Onan RV7000 Generator Installation
Contents
1. 2 A035D005 Issue 7 4 2014 1 Important Safety Instructions 14 Automatic Generator Start Control Hazards Accidental starting can cause severe personal injury or death Turn off the AGS whenever performing maintenance or service when the vehicle is stored between uses is awaiting service or is parked in a garage or other confined area Unexpected starting may occur if the generator set is equipped with an inverter charger or other Automatic Generator Start AGS control This may cause exposure to e Unexpected generator starting e Moving parts hazards e Electric shock e Exhaust carbon monoxide CO 1 5 Electrical Shock and Arc Flash Can Cause Severe Personal Injury or Death Electrical shocks and arc flashes can cause severe personal injury or death Adhere to the following guidelines Only qualified service personnel certified and authorized to work on power circuits should work on exposed energized power circuits All relevant service material must be available for any electrical work performed by certified service personnel Exposure to energized power circuits with potentials of 50 VAC or 75 VDC or higher poses a significant risk of electrical shock and electrical arc flash Refer to standard NFPA 70E or equivalent safety standards in corresponding regions for details of the dangers involved and for safety requirements 1 6 Generator Voltage Is Deadly Improperly connected generator electrical outpu2. 1 Battery COMB 20555556 Son li lid 45 ree Batty CODI occ 46 CDA EEEE 46 6 3 4 Battery Cable Connections at the Generator Set i aaaiasnsaassas a sassasasaaaaaaaa 48 6 3 5 Generator Set Equipment Grounding SCreW aaniianiaasssssia aas aasaaaaaananaaaanaanaa 48 7 INSJAR ATJO NREVERVWV ANDISTARTUP 22222222i2iaa aa iv snssni sa sssrnnsissadslasi sudsaniruasdsdsn aanandalanr 49 1 METEO REVEN Locoacocononoogaogonacono coco EEES EET EET 49 O 6 ihe eta E EE 49 FSotArrRecirculatonskest TT FV NH ira rocoso coins aia ado 50 SOS FEE E 50 ko 2 Test Requirement aaa Si E ACS tran maces Iii 52 ABRENDIDGASZOUTEINEIDRAWINGS TT T H TJ TI 53 FO QUE DEA OE r E 55 ii A035D005 Issue 7 1 Important Safety Instructions 1 1 Overview Thoroughly read the Operator Manual before operating the generator set It contains important instructions that should be followed during operation and maintenance Safe operation and top performance can only be achieved when equipment is properly operated and maintained The owners and operators of the generator set are solely responsible for its safe operation Generator set operation maintenance and installation must comply with all applicable local state and federal codes and regulations Electricity fuel exhaust moving parts and batteries present hazards which can result in severe personal injury or death Only trained and experienced personnel with knowledg
3. 7 0 HGJAA 7 0 HGJAB 5 5 HGJAA 5 5 HGJAB GENERATOR 2 Pole Revolving Field Self Excited 1 Phase Capped Digital Voltage Regulated 2 Bearing Vertical Shaf aft 7000 Watts 5500 Watts Frequency 60 Hz Voltage 120 Volts Ei IES 3600 RPM FUEL CONSUMPTION 1 6 Vh 0 43 gph ENGINE 90 V Twin Cylinder 4 Cyle Spark Ignited OHV Air Cooled Vertical Shaft SFI Carburetor SFI Carburetor 80 mm 3 15 in 65 mm 2 56 in Displacement _ in Bo St Displacement 653 cm 39 8 in 7 Compression Oil Capacity 1 8 liters 2 0 qt A035D005 Issue 7 9 2 Introduction 4 2014 Mo 7 0 HGJAA 7 0 HGJAB 5 5 HGJAA 5 5 HGJAB Intake Valve Lash Cold 0 10 mm 0 004 in Exhaust Valve Lash Cold 0 10 mm 0 004 in Spark Plug Gap 6 7 mm 0 025 in Spark Plug Torque 23 32 Nm 18 25 ft lbs Ignition Timing 20 BTDC non adjustable Magneto Air Gap 0 3 mm 0 012 in Compression 3 9 kgf cm 55 47 Ibf in 500 RPM DC SYSTEM Battery Voltage 12 Volts Minimum Battery o o Rating 450 CCA 18 C 0 F INSTALLATION Exhaust O D 31 75 mm 1 25 in Fuel Supply 5 16 in SAE J1231 1 4 in SAE J1231 5 16 in SAE J1231 1 4 in SAE J1231 Connection Type 1 Type 1 Type 1 Type 1 Fuel Return 1 4 in SAE J1231 1 4 in SAE J1231 Connection Type 1 Type 1 Minimum Free Air Inlet Area 232 cm 36 in Weight 136 kg 299 Ibs 131 kg 288 Ibs Minimum Compartment 438 mm x 589 mm
