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7.0HGJAD-2139 Owner`s Manual

1. FIGURE 14 HJGAA CLEANOUT PLUG VIEW FROM BELOW CLEANOUT PLUG FIGURE 15 HJGAB CLEANOUT PLUG VIEW FROM BELOW FIGURE 16 TYPICAL SPARK SCREEN Redistribution or publication of this document by any means is strictly prohibited FA z Troubleshooting AWARNING Hot engine parts can cause severe burns Always allow the engine time to cool before performing any maintenance or service TABLE 4 TROUBLESHOOTING lists the shutdown codes in numerical order along with step by step corrective actions If you are unable to resolve the problem after taking the corrective actions sug gested contact an authorized Onan dealer See How to Obtain Service Page 32 First note the following e Maintaining engine oil level keeping battery connections clean and tight watching the fuel gauge not overloading the genset keeping the air inlet and outlet openings clear etc will prevent most shutdowns e When the genset and vehicle engine share a common fuel tank the fuel dip tubes are usual ly arranged so that the genset will run out of fuel first Marking the genset empty point on the fuel gauge will make it easier to
2. Never sleep in the vehicle with the genset running unless the vehicle is equipped with a working car bon 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 wor king 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 nec essary PRIMING GASOLINE FUEL SYSTEMS If a gasoline genset ran out of fuel prime the fuel sys tem by holding the control switch at STOP PRIME GA Power _ 1 Generation tq
3. Electricity fuel exhaust moving parts and batteries present hazards which can result in severe personal injury or death GENERAL PRECAUTIONS e Keep children away from the genset e Do not use evaporative starting fluids They are highly explosive e To prevent accidental or remote starting while working on the genset disconnect the nega tive battery cable at the battery e 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 e Make sure all fasteners are secure and torqued properly e Do not work on the genset when mentally or physically fatigued or after consuming alcohol or drugs GA Power _ A Generation tq You must be trained and experienced to make adjustments while the genset is running hot moving or electrically live parts can cause se vere 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 gaso line or its vapors Keep multi class ABC fire extinguishers handy Class A fires involve ordinary combustible ma terials such as wood and cloth Class B fires combustible and flammab
4. FUEL INJECTOR SHUTDOWN CODE NO 52 Open or short circuit in fuel injector Corrective Action See an authorized Onan dealer MAT SENDER SHUTDOWN CODE NO 54 Open or short circuit in MAT sender Corrective Action See an authorized Onan dealer JP 27 GA ower a Redistribution or publication of this document Gua Generation by any means is strictly prohibited TABLE 4 TROUBLESHOOTING CONT Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions MAP SENDER SHUTDOWN CODE NO 56 Open or short circuit in MAP sender Corrective Action See an authorized Onan dealer OVERPRIME SHUTDOWN CODE NO 57 Prime mode exceeded 3 minutes Corrective Action Check for and remove any object that may be holding either control switch remote or local in the prime position on 28 GA ower Redistribution or publication of this document Generation by any means is strictly prohibited 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 FUEL CONSUMPTION Ful Toad 1518 gph 8TH 0 95 ooh GTM ENGINE Air Cooled 4 Cycle Spark Ignited OHV 90 V Twin Cyl
5. Onon Commercial Mobile Power Operator s Manual Models HGJAD HGJAE HGJAF Printed in U S A 983 0102 11 2001 Redistribution or publication of this document by any means is strictly prohibited Fd Z Power _ Generation A WARNING A The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm A WARNING A Do not use this genset on a boat Such use may violate U S Coast Guard regulations and can result in severe personal injury or death from fire electrocution or carbon monoxide poisoning gasoline warnings Redistribution or publication of this document by any means is strictly prohibited Table of Contents SAFETY PRECAUTIONS scse vested reeusak reser eadeee vein foevese tees iendexs 2 INTRODUCTION o icini 22864 cb teeter cited e a one iiia 4 About this Manual naanaaaanunanea eee 4 Na amepla te cs cutee ode Eos ache hos BREESE BIAS a aa oa Rete eRe Aa EERE 4 Typical GONSet s acc iemenet evar eteveur user eeey de weneye doen EON EREE 5 Fuel Recommendations icici ciceitintigiiin tedden titbire ebincened ads 6 Engine Oil Recommendations 2 i 222 acandae hel elle hele heh eiedskdee ends 6 Starting Batteries 0 eee eee 6 Genset Control Panel 2 c 23141 42 tees eae eee edie Sener ds ees 7 Remote Control Panel 22 0 ceces tu dead wadcwws 64 daw eee deat wee esas a wees 7 OPERATION ioeie pcp
6. 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 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 be fore stopping This reduces backfiring and run on Then press the switch to STOP to stop the genset 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 al lows 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 can be powered depends upon the genset power rating The genset will shut down
7. 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 temper atures are consistently above freezing Multigrade oils are better when wide temperature variations are expected TABLE 1 OIL VISCOSITY VS TEMPERATURE EXPECTED AMBIENT SAE VISCOSITY TEMPERATURES GRADE 32 F 0 C and higher 10 F to 100 F 12 C to 38 C TSA A0 OnaMax 0 F to 80 F 18 C to 27 C ee 20 F to 50 F 28 C to 10 C 5W 30 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 instruc tions regarding battery maintenance Reliable gen set starting and starter service life depend upon adequate battery system capacity and proper main tenance The genset provides up to 10 amps of regulated bat tery charging current Redistribution or publication of this document by any means is strictly prohibited GENSET CONTROL PANEL The genset control panel Figure 3 is located be hind the maintenance access cover Figure 2 and has the following features Control Switch Th
8. Vertical Shaft Fueling Method SFI Carburetor Carburetor SFI Carburetor Carburetor Oil Capaciy 20 quae 18 Valve Lash Cold 0 004 in 0 10 mm Intake amp Exhaust Spark Plug 18 25 sh 25 52 Nem 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 a Fuel Supply 5 16 in SAE J1231 1 4 in SAE J1231 1 4 in SAE J1231 5 16 in SAE J1231 1 4 in SAE J1231 1 4 in SAE J1231 Connection Type 1 Type 1 Type 1 Type 1 Type 1 Type 1 Fuel Return 5 16 in SAE J1231 5 16 in SAE J1231 Connection Type 1 Type 1 Hydraulic Fluid Transmission or Petroleum Based Hydraulic Fluid Operating Transmission or Petroleum Based Hydraulic Fluid Operating y Viscosity 80 1000 SSU Maximum Start Up Viscosity 4000 SSU Viscosity 80 1000 SSU Maximum Start Up Viscosity 4000 SSU ne ump Inlet Not to exceed 5 in Hg Vacuum or 20 psi Pressure Not to exceed 5 in Hg Vacuum or 20 psi Pressure Hydraulic Pump Con nections Outlet 3 4 16 UNF 2B SAE 3 4 16 UNF 2B SAE Inlet 7 8 14 UNF 2B SAE 7 8 14 UNF 2B SAE Noise dB A 2 290 Ib 132 Kg 290 Ib 132 Kg 239 Ib 107 Kg 279 Ib 127 Kg 279 Ib 127 Kg 228 Ib 104 Kg Compartment HGJAD HGJAE 17 2 in x 23 2 in x 34 6 in 438 mm x 589 mm x 879 mm H x D x W 3 HGJAF 16 5 in x 22 8 in x 27 9 in 420 mm x 579 mm x 709 mm 1 Sequential Mu
