Onan HGJAA, HGJAB, HGJAC, HGJAD, HGJAE, HGJAF Generator Set Complete Factory Service Repair Workshop Manual

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Printed in U.S.A. 983−0600B 07-06 HGJAA, HGJAB, HGJAC Installation Manual

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

i 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 HGJAA / HGJAB 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Muffler—Model HGJAC 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailpipe 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. FUEL CONNECTIONS 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline—Model HGJAA 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline—Models HGJAB / HGJAC 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Pressure Propane Supply (Vapor Withdrawal) 4-5 . . . . . . . . . . . . . . . . . . . . . . . . High Pressure Propane Supply (Liquid Withdrawal) 4-6 . . . . . . . . . . . . . . . . . . . . . . . . 5. ELECTRICAL CONNECTIONS 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Power Output Connections 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Control Connections 5-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Connections 5-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii SECTION PAGE 6. INSTALLATION REVIEW AND STARTUP 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hot Air Recirculation Test 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Review 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Startup 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. SPECIFICATIONS 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTLINE DRAWING—HGJAA / HGJAB A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTLINE DRAWING—HGJAC A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM—HGJAA A-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM—HGJAB / HGJAC A-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii 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 main- tained. The following symbols in this manual alert you to potential hazards to the operator, service person and equipment. DANGER alerts you to an immediate hazard that will result in severe personal injury or death. WARNING alerts you to a hazard or unsafe practice that can result in severe personal injury or death. CAUTION alerts you to a hazard or unsafe 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. 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, arc- producing 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 base- ments 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. • 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 accordance 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 electri- cian in accordance with applicable codes. • 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.

iv 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. 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. • 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. • 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

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, mechani- cal, fuel and exhaust equipment. WARNING This genset is not a life support system. It can stop without warning. Children, per- sons 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 criti- cal. CAUTION Unauthorized modifications or re- placement 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 HGJAA, HGJAB and HGJAC 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 main- tenance instructions. Note: Manuals are updated from time to time to re- flect 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 Recreational Vehicle. The installer bears sole responsibility for the selec- tion of the appropriate genset, for its proper installation and for obtaining approvals from the authorities (if any) having jurisdiction over the installation. These sets meet the basic requirements of the Standard for Safety for Engine Generator Sets for Recreational Vehicles, ANSI/RVIA EGS-1. They are suitable for installation in accordance with: • NFPA No. 1192—Recreational Vehicles • NFPA No. 70, Article 551—Recreational Ve- hicles and RV Parks • NFPA No. 58—Liquefied Petroleum Gas Code • CSA Electrical Bulletin 946—Requirements for Internal Combustion Engine-Driven Electric Generators for Use in Recreational Vehicles Federal, State and local codes, such as the Califor- nia Administrative Code—Title 25 (RV installation), might also be applicable. Installation codes and rec- ommendations can change from time-to-time and are different in different countries, states and munic- ipalities. 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 7-1) 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 — AL- WAYS 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 Figure 2-1. The location must pro- vide: 1. Ready access for starting and stopping the genset and performing all periodic mainte- nance 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 clear- ances apply to any thermal or acoustic insula- tion with which a compartment may be lined. See Specifications (Page 7-1) for minimum compartment dimensions. 8. For a Model HGJAC genset, which does not have an integral enclosure, protection from rain and road splash. FIGURE 2-1. TYPICAL GENSET LOCATIONS

Onan HGJAA, HGJAB, HGJAC, HGJAD, HGJAE, HGJAF Generator Set Complete Factory Service Repair Workshop Manual

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