4. Cable Terminal Ss FIGURE 28 BATTERY CABLE CONNECTIONS 6 3 5 Generator Set Equipment Grounding Screw When required connect the generator set grounding screw 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 11 Nm 8 ft lbs 48 A035D005 Issue 7 7 1 7 2 Installation Review and Startup Installation Review Before starting the generator set inspect the installation and check Y 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 generator set easily accessible for starting and stopping the generator set 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 generator set 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 tailpipe terminate at least 25 mm 1 in beyond the perimeter of the vehicle and at least 153 mm 6 in away from any opening into the vehicle Is the generator set located outside the vehicle interior or separated by approved vapor
5. Space to mount the generator set with at least 12 7 mm 1 2 in clearance at the top and any side of the generator set Minimum clearances apply to any thermal or acoustic insulation with which a compartment may be lined Locating a generator set more than 5 feet above the floor and at the very back of the vehicle can result in g forces imparted to the generator set that causes physical damage to it as it travels down the road Generator sets located in these areas do not have warranty coverage for damage resulting from high g loads NOTICE Consider air flow requirements for passenger side installations when the generator is required to operate while the vehicle is in motion Installations must meet rise over ambient tests see Hot Air Recirculation Test in various modes of operation A035D005 Issue 7 15 3 Location Mounting and Ventilation 4 2014 3 1 1 Typical Generator Set Locations Class A RV FIGURE 1 TYPICAL GENERATOR SET LOCATIONS CLASS A RV 3 1 2 Typical Generator Set Locations Class C RV FIGURE 2 TYPICAL GENERATOR SET LOCATIONS CLASS C RV 16 A035D005 Issue 7 4 2014 3 Location Mounting and Ventilation 3 1 3 Typical Generator Set Locations Class B Van FIGURE 3 TYPICAL GENERATOR SET LOCATIONS CLASS B VAN 3 1 4 Typical Generator Set Locations Pickup Truck Camper FIGURE 4 TYPICAL GENERATOR SET LOCATIONS PICKUP TRUCK CAMPER 3 2 Mounting The generator
6. 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 generator set 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 Has the fuel line s been secured at sufficiently close intervals to prevent chaffing and contact with sharp edges electrical wiring and hot exhaust parts Startup Batteries give off explosive gases that can cause severe personal injury Do not smoke near batteries Keep flames sparks pilot lights switches arc producing equipment and all other ignition sources away When all the items on the Installation Review check list have been checked connect the battery cables to the battery positive cable first A035D005 Issue 7 49 7 Installation Review and Startup 4 2014 7 3 7 3 1 50 Read the Operator Manual and perform the maintenance and pre start checks as instructed The generator set is shipped from the factory with the proper level of engine oil but the oil level should be checked before starting the generator set This product
7. cotton organic fibers etc unless it is insulated or shielded The temperature rise above ambient on adjacent combustible material must not exceed 65 C 117 F 6 Do not route the exhaust tailpipe underneath the oil drain 7 Do not route the exhaust tailpipe such that it will restrict the air inlet outlet 8 To keep the tailpipe from being damaged do not route it such that it protrudes into the approach or departure angles of the vehicle or below the axle clearance line 9 Do not interconnect generator set and vehicle engine exhaust systems 22 Do not terminate the tailpipe underneath the vehicle Extend it a minimum of 25 mm 1 in beyond the perimeter of the vehicle Support the end of the tailpipe such that it cannot be pushed in and up under the skirt of the vehicle Do not terminate