9. 19 Redistribution or publication of this document by any means is strictly prohibited REPLACING SPARK PLUGS plug that fouls frequently or has heavy soot deposits indicates the need for engine service See Trouble shooting Page 22 Refer to Table 3 for scheduled spark plug replace ment The genset has two spark plugs Figure 13 To prevent cross threading always thread a spark The spark plugs must be in good condition for plug in by hand until it seats and then torque to proper engine starting and performance A spark 10 Ibs ft 13 N m FIGURE 13 SPARK PLUGS 20 FA Power m Redistribution or publication of this document a Generation by any means is strictly prohibited CLEANING THE SPARK ARRESTOR Refer to Table 3 for scheduled cleaning of the spark arrestor muffler Cleaning is required for maximum genset performance Park the vehicle away from grass brush or debris that could be ignited by sparks expelled during this procedure A hot muffler can cause severe burns Let the muffler cool down before remov ing or installing cleanout plugs or screens Series HGJAD A double drum muffler is mounted inside the genset The cleanout plug is in the top drum but accessible from below though not readily visible In Figure 14 a portion of the lower drum is cut out so that the location of the plug is
10. Power _ i Generation lt m 12 carburetor and removes oxides from electrical con tacts and generator slip rings The result is better starting more reliable operation and longer engine life STORING THE GENSET Proper storage is essential for preserving top gen set performance and reliability when the genset cannot be exercised regularly and will be idle for more than 120 days Storing Genset 1 Gasoline Models Only Fill the fuel tank with fresh fuel and add a fuel preservative Ona Fresh following the instructions on the con tainer label Unless a preservative stabilizer is added the gasoline in the fuel system will dete riorate causing fuel system corrosion gum formation and varnish like deposits which can lead to hard starting and rough operation Then run the genset for about 10 minutes at approximately 1 2 rated power to fill the fuel lines with the fresh fuel and preservative Gasoline preservatives stabi lizers are toxic Follow the instructions on the container Avoid skin contact Wash hands with soap and water after using 2 Change the engine oil Page 18 and attach a tag indicating grade of oil viscosity Page 6 3 Remove the air filter Page 19 and restart the genset While the genset is running spray an engine fogger OnaGard into the carburetor following the instructions on the container la bel and stop the genset The fogger leaves a protective coat of oil on the intern
11. call Onan Corpo ration at 1 763 574 5000 from 7 30 AM to lt m 32 4 00 PM Central Standard Time Monday through Friday or fax 1 763 528 7229 Before calling for service have the following infor mation available 1 The complete genset model number and serial number See Model Identification Page 4 2 The date of purchase 3 The nature of the problem See Troubleshoot ing Page 22 If you have difficulty in arranging service or resolv ing a problem please contact the Service Manager at the nearest Cummins Onan distributor for assis tance Improper service or replacement of parts can result in severe personal injury death and or equipment damage Service personnel must be trained and experienced in performing electrical and or mechanical service Redistribution or publication of this document by any means is strictly prohibited Maintenance Record Record all periodic and unscheduled maintenance and service See Periodic Maintenance Page 15 HOUR METER MAINTENANCE OR SERVICE PERFORMED READING Record the name address and phone number of your authorized Onan service center 33 FA Power s Redistribution or publication of this document amp Generation by any means is strictly prohibited a om Onon Cummins Power Generation 1400 73rd Avenue N E Minneapolis MN 55432 763 574 5000 Fax 763 528 7229 Cummins and Onan are registered trademarks of Cummins Inc Power _ Ge
12. 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 re mote 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 shut down code No 4 Wait 5 seconds for the con trol to reset before trying again See Trouble shooting Page 22 if the genset does not start after two or three tries Do not risk burning out the 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 Redistribution or publication of this document by any means is strictly prohibited 4 Check for fuel and exhaust leaks Stop the gen set immediately if there is a fuel or exhaust leak and have it repaired
13. or its circuit break ers will trip if the sum of the loads exceeds genset power To avoid overloading the genset and causing shut downs 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 over load 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 con ditioners are cycling on and off Note also that air density decreases as altitude in creases causing rated genset engine power to de crease 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 Genset Rated Genset Rated 7 0 kw 6 5 kw 5 5 kw 7000 watts up to 6500 watts up to 5500 watts up to 3000 ft 914 m 3000 ft 914 m 5000 ft 1524 m 6755 watts 6272 watts
14. or replace the battery Refer to the battery manufacturer s recommendations 3 Have a battery charging system installed or serviced in the vehicle STARTER ENGAGES DISENGAGES Cranking voltage dips below 6 volts low battery charge poor connections long cables Corrective Action Have the vehicle propulsion engine running while trying to start the genset the battery charging alternator may be able to maintain starting voltage high enough to get the genset started Clean and tighten the positive and negative battery cable connections at the battery vehicle frame and genset Recharge or replace the battery Refer to the battery manufacturer s recommendations Increase battery cable size or run parallel cables NO POWER GENSET RUNNING STATUS LIGHT ON Line circuit breaker OFF or tripped due to short circuit or overload Corrective Action 1 Turn on or reset the line circuit breaker on the genset Page 10 2 Turn on or reset the line circuit breakers on the main distribution panel in the vehicle LOW OIL PRESSURE SHUTDOWN CODE NO 2 First level shutdown code Low oil pressure cutoff switch did not open Corrective Action 1 Check engine oil level and add oil as necessary Page 17 2 Drain excess oil above dipstick Full mark SERVICE CHECK SHUTDOWN CODE NO 3 First level shutdown code lIndicates fault with second level shutdown code Corrective Action Check the second level shutdown code by
