IN THE REMOTE CONNECTOR TO ACTIVATE ”CONTINUOUS STOP.

4. ENGINE RUN ONLY (ERO) IS ACTIVE WHEN THE SET IS RESTARTED WITHIN

1 MINUTE OF A BYPASSABLE GENERATOR FAULT.

5. P1−17 IS CONNECTED TO GND ON CARBURATED SETS AND LEFT OPEN ON

EFI SETS.

OPEN

EFI/CARB

J1.17

CONTINUOUS STOP

P1.18

J1.18

S2

2

1

F 1

P1.34

J1.34

K1

E2

B+

TIME TOTAL M1

BATT
CHARGE

OPTIONAL BATTERY CHARGER

TO K1 B+

GND

B+

AC

AC

TO OPTIONAL
BATTERY CHARGER

N. O.

T4T3

T2

T1

−

+

J1.20

J1.25

J1.30

J1.22

J1.31

MANIFOLD ABSOLUTE PRESSURE

MANIFOLD ABSOLUTE TEMP SENSE (MAT)

(MAP)

P1.20

P1.25

P1.30

P1.22

P1.31

J1.28

B+

P1.11

J3.2

J3.3

J3.5

ONLYTEST

FACTORY

GND

STOP

START

REMOTE STATUS

VOLTAGE

TIME TOTAL

G1

GND

J1.1

J1.14

J1.13

J1.3

J1.33

P1.1

P1.14

P1.13

P1.3

P1.33

AC SENSE 2 (NEUTRAL)

QUAD 2

QUAD 1

FIELD −

FIELD +

J1.24

J1.6

J1.12

J1.10

J1.27

J1.11

P1.24

P1.6

P1.12

P1.10

P1.27

P1.7

P1.19

P1.26

P1.9
P1.32

P1.8

A1

J1.4

J1.5

P1.4

GENERATOR

FIELD

GND

GND

IGNITION MODULE 2

IGNITION MODULE 1

P1.5

GND

GND

P9.7

P9.1

P9.2

P9.3

P9.8

S1.7

S1.1

S1.2

S1.3

S1.8

STOP

GND

START

LOCAL
START/
STOP

B−

B+

GND

CHASSIS GND

BT1

FUEL PUMP

LOW ENGINE OIL PRESS

FUEL PUMP OUTPUT

STARTER SOLENOID

OIL PRESSURE SWITCH

STARTER SOLENOID

STARTER MOTOR

J2.F

J2.D

J2.G

J2.H

J2.C
J2.B
J2.A
J2.E

LOCAL STATUS

TRANSMIT RS−232

RECEIVE RS−232

START
STOP
GND
LOCAL RUN (SWITCHED B+)

P2.F

P2.D

P2.G

P2.H

P2.C
P2.B
P2.A
P2.E

REMOTE PANEL (OPTIONAL)

P1.23

P1.35

J1.23

J1.35

FUEL INJECTOR 2

FUEL INJECTOR 1

GOVERNOR ACTUATOR

J1.7

J1.19

J1.26

J1.9
J1.32

J1.8

AAB

B

C

P1.28

B

B

A

A

LOCAL
STATUS

VR

WIRING DIAGRAM—HGJAD

A-4

611-1273

WIRING DIAGRAM—HGJAE / HGJAF

Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
763-574-5000
Fax: [phone]

Cummins and Onan are registered trademarks of Cummins Inc.