the tailpipe such that it is closer than 153 mm 6 in to any opening such as a door window vent or unsealed compartment into the vehicle interior Excessive back pressure can cause loss of performance and engine damage Make sure a tailpipe deflector will not cause excessive back pressure Exhaust back pressure cannot exceed 6 to 8 inches of water column 1 3 psi Pressure is measured by drilling a hole located in the rear muffler outlet flange Install a barb fitting in the hole Using a u tube manometer measure the difference of the water in the water column This difference should be 6 to 8 inches 1 3 psi After tes
8. Power Generation 1400 73rd Ave NE Minneapolis MN 55432 USA Phone 1 763 574 5000 Toll free 1 800 888 6626 Fax 1 763 574 5298 Copyright O 2014 Cummins Power Generation Inc All rights reserved Cummins Onan the C logo and Performance you rely on are trademarks of Cummins Inc
9. double flare hose beads e Recommended for all tubing and fittings Flexible Hose Use 1 4 inch I D fuel hose that meets applicable standards for evaporative emissions 5 1 3 Routing Fuel Lines Electric arcs can ignite gasoline leading to severe personal injury or death Do not run wiring and fuel lines together 1 Route the fuel line along bulkheads and frame members such that it is protected The entire length of the fuel line must be visible for inspection and accessible for replacement It is preferred that fuel line routing be parallel to the motorized chassis fuel line FIGURE 14 FUEL LINE PREFERRED ROUTING NOTICE The fuel line should be at or above the top of the fuel tank to reduce siphoning if a line breaks or a hose comes off 2 Support and protect fuel lines to restrain movement and prevent chaffing or contact with sharp edges electrical wiring and hot exhaust parts A035D005 Issue 7 29 5 Fuel Connections 4 2014 5 2 Gasoline EFI The installer is responsible for meeting all CARB and EPA evaporative emissions requirements that may be applicable for the fuel system Beginning January 1 2011 all 50 states require evaporative regulation compliance 30 A035D005 Issue 7 4 2014 5 Fuel Connections No Description No Description Carbon Canister FJ Generator Set Bottom View 0148 1343 Vent Filter 3 5 16 in Purge Hose vapor 8 5 16 in Fuel Line from Pump li
10. going to print In line with Cummins Power Generation policy of continuous development and improvement information may change at any time without notice The users should therefore make sure that before commencing any work they have the latest information available The latest version of this manual is available on QuickServe Online https qsol cummins com info index html 2 2 Related Literature Before any attempt is made to operate the generator set the operator should take time to read all of the manuals supplied with the generator set and to familiarize themselves with the warnings and operating procedures A generator set must be operated and maintained properly if you are to expect safe and reliable operation The Operator manual includes a maintenance schedule and a troubleshooting guide The Health and Safety manual must be read in conjunction with this manual for the safe operation of the generator set e Health and Safety Manual 0908 01 10 The relevant manuals appropriate to your generator set are also available the documents below are in English e Operator Manual for RV Generator Set HGJAA Spec J and HGJAB Spec J K A035D009 e Installation Manual for RV Generator Set HGJAA Spec J and HGJAB Spec J K A035D005 A035D005 Issue 7 7 2 Introduction 4 2014 e Generator Set Service Manual for RV Generator Set HGJAA Spec J and HGJAB Spec J K A035D011 e Recommended Spares List RSL for RV Gener