15. reconnect it last Redistribution or publication of this document by any means is strictly prohibited Mechanical Look for mechanical damage Start the genset and look listen and feel for any unusual noises and vibrations Check the genset mounting bolts to make sure they are secure Check to see that the genset air inlet and outlet openings are not clogged with debris or blocked Clean accumulated dust and dirt from the genset Do not clean the genset while it is running or still hot Protect the generator air cleaner control panel and electrical connections from water soap and clean ing solvents AWARNING Always wear safety glasses when using compressed air a pressure washer or a steam cleaner to avoid severe eye injury CHECKING ENGINE OIL LEVEL Park the vehicle on level ground and shut off the genset before checking the engine oil level Crankcase pressure can blow hot engine oil out the fill opening causing severe burns Always stop the genset before removing the oil fill cap 1 Unscrew the oil fill cap and wipe oil off the dip stick Figure 10 Screw the cap back on remove it and check the oil level on the dip stick 2 Add or drain oil as necessary See ENGINE OIL RECOMMENDATIONS Page 6 Keep the oil level between the FULL and ADD marks The oil fills slowly because it takes time for the air in the crankcase to escape Recheck the level in a few minutes to make sure Too much oil can cause hig
16. visible 1 Locate the square headed cleanout plug by hand and solidly seat a 7 16 inch eight point 3 8 inch drive socket wrench with 3 inch exten sion on the plug Then add a swivel section and 6 inch extension and turn with a ratchet to re move the plug 2 Start and load the genset to near full power Let the genset run for about five minutes to expel the soot in the muffler 3 Stop the genset allow the muffler to cool down and then reinstall the plug Series HGJAE See Figure 14 if double drum or Figure 15 if single drum On a single drum muffler the cleanout plug is accessible from below as shown in Figure 15 1 Remove the plug with a 7 16 inch eight point socket wrench 2 Start and load the genset to near full power Let the genset run for about five minutes to expel the soot in the muffler 3 Stop the genset allow the muffler to cool down and then reinstall the plug Series HGJAF The muffler is externally mounted If it has a clean out plug like the one shown in Fig ure 15 use the instructions for Series HGJAE as a guide Alternatively the end of the tail pipe may have a spark screen Figure 16 If so remove the screw that secures the spark screen clean the screen with a wire brush and re install it Power _ Generation lt m 21 CLEANOUT PLUG
17. 5307 watts 4000 ft 1219 m 4000 ft 1219 m 6000 ft 1829 m 6510 watts 6044 watts 5114 watts 5000 ft 1524 m 7000 ft 2134 m 5000 ft 1524 m Subtract 245 watts Subtract 228 watts Subtract 193 watts each additional each additional each additional 1000 ft 305 m 1000 ft 305 m 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 Load and genset power are measured in terms of watts W or kilowatts kW where 1 kilowatt kW 1000 watts W Power Generation tq Redistribution or publication of this document by any means is strictly prohibited RESETTING CIRCUIT BREAKERS If a circuit breaker in the main power distribution panel of the vehicle or on the genset Figure 7 trips either a circuit shorted or too many loads were run ning Note that the genset may continue to run after a circuit breaker trips If a circuit breaker trips disconnect or turn off as many loads as possible and reset the circuit breaker Push the circuit breaker to OFF to reset it and then to ON to reconnect the circuit If the circuit breaker trips right away either the electrical dis tribution system has a short circuit or the circuit breaker is faulty Call a qualified electrician If the circuit breaker does not trip reconnect the loads one by on
18. RONMENTS Pay particular attention to the following items when operating the genset in dusty environments 1 Do not let dirt and debris accumulate inside the genset compartment Keep the genset clean 2 Perform air cleaner maintenance more often Page 19 3 Change engine oil every 50 hours 4 Keep containers of engine oil that have been opened tightly closed to keep out dust BREAKING IN A NEW ENGINE Proper engine break in on a new genset or on one with a rebuilt engine is essential for top engine per formance and acceptable oil consumption Run the genset at approximately 1 2 rated power for the first 1 hour and then at 3 4 rated power for 1 more hour Proper engine oil and oil level are especially critical during break in because of the higher engine tem peratures that can be expected Change the oil if not appropriate for the ambient temperatures during break in See ENGINE OIL RECOMMENDATIONS Page 6 Check oil level twice a day or every 4 hours during the first 20 hours of operation and change the oil after the first 20 hours of operation EXERCISING THE GENSET Exercise the genset at least 1 hour each month if use is infrequent Run the genset at approximately 1 2 rated power A single long exercise period is better than several short periods Exercising a genset drives off moisture re lubri cates the engine replaces stale fuel in fuel lines and OnaFresh and OnaGard are trademarks of Onan Corporation GA
19. Redistribution or publication of this document by any means is strictly prohibited Fad z CONDUCTING GENERAL INSPECTIONS Inspect the genset before the first start of the day and after every eight hours of operation Oil Level Check engine oil level Page 17 Exhaust System Look and listen for exhaust system leaks while the genset is running Shut down the genset if a leak is found and have it repaired before operating the gen set again Look for openings or holes between the genset compartment and vehicle cab or living space if the genset engine sounds louder than usual Have all such openings or holes closed off or sealed to pre vent exhaust gases from entering the vehicle Replace dented bent or severely rusted sections of the tailpipe and make sure the tailpipe extends at least 1 inch 25 4 mm beyond the perimeter of the vehicle Park the vehicle so that genset exhaust gases dis perse away from the vehicle Barriers such as walls snow banks high grass and brush and other ve hicles can cause exhaust gases to accumulate in and around the vehicle Do not operate power ventilators or exhaust fans while the vehicle is standing with the genset run ning The ventilator or fan can draw exhaust gases into the vehicle Check all CO monitors to assure proper operation EXHAUST GAS IS DEADLY Do not operate the genset if there is an exhaust leak or any danger of exhaust gases entering or being drawn into the vehic