11. incorporates a catalyst exhaust system which leads to subsequent higher exhaust gas temperatures and higher cooling air outlet temperatures Due to these higher exhaust gas temperatures and higher cooling air outlet temperatures the installer must review and follow all guidelines for the installation Care must be taken to ensure that all installation requirements in this entire manual are met EXHAUST GAS IS DEADLY Do not operate the generator set when the vehicle is indoors or where exhaust can accumulate Start and operate the generator set following all the instructions and safety precautions in the Operator Manual Check for fuel and exhaust leaks and unusual noises while the generator set is running under full and intermediate loads Do not place the generator set in service until all fuel and exhaust leaks have been fixed and operation is satisfactory Hot Air Recirculation Test A representative installation of the generator set must be tested to determine that the generator set will not overheat due to recirculation of hot air back into the generator set Beginning with Spec J EPA Phase 3 and CARB Tier 3 product incorporates a catalyst exhaust system which leads to subsequent higher exhaust gas temperatures and higher cooling air outlet temperatures Due to these higher exhaust gas temperatures and higher cooling air outlet temperatures the installer must review and follow all guidelines for the installation Care must be taken
12. injury or death Only trained and experienced personnel should make adjustments while the generator set is running Moving parts can catch on loose items such as clothing or jewelry Do not wear loose clothing or jewelry near moving parts such as PTO power take off shafts fans belts and pulleys Moving parts can entangle appendages such as fingers Keep the protective guards in place over fans belts pulleys and other moving parts and keep hands away from all moving parts 1 11 CARB 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 6 A035D005 Issue 7 2 Introduction 2 1 About This Manual This manual is a guide for the installation of the generator sets listed on the front cover Proper installation is essential for top performance Read through this manual before starting the installation Leave this manual in the vehicle The installer must be qualified to perform installation of electrical and mechanical equipment This manual addresses the following aspects of the installation e Location Mounting and Ventilation e Exhaust Connections e Fuel Connections e Electrical Connections e Startup See the Operator Manual for operation and maintenance and the Service Manual for service The information contained within the manual is based on information available at the time of
13. municipalities Obtain the standards listed in the table below for reference TABLE 1 REFERENCE CODES AND STANDARDS R a of ae Superintendent of Documents egulations Title 49 Chapter Ill and I P O Box 371954 Chapter V Pittsburgh PA 15250 7954 National Fire Protection Association NFPA 58 70 1192 470 Atlantic Avenue Boston MA 02210 Recreational Vehicle Industry Association ANSI RVIA EGS 1 14650 Lee Road Chantily VA 22021 R Pride State of California Documents Section ministrative Code Title 25 P O Box 1015 Chapter 3 North Highlands CA 95660 8 A035D005 Issue 7 4 2014 2 Introduction CAN CSA Z240 Canadian Standards Association Housing and Construction Materials Section Recreational Vehicles 178 Rexdale Blvd Bulletin 946 Rexdale Ontario Canada M9W 1R3 SAE J1231 31508 SAE World Headquarters J2044 J2599 400 Commonwealth Drive Warrendale PA 15096 2 4 Electromagnetic Compatibility Compliance Generator sets emit and receive electromagnetic radio frequency energy If the generator set affects operation of nearby devices or nearby devices affect generator set operation increase the distance between them When used in countries where compliance to the EMC directive is required This generator set has been evaluated for use in the residential commercial and light industrial environments 2 5 Specifications 2 5 1 Gasoline Model Specifications TABLE 2 GASOLINE MODEL SPECIFICATIONS a
14. the generator set with the cover or service doors removed Starting fluids such as ether can cause explosion and generator set engine damage Do not use Benzene found in some fuels has been identified by some state and federal agencies to cause cancer or reproductive toxicity Do not ingest breathe the fumes or contact gasoline when checking draining or adding gasoline Used engine oils have been identified by some state and federal agencies to cause cancer or reproductive toxicity Do not ingest breathe the fumes or contact used oil when checking or changing engine oil To prevent accidental or remote starting while working on the generator set disconnect the negative battery cable at the battery using an insulated wrench Unsecured or loose fasteners can cause equipment damage Make sure all fasteners are secure and properly torqued Oily rags and other material can cause fire and restrict cooling Keep the generator set drip pan and compartment clean Accumulated grease and oil can cause overheating and engine damage presenting a potential fire hazard Keep the generator set clean and repair any oil leaks promptly NOTICE Keep multi class ABC fire extinguishers handy Class A fires involve ordinary combustible materials such as wood and cloth Class B fires involve combustible and flammable liquid fuels and gaseous fuels Class C fires involve live electrical equipment Refer to NFPA No 10 in applicable region
15. 18 6 to 24 4 m 61 to 80 ft 00 AWG 1 Battery cable lengths are total lengths from battery to the generator back to the battery and when using a total of 1000 CCA Cold Cranking Amps 2 A total length of up to 6 m 20 ft may be used in warmer climates or when battery capacity totals at least 1000 CCA Battery Cables Size battery cables according to the Battery Cable Sizes table The current path between the generator set 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 generator set to the negative battery terminal Note also that codes may require bonding conductors from the generator set and the battery to the vehicle frame If a vehicle frame is used as the path between the negative battery terminal and the generator set 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 must be used to connect the frame to the designated negative terminal on the generator set NOTICE The generator set mounting bolts are not considered an adequate means of bonding the generator set to the vehicle frame either for the purpose of carrying cranking currents or for complying with
16. 20 LPG FUEL LINE APPLIANCE CONNECTIONS 2 5 THROUGH 5 5 RVV LPG SYSTEMS LPG systems vvith 6 5 RVV must have dedicated e Tank e Regulator e Piping Connections Upon completion of the installation fill the LPG tank and test every joint and fitting in the LPG supply system using an approved method such as soap bubbles Because variations in fuel altitude and ambient temperature affect performance it might be necessary to make governor and fuel mixture adjustments once the generator set has been installed See the Service Manual A035D005 Issue 7 39 5 Fuel Connections 4 2014 No Description No Description Bl Shutoff Valve 5 Demand Regulator EN Two Stage Regulator H Fuel Shutoff Solenoid 11 in W C Outlet Pressure Fuel Line Size 3 8 in 1 D up to 0 9 m 3 ft or 1 2 in I D up to 4 6 m 15 ft He LPG Vent Hose vent outside compartment FIGURE 21 TYPICAL LPG VAPOR WITHDRAWAL FUEL SYSTEM 40 A035D005 Issue 7 6 Electrical Connections HAZARDOUS VOLTAGE Touching uninsulated live parts inside the generator set and 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 Secure protective covers when completing installation IMPROPER WIRING can cause fire or electric shock resulting in severe personal injury or
17. 30 mm 9 13 in WC Pressure LPG Liquid Connection 1 4 18 NPTF Tank Pressure Pressure 136 kg 299 Ibs 131 kg 288 Ibs Minimum Compartment 438 mm x 589 mm x 879 mm 17 2 in x 23 2 in x 34 6 in Size H x D x WF 1 60 Hz models are listed by CSA and the US Testing Company 2 See the Installation Manual for additional considerations when sizing the generator set compartment A035D005 Issue 7 11 2 Introduction 4 2014 2 6 List of Acronyms TABLE 4 ACRONYM DEFINITIONS Acronym C Gs Pl W o e 3 z z z le 3 FT 4 n W lt S BTDO CA o PG CSA c EEPROM EGT Exhaust Gas Temperature EMC Electromagnetic Compatibility il i EPA Environmental