20. al surfaces of the engine Redistribution or publication of this document by any means is strictly prohibited 4 Gasoline Models with Carburetor Shut off the fuel supply valve if so equipped and drain the carburetor float bowl Figure 9 into a con tainer Dispose of the fuel in accordance with lo cal environmental regulations Draining the float bowl prevents deposits of gum from clog ging the tiny passages in the carburetor as the gasoline in the bowl evaporates during storage 5 Disconnect the battery cables negative cable first from the starting battery and store the battery according to the battery manufac turer s recommendations See MAINTAINING THE BATTERY AND BATTERY CONNEC TIONS Page 19 CARBURETOR apace FLOAT BOWL 6 Plug the exhaust tail pipe to keep out dirt mois DRAIN VALVE ture bugs rodents etc Use a plug that will completely blow out on next startup FIGURE 9 DRAINING CARBURETOR FLOAT BOWL 7 LPG Models Check the local ordinances if the vehicle is to be garaged Generally ordi nances require that the LPG system be leak free that the LPG container not be filled beyond specified limits that the container shutoff valve be closed and that the vehicle not be parked near sources of heat or ignition LPG leaks can lead to explosive accumulations in pits sumps or other below grade locations Comply with all lo cal ordinances regarding the garaging of
21. before loosening or tightening fit tings 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 Redistribution or publication of this document by any means is strictly prohibited Introduction ABOUT THIS MANUAL This manual covers the operation and maintenance of the HGJAD HGJAE and HGJAF Series of gener ator 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 Trouble shooting provide the instructions necessary for operating the genset and maintaining it at top per formance The owner is responsible for performing maintenance in accordance with the PERIODIC MAINTENANCE SCHEDULE Page 15 This man ual also includes genset specifications information on how to obtain service and information for Califor nia users This genset is not a life support sys tem It can stop without warning Children per sons with physical or mental limitations and pets could suffer personal injury or death A per sonal attendant redundant power or an alarm system must be used if genset operation is criti cal NAMEPLATE Model and Serial Numbers Have the model and serial numbers handy gray
22. boxes Figure 1 when contacting an Onan dealer for parts service or prod uct information Each character is significant The last character of the model number is the specifica tion letter which is important for obtaining the right parts Record these numbers in the boxes in Fig ure 1 so that they are handy when you need them Genuine Onan replacement parts are recom mended 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 IMPORTANT ENGINE INFORMATION CUMMINS POWER G 1400 73rd Ave NE Minneapolis MN 55432 Model No ZVHGJAD 1910A Made in U S A sa D000012345 AC Volts KVA Amps Pf Fuel Hz Options Wiring Diagram Insulation NEMA Class F Ambient 40 C The engine family designation engine displacement state ment 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 GA Power _
23. c0c2c0234 pieutiowtenbadieet he dibieeeoe ees 17 Changing Engine Oil and Oil Filter 0 0 00 cece eee eee 18 Maintaining Battery and Battery Connections 0 0 2 cece eee 19 Replacing the Air Filter Element 2 iscies ces cees vi Gewese ecee ees seus bes eeeees 19 Replacing Spark PUGS 20 4h0caeicdieeige nes coks e oe Ea ee Ea aE E h 20 Cleaning the Spark Arrestor 02 e2arscisreee tic ory acts ded ati dddnesbedens 21 TROUBLESHOOTING 0 cece ene nee 22 SPECIFICATIONS cis dee ercbven eat hee ve HARE a NEET a EE a a E EEAS 29 INFORMATION FOR CALIFORNIA GENSET USERS 05 31 HOW TO OBTAIN SERVICE 0 ccc cece 32 MAINTENANCE RECORD 00 0 ccc eee 33 1 Power Redistribution or publication of this document g Generation by any means is strictly prohibited Safety Precautions 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 po tential hazards to the operator service person and equipment alerts you to an immediate hazard which will result in severe personal injury or death alerts you to a hazard or unsafe practice which can result in severe personal injury or death alerts you to a hazard or unsafe practice which can result in personal injury or equipment damage
24. ck for and repair a blocked exhaust system LOW OIL PRESSURE CUTOFF SWITCH SHUTDOWN CODE NO 23 Controller sensed switch still open during start not a running fault Corrective Action See an authorized Onan dealer VOLTAGE SENSE SHUTDOWN CODE NO 27 Controller unable to sense output voltage Corrective Action See an authorized Onan dealer HIGH BATTERY VOLTAGE SHUTDOWN CODE NO 29 Voltage across battery system greater than 19 volts Corrective Action 1 Check battery bank connections and reconnect if necessary so that the 12 volt batteries serving the genset are connected in parallel 12 volt rather than in series 24 volt 2 Select a lower battery boost charge rate OVERSPEED SHUTDOWN CODE NO 31 Engine speed greater than 3400 rpm Corrective Action See an authorized Onan dealer LOW CRANKING SPEED SHUTDOWN CODE NO 32 Cranking speed less than 180 rpm for more than 2 seconds Corrective Action 1 Clean and tighten the positive and negative battery cable connections at the battery and at the genset 2 Recharge or replace the battery Refer to the battery manufacturer s recommendations 3 Replace engine oil with oil of proper viscosity for ambient temperatures Page 6 High oil viscosity can slow down cranking speed JP 25 GA ower a Redistribution or publication of this document Generation Gua by any means is strictly prohibited TABLE 4 TROUBLESHOOTING CONT Some gens
25. d TABLE 4 TROUBLESHOOTING Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions STATUS INDICATOR LIGHT DEAD Genset locked out faulty connections no battery voltage Corrective Action 1 Unlock the genset with the lockout switch in the cab and or boom bucket 2 Try the genset Start Switch if the remote Start Switch does not work and vice versa 3 Clean and tighten the positive and negative battery cable connections at the battery vehicle frame and genset 4 Recharge or replace the battery Refer to the battery manufacturer s recommendations Power _ Generation 22 Redistribution or publication of this document by any means is strictly prohibited TABLE 4 TROUBLESHOOTING CONT Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions STARTING BATTERIES RUN DOWN Marginal batteries connections or charging system or parasitic loads Corrective Action 1 Clean and tighten the positive and negative battery cable connections at the battery vehicle frame and genset 2 Recharge
26. e up to a total that does not overload the genset or cause the circuit breaker to trip If a cir cuit breaker trips right away when an appliance is connected the appliance probably has a short Electrical appliances and tools must be used and maintained properly and be properly grounded to cause the line circuit breakers to trip when short cir cuits occur Short circuits in electrical appliances and tools can cause fire and electri cal shock leading to severe personal injury or death Read and follow the equipment and tool manufacturer s instructions and warnings regarding use maintenance and proper grounding CONNECTING UTILITY POWER A vehicle with provisions for connecting utility power must have an approved device to keep the genset and utility from being interconnected See the gen set Installation Manual for more information Interconnecting the genset and the public utility or any other power source can lead to electrocution of utility line workers equipment damage and fire Use an approved switching device to prevent interconnections Power _ i Generation lt m 10 LINE CIRCUIT BREAKERS FIGURE 7 LINE CIRCUIT BREAKER Redistribution or publication of this document by any means is strictly prohibited OPERATING IN COLD WEATHER Pay particular attention to the following items when operating the genset in cold weather 1 Make sure engine oil viscosity is appropriate for the ambient temperatu
27. erece cts rete tia Cis E aaiae ai eilediedd Hace ap ihe ceed 8 Conducting Pre Start Checks 2 122 citets ied dositeibteebiavhieliawierleniies 8 Priming Gasoline Fuel Systems 0 0 00 cece eee eens 8 Starting the Genset cc cn cuties ee hows eiiee tolled histo aa aE ened 8 Stopping the Genset 22 cess cee sateacdesdenceheSesessse Reeth weaeeses teed 9 Restarting the Genset cc toss ertdetsbeeentiabibehic beards beeanridieeds 9 Engine Only Operation s 10 lt 26 lt dhe ses ede ise tetaadededbadeseseaustousyeseens 9 Restarting the Genset 0 c cece eee nents 9 Genset Locko t SWIC 2 t34ediewtueiietineeiactingedxc aires EEES 9 Resetting Circuit Breakers 20 00 cece ete eens 10 Connecting Utility Power i ccto Piatti dibedet ice edite ditt oibdedle ites 10 Operating in Cold Weather 2 22 500n08k eeedew terenit te EEA E EI ENE ees 11 Operating in Hot Weather css0ecteccese sees eteev bea see be eeeeav eee eene eee us 11 Operating at High ANCE lt ku 5022e ewenes Sev ereue sures EAEN 11 Operating in Dusty Environments 00 0c areren rana 12 Breaking In a New Engine 22 40ccevedivwieididwietdiewuiebienetenedneas 12 Exercising the Gensel teat weeteus Heddane HUebteededetener date netaawecs 12 Storing the Genset sciscdneseee epee eras See see Lee ake w Ree Oe REL ERE ENE AD 12 PERIODIC MAINTENANCE oooh aaae 15 Conducting General Inspections nusen naear nanne 16 Checking Engine Oil Level co 2i25
28. et service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions CONTROL CARD FAILURE SHUTDOWN CODE NO 35 Microprocessor EEPROM error during self test Corrective Action See an authorized Onan dealer ENGINE STOPPED SHUTDOWN CODE NO 36 Engine stopped without command by controller Corrective Action 1 Gasoline Models Check and fill the fuel tank as necessary Note The genset fuel pickup tube is probably higher up in the fuel tank than the vehicle engine pickup 2 Low Pressure LPG Models Check and fill the LPG container as necessary On cold days the LPG container may have to be kept at least half full to provide the rate of vaporization necessary to keep up with the genset fuel demand Secure the spark plug leads on the spark plugs Page 20 Replace the spark plugs Page 20 Service the air cleaner Page 19 Check for mechanical damage INVALID GENSET CONFIGURATION SHUTDOWN CODE NO 37 Wrong frequency rpm ratio Corrective Action See an authorized Onan dealer OVERCURRENT FIELD OVERLOAD SHUTDOWN CODE NO 38 Low power factor loads Corrective Action 1 Reduce the number of appliances running at the same time especially those with high motor starting loads such as air conditioners 2 Have air condit
29. f running e Make sure there is ample fresh air when operat ing the genset in a confined area FUEL IS FLAMMABLE AND EXPLOSIVE e Do not smoke or turn electrical switches ON or OFF where fuel fumes are present or in areas sharing ventilation with fuel tanks or equip ment Keep flame sparks pilot lights arc pro ducing equipment and switches and all other sources of ignition well away e Fuel lines must be secured free of leaks and separated or shielded from electrical wiring e 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 Commercial Mobile 1 Power _ Generation ments and other below grade spaces Prevent leaks and the accumulation of gas 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 MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Do not wear loose clothing or jewelry near mov ing 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 hy draulic pump
30. h oil consumption Too little oil can cause severe engine damage Keep the oil level between the FULL and ADD marks 3 Screw the oil fill cap back on securely Power _ Generation lt m 17 1s OIL FILL OIL DRAIN CAP DIPSTICK VALVE FIGURE 10 OIL FILL DIPSTICK AND DRAIN VALVE Redistribution or publication of this document by any means is strictly prohibited CHANGING ENGINE OIL AND OIL FILTER State and federal agencies have de termined that contact with used engine oil can cause cancer or reproductive toxicity Try to avoid skin contact and breathing of vapors Use rubber gloves and wash exposed skin Refer to Table 3 for scheduled engine oil change Change oil more often in hot or dusty environments 1 Place a pan underneath the oil drain hose and filter Figure 11 The genset may have been installed with a remote oil filter Run and then stop the engine when it is warm Crankcase pressure can blow hot engine oil out the fill opening causing severe burns Always stop the genset be fore removing the oil fill cap Remove the oil fill cap open the oil drain valve Figure 10 let all oil drain from the engine and then close the drain valve 3 Spin off the old oil filter and thoroughly wipe off the filter mounting surface Remove the old gasket if it does not come off with the filter Apply a film of oil to the filter gasket and spin the new filter on by hand until
31. horized Onan dealer UNDERVOLTAGE SHUTDOWN CODE NO 13 Controller unable to maintain rated voltage Corrective Action Reduce the number of connected appliances especially when air conditioners and battery chargers are running OVERFREQUENCY SHUTDOWN CODE NO 14 Engine governor unable to maintain rated frequency Corrective Action See an authorized Onan dealer UNDERFREQUENCY SHUTDOWN CODE NO 15 Engine governor unable to maintain rated frequency Corrective Action 1 Reduce the number of connected appliances especially when air conditioners and battery chargers are running GOVERNOR ACTUATOR SHUTDOWN CODE NO 19 Controller sensed open or shorted circuit Corrective Action See an authorized Onan dealer JP 24 GA ower Redistribution or publication of this document Gua Generation by any means is strictly prohibited TABLE 4 TROUBLESHOOTING CONT Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions GOVERNOR ACTUATOR OVERLOAD SHUTDOWN CODE NO 22 Duration of operation at or near full duty cycle beyond design limit Corrective Action 1 Reduce the number of connected appliances especially when air conditioners and battery chargers are running 2 Service the air cleaner Page 19 3 Che
32. i Generation lt m Redistribution or publication of this document by any means is strictly prohibited TYPICAL GENSET Operating the genset with the ac cess cover off can lead to overheating of com Figure 2 illustrates a typical self enclosed genset ponents Always secure the cover after starting with the maintenance access cover removed the genset CONTROL SWITCH amp STATUS INDICATOR LIGHT CIRCUIT AIR CLEANER ALTITUDE ADJUST MAINTENANCE BREAKERS COVER KNOB GASOLINE ACCESS COVER HGJAE HGJAF BATTERY CABLE amp REMOTE CONTROL WIRING ENTRANCE Power Cay Generation J OIL DRAIN OIL FILTER OIL FILL CAP amp VALVE ACCESS BELOW DIPSTICK EXIT BELOW FIGURE 2 TYPICAL SELF ENCLOSED GENSET Redistribution or publication of this document by any means is strictly prohibited Fad z FUEL RECOMMENDATIONS Gasoline and LPG are highly flam mable and explosive and can cause severe per sonal injury or death Do not smoke or turn elec trical switches ON or OFF where fuel fumes tanks or equipment are present or in areas sharing ventilation Keep flames sparks p
33. ilot 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 mini mum octane rating Anti Knock Index of 87 ACAUTION Do not use gasoline or gasoline ad ditives containing methanol because methanol can be corrosive to fuel system components Avoid using leaded gasoline because of the ex tra 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 High LPG supply pressure can cause gas leaks which can lead to fire and se vere personal injury or death LPG supply pres sure must be adjusted to Specifications by trained and experienced personnel OnaMax is a trademark of Onan Corporation Power Generation ENGINE OIL RECOMMENDATIONS Use API American Petroleum Institute perfor mance 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
34. ioners and other appliances checked for proper operation A locked compressor rotor can cause very low power factor GENERATOR ROTOR SHUTDOWN CODE NO 41 Controller unable to sense field or output voltage Corrective Action See an authorized Onan dealer PROCESSOR SHUTDOWN CODE NO 42 Microprocessor ROM error during self test Corrective Action See an authorized Onan dealer JP 26 GA ower a Redistribution or publication of this document Gua Generation by any means is strictly prohibited TABLE 4 TROUBLESHOOTING CONT Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions PROCESSOR SHUTDOWN CODE NO 43 Microprocessor RAM error during self test Corrective Action See an authorized Onan dealer SPEED SENSE SHUTDOWN CODE NO 45 Controller unable to sense quadrature frequency Corrective Action See an authorized Onan dealer IGNITION SHUTDOWN CODE NO 47 Controller unable to sense ignition Corrective Action See an authorized Onan dealer GENERATOR FIELD SENSE SHUTDOWN CODE NO 48 Controller unable to sense field voltage Corrective Action See an authorized Onan dealer PROCESSOR SHUTDOWN CODE NO 51 Microprocessor malfunction Corrective Action See an authorized Onan dealer
35. is 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 mod els 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 Peri odic 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 e Remote switch status lamp Figure 4 e Remote switch status lamp and hour meter Figure 5 e Remote switch status lamp and DC voltmeter Figure 6 The DC voltmeter indicates whether voltage across the 12 VDC control syste
36. l Other Models The precision manufactured carburetor is not adjustable Gasoline Models Fuel Injection Not applicable Engine Adjustments Gasoline Models Carburetor See Figure 8 Page 11 LPG Models Not applicable Gasoline Models Fuel Injection The engine emissions con trol system consists of Sequential Multiport Fuel Injection SFI Engine Emission Control System All Other Models The engine emissions control system con sists of inherent engine design Power 31 Generation FA z Redistribution or publication of this document by any means is strictly prohibited a Power _ f Generation How to Obtain Service When you need service parts or product literature such as the Service Manual for your genset con tact the nearest authorized distributor Onan has factory trained representatives to handle your needs for genset parts and service Call 1 800 888 ONAN to contact the nearest Cum mins Onan or Onan only distributor in the United States or Canada This automated service utilizes touch tone phones only Select OPTION 1 press 1 to be automatically connected to the dis tributor nearest to you If you are unable to contact a distributor using the automated service consult the Yellow Pages Typi cally our distributors are listed under GENERATORS ELECTRIC ENGINES GASOLINE OR DIESEL or RECREATIONAL VEHICLES EQUIPMENT PARTS AND SERVICE If you are outside North America
37. le Power Generation 16 Do not park the vehicle in high grass or brush Contact with the exhaust system can cause a fire Fuel System Check for leaks at the hose tube and pipe fittings in the fuel supply and return systems while the genset is running and while it is stopped Do not use a flame to check for LPG leaks Check flexible fuel hose sections for cuts cracks and abrasions Make sure the fuel line is not rubbing against other parts Replace worn or damaged fuel line parts before leaks occur If you smell gas close the LPG container shutoff valve and have the genset serviced before using it again Gasoline and LPG are highly flam mable and explosive and can cause severe per sonal injury or death Shut down the genset and repair leaks immediately Battery Connections Check the battery terminals for clean tight connections Loose or corroded connections have high electrical resistance which makes starting harder See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Page 19 Arcing at battery terminals or light switch or other equipment or flames and sparks can ignite battery gas causing severe personal injury Ventilate battery area before working on or near battery Wear safety glasses Do not smoke Switch trouble light ON OFF away from battery Do not disconnect battery cables while genset is running or vehicle battery charg ing system is on Always disconnect nega tive cable first and
38. le 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 electri cian 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 inju ry or death and damage to equipment An ap proved switching device must be used to pre vent interconnections Use caution when working on live electrical equipment Remove jewelry make sure cloth ing and shoes are dry stand on a dry wooden platform or rubber insulating mat and use tools with insulated handles Redistribution or publication of this document by any means is strictly prohibited d S ENGINE EXHAUST IS DEADLY e Learn the symptoms of carbon monoxide poi soning in this manual and never sleep in the vehicle while the genset is running unless the vehicle is equipped with a working carbon mon oxide detector e 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 e Inspect for exhaust leaks at every startup and after every eight hours o
39. ltiport 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 Jp 29 FA ower Redistribution or publication of this document Generation Gua by any means is strictly prohibited 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 60 Herz 60 Herz 1 Ph 4 Wire V A 120 240 Volts 27 Amps 120 240 Volts 22 9 Amps 3600 rpm 3600 rpm FUEL CONSUMPTION FUEL CONSUMPTION O O 2 2 Ibs h 1 0 kg h 2 2 Ibs h 1 0 kg h 1 8 Ibs h 0 8 kg h 1 8 Ibs h 0 8 kg h Half load 3 9 Ibs h 1 8 kg h 3 9 Ibs h 1 8 kg h 3 3 Ibs h 1 5 kg h 3 3 Ibs h 1 5 kg h 5 3 Ibs h 2 4 kg h 5 3 Ibs h 2 4 kg h 4 6 Ibs h 2 1 kg h 4 6 Ibs h 2 1 kg h ENGINE Air Cooled 4 Cycle Spark Ignited OHV 90 V Twin Cyl Vertical Shaft Governor Mechanical Mechanical Speed Bore Stroke Comp Rato Oi Capacity Valve Lash Cold Spark Plug 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 LPG Vapor Connection 3 8 18 NPTF 3 8 18 NPTF Pressure 9 13 i
40. m and battery is normal If the indicator consistently stays above or below the normal zone see MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Page 19 GA Power _ i Generation lt m CONTROL SWITCH amp STATUS IN L CATOR LIGHT LINE CIRCUIT BREAKERS FIGURE 3 GENSET CONTROL PANEL gt GenGet Start Stop O A FIGURE 4 REMOTE SWITCH N Gen et Start l ol ToL fof Tol fol sf O TOTAL HOURS QUARTZ Stop CT o FIGURE 5 REMOTE SWITCH HOUR METER Genet Start A FIGURE 6 REMOTE SWITCH DC VOLTMETER Redistribution or publication of this document by any means is strictly prohibited Operation EXHAUST GAS IS DEADLY Exhaust gases contain carbon monoxide an odorless colorless gas Carbon monoxide is poisonous and can cause unconsciousness and death Symptoms of carbon monoxide poisoning include e Dizziness e Throbbing in Temples e Nausea e Muscular Twitching e Headache e Vomiting e Weakness and Sleepiness e 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 op erate it until it has been inspected and repaired
41. n 228 330 mm WC 9 13 in 228 330 mm WC LPG Liquid Connection 1 4 18 NPTF 1 4 18 NPTF Pressure Tank Pressure Tank Pressure Hydraulic Fluid Transmission or Petroleum Based Hydraulic Fluid Operating Transmission or Petroleum Based Hydraulic Fluid Operating y Viscosity 80 1000 SSU Maximum Start Up Viscosity 4000 SSU Viscosity 80 1000 SSU Maximum Start Up Viscosity 4000 SSU Sater ump nie Not to exceed 5 in Hg Vacuum or 20 psi Pressure Not to exceed 5 in Hg Vacuum or 20 psi Pressure Hydraulic Pump Con nections Outlet 3 4 16 UNF 2B SAE 3 4 16 UNF 2B SAE Inlet 7 8 14 UNF 2B SAE 7 8 14 UNF 2B SAE Noise GAY 290 Ib 132 Kg 239 Ib 107 Kg 279 Ib 127 Kg 228 Ib 104 Kg Compartment HGJAD HGJAE 17 2 in x 23 2 in x 34 6 in 438 mm x 589 mm x 879 mm H x D x W 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 Jp 30 GA ower Redistribution or publication of this document Generation Gua by any means is strictly prohibited Information for California Genset Users This genset meets the requirements of California s Exhaust Emissions Standards as stated on the nameplate Figure 1 Page 4 illustrates where this information appears on the nameplate As a California user of this genset please be aware tha
42. nance is essential for top perfor mance and long genset life Use Table 3 as a guide for normal periodic maintenance In hot and dusty environments some maintenance procedures should be performed more frequently as indicated by the footnotes in the table Keeping a log of main tenance performed and hours run will help you keep genset maintenance regular and provide a basis for supporting warranty claims Page 33 Maintenance replacement or repair of emission control devices and systems may be performed by any engine repair establishment or individual How ever warranty work must be completed by an authorized Onan dealer TABLE 3 PERIODIC MAINTENANCE SCHEDULE MAINTENANCE FREQUENCY Every Every 50 Month Hours aan e E E E e wmn x ammora P O O emsan S S S e o awesome pe renen O O O e wem OO O e Clean Engine Cooling Fins 2 weren S O O o S e mwmw S S S e e mams O O E 1 As a part of engine break in change the engine oil after the first 20 hours of operation 2 Perform more often when operating in dusty environments 3 Perform more often when operating in hot weather 4 Perform at least once a year 5 Perform sooner if engine performance deteriorates 6 Must be performed by a qualified mechanic authorized Onan dealer MAINTENANCE PROCEDURE Every Day After First or Every 8 Hours 20 Hours Every 150 Every 450 Hours Power 15 Generation FA z
43. neration Redistribution or publication of this document by any means is strictly prohibited
44. pressing STOP once The second level shutdown code will have two digits The faults are listed in numerical order in this table JP 23 GA ower Redistribution or publication of this document Generation Gua by any means is strictly prohibited TABLE 4 TROUBLESHOOTING CONT Some genset service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions OVERCRANK SHUTDOWN CODE NO 4 First level shutdown code Cranking exceeded 30 seconds without engine starting Corrective Action 1 Gasoline Models Check and fill the fuel tank as necessary Note The genset fuel pickup tube is probably higher up in the fuel tank than the vehicle engine pickup 2 Prime the engine fuel system by holding the control switch at Stop Prime for 30 seconds 3 Low Pressure LPG Models Check and fill the LPG container as necessary On cold days the LPG container may have to be kept at least half full to provide the rate of vaporization necessary to keep up with the genset fuel demand Open any closed fuel valves Secure the spark plug leads on the spark plugs Page 20 Replace the spark plugs Page 20 Service the air cleaner Page 19 OVERVOLTAGE SHUTDOWN CODE NO 12 Controller unable to maintain rated voltage Corrective Action See an aut
45. res Change oil if there is a sudden drop in temperature See ENGINE OIL RECOMMENDATIONS Page 6 2 Perform spark plug maintenance Page 20 Perform battery maintenance Page 19 4 If so equipped reset the carburetor for altitude Figure 8 OPERATING IN HOT WEATHER Pay particular attention to the following items when operating the genset in hot weather 1 Make sure nothing blocks airflow to and from the genset 2 Make sure engine oil viscosity is appropriate for the ambient temperatures See ENGINE OIL RECOMMENDATIONS Page 6 3 Keep the genset clean 4 Perform maintenance due See PERIODIC MAINTENANCE SCHEDULE Page 15 5 If so equipped reset the carburetor for altitude Figure 8 OPERATING AT HIGH ALTITUDE Series HGJAE HGJAF Only For best fuel econ omy and genset operation reset the carburetor for the current altitude Figure 8 Altitude may be found on road maps and road signs For the effect of alti tude on maximum power see LOADING THE GEN SET Page 9 Operating the genset at low altitude with a high altitude setting can cause power loss overheating and engine damage Always reset when returning to lower altitudes oo Power _ Generation lt m 11 ALTITUDE ADJUST KNOB FIGURE 8 ALTITUDE ADJUST KNOB SERIES HGJAE HGJAF GASOLINE ONLY Redistribution or publication of this document by any means is strictly prohibited OPERATING IN DUSTY ENVI
46. t unauthorized modifications or replacement of fuel exhaust air intake or speed control system components that affect engine emissions are pro hibited Unauthorized modification removal or re placement of the genset label is prohibited You should carefully review Operator Owner Installation and other manuals and information you receive with your genset If you are unsure that the installation use maintenance or service of your genset is authorized you should seek assistance from an approved Onan dealer California genset users may use Table 5 as an aid in locating information related to the California Air Re sources Board requirements for emissions control TABLE 5 EMISSIONS CONTROL INFORMATION The California emissions control warranty statement is located in the same packet of information as this manual when the genset is shipped from the factory Engine Valve Lash See Specifications Page 29 Engine Ignition Timing See Specifications Page 29 Gasoline Models The engine is certified to operate on unleaded gasoline See Fuel Recommendations Page 6 Genset Warranty Information Engine Fuel Requirements Engine Lubricating Oil Requirements Engine Fuel Mixture Settings LPG Models The engine is certified to operate on LPG See Fuel Recommendations Page 6 See ENGINE OIL RECOMMENDATIONS Page 6 Gasoline Models Fuel Injection The precision manufac tured fuel injection system is not adjustable Al
47. tell when to stop the genset before running it out of fuel SHUTDOWN CODES The genset controller provides extensive diagnos tics by causing the status indicator light on the Con trol Switch to blink in a coded fashion Following a fault shutdown the indicator light will repeatedly blink 2 3 or 4 blinks at a time e Two blinks indicates a low oil pressure fault e Three blinks indicates a service fault Press Stop once to cause the two digit second level shutdown code to blink Pressing Stop again will stop the blinking The two digit code consists of 1 2 3 4 or 5 blinks a brief pause and then 1 to 9 blinks The first set of blinks represents the tens digit and the sec ond set of blinks the units digit of the shut down code number For example shutdown code No 36 appears as blink blink blink pause blink blink blink blink blink blink long pause repeat e Four blinks indicates that cranking exceeded 30 seconds without the engine starting e Note shutdown code Nos 3 and 4 are first level faults Avoid interpreting them as sec ond level shutdown code Nos 33 and 44 which have not been assigned as shutdown codes Restoring shutdown code Blinking The shut down code stops blinking after five minutes 15 min utes Series HGJAD Press Stop three times within five seconds to restore blinking Note that the last fault logged will blink even after the condition that caused the shutdown has been correcte
48. tery area before working on or near battery Wear safety glasses Do not smoke Switch trouble light ON OFF away from battery Do not disconnect battery cables while genset is running or vehicle battery charg ing system is on Always disconnect nega tive cable first and reconnect it last Refer to Table 3 for scheduled battery maintenance and follow the battery manufacturer s instructions Have the battery charging system serviced if DC system voltage is consistently low or high Always 1 Keep the battery case and terminals clean and dry and the terminals tight FILTER ELEMENT 2 Remove battery cables with a battery terminal puller 3 Make sure which terminal is positive and which is negative before making battery connections always removing the negative cable first and reconnecting it last to reduce arcing REPLACING THE AIR FILTER ELEMENT Refer to Table 3 for scheduled air filter element replacement In dusty environments the filter ele ment should be inspected and changed more fre quently To change the filter element Figure 12 1 Unlatch the three spring clips and rotate the cover out and away from the hooks on top Re move the air filter element 2 Wipe the filter element sealing surfaces clean and reassemble the air filter with a new filter element CARBURETOR SPRING CLIPS FIGURE 12 REPLACING THE AIR FILTER ELEMENT Power _ Generation
49. the gasket just touches the mounting pad Then turn it 1 2 to 3 4 turn not more Refill with 2 quarts 1 8 I of oil See ENGINE OIL RECOMMENDATIONS Page 6 Check and add or drain oil as necessary Too much oil can cause high oil consumption Too little oil can cause severe engine damage Keep the oil level between the FULL and ADD marks OIL FILLS VERY SLOWLY TAKE YOUR TIME AND CHECK LEVEL OFTEN WHILE FILLING IT TAKES TIME FOR THE AIR IN THE CRANKCASE TO ESCAPE AND AL LOW OIL TO ENTER Dispose of the used oil and oil filter in accor dance with local environmental regulations OIL FILTER OIL DRAIN HOSE FIGURE 11 OIL FILTER AND DRAIN HOSE VIEW FROM BELOW OF FRONT EDGE OF GENSET 18 Power _ Generation Fad z Redistribution or publication of this document by any means is strictly prohibited Fad z MAINTAINING BATTERY AND BATTERY CONNECTIONS Arcing at battery terminals or light switch or other equipment or flames and sparks can ignite battery gas causing severe personal injury Ventilate bat
50. vehicles with LPG engine fuel systems 8 Push the genset line circuit breaker OFF Page 10 p 13 T ower Redistribution or publication of this document Generation by any means is strictly prohibited Returning Genset to Service 1 Check the oil tag on the genset and change the oil if the viscosity indicated is not appropriate for the temperatures expected See ENGINE OIL RECOMMENDATIONS Page 6 Reconnect the starting battery negative ca ble last See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Page 19 Remove the plug from the exhaust tailpipe Change the air filter element if it is dirty Page 19 Open the fuel supply valve if so equipped 14 Inspect the genset See CONDUCTING GEN ERAL INSPECTIONS Page 16 Gasoline Models Prime the genset fuel sys tem by holding the control switch at STOP PRIME for 30 seconds The status indicator light will stay on solid while the pump is on Start the genset There may be smoke and rough operation for a few minutes until the oil from the fogger burns off If the engine does not start clean or replace the spark plugs which may have been fouled by the fogger Push the genset line circuit breaker ON Page 10 when the genset is ready to power appliances Power _ Generation ad z Redistribution or publication of this document by any means is strictly prohibited Periodic Maintenance Periodic mainte

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