Protection Agency Grounded Fault Circuit Interrupters E LPG AP AT NFPA National Fire Protection Agency NPTF National Pipe Taper Fuel Engine Run Only GR Q SO RO D E Outside Diameter Original Equipment Manufacturer Personal Protective Equipment TO Power Take Off AM Random Access Memory m V m V 12 A035D005 Issue 7 4 2014 2 Introduction ROM ReadOnyMemoy OOOO Society of Automotive Engineers S Society of Automotive Engineers Sequential Multiport Fuel Injection Standard Repair Times we TABLE 5 ACRONYMS FOR UNITS OF MEASUREMENT Bo d E F E AA psi OR Ibf in CA A q Quart A035D005 Issue 7 13 2 Introduction 4 2014 RPM Revolutions per Minute
18. A035D005 Issue 7 19 3 Location Mounting and Ventilation 20 This page is intentionally blank 4 2014 A035D005 Issue 7 4 1 Exhaust Connections This product incorporates a catalyst exhaust system which leads to higher exhaust gas temperatures The installer must review and follow all guidelines for the installation Care must be taken to make sure that all installation requirements in this entire manual are met The generator set is equipped with a U S Forest Service approved spark arrest muffler Failure to provide and maintain a spark arrester can be a violation of the law Liability for damage injury and warranty expense due to the modification of the exhaust system or the use of unapproved parts is the responsibility of the person performing the modification or installing the unapproved exhaust system parts EXHAUST GAS IS DEADLY To keep exhaust gases from entering the vehicle do not terminate the exhaust tailpipe underneath the vehicle or closer than 153 mm 6 in to openings into the vehicle or route it such that it is not protected Use approved materials only The tailpipe of the generator set will be hot during operation and can cause severe burns To reduce the risk of contact concentration must be used where the tailpipe will be located and routed The generator set exhaust system must be gas tight and designed to prevent entry of exhaust gasses into the vehicle interior Tailpipe Installation Beg
19. Cummins Onan Installation Manual RV Generator Set HGJAA Spec J HGJAB Spec J K English Original Instructions 4 2014 A035D005 Issue 7 California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Table of Contents 1 IMPORTANT SAFETY INSTRUC LONSarrrr e es 1 1 OvervieW A O S 1 2 Warning Caution and Note Styles Used In This Manual oooionnccniconicononononcoonconconconccnnccnnnoss 1 3 Generalfsare y A RE EO Lee dE 1 4 Automatic Generator Start Control Hazards iaaaaaas saaansnsansaaanansaasanannnssanannnnanannin 1 5 Electrical Shock and Arc Flash Can Cause Severe Personal Injury or Death LO CTE voltage S Deadly o cc HERP oe ae ae ee rate Ce 1 7 Engine Exhaust Carbon Monoxide Is Deadly aaaaaaaaas saaas aas saaannasaananannnsaaaaannnasaania 1 8 Fuel Is Flammable and Explosive cc cecseccacecsccceceeeeeeececeeeeeeeeeeeeeeeeeeeeesseeseeeesseeesseeees TIBIA EOS A A Seecneaae aun asec pence OR a 1 10 Moving Parts Can Cause Severe Personal Injury or Death ooooocccccnncccocccccccccccnanannccnoncnannnns AMAR A o co a o O tty eo aS TROTE co cc E EN TT ree 21 AU TS A EEE ZePaRClalegiLiteratuney Mepeeeeesgtee cccccccccsececsccccuccucccsscsecceceesessess seus tsesuestadseusensccedeesscssana
20. Gas Leakage Connect LPG fuel system 1 Adjust the gas supply pressure at the gas inlet of the pressure regulator to at least 229 mm 9 in Water Column WC The pressure must not exceed 330 mm 13 in WC 2 Route LPG fuel lines away from electrical wiring and hot engine exhaust components Fuel lines should be accessible for inspection and replacement protected from damage and secured to prevent kinking contact with sharp edges and chafing due to vibration 3 Route the LPG vent hose so that it vents to the outside or provide required openings 4 For a long fuel line run use seamless steel tubing with flared ends Make flexible hose connections at the fuel tank and at the generator set Use 3 8 inch I D fuel line for runs up to 0 9 m 3 ft and 1 2 inch 1 D up to 4 6 m 15 ft A035D005 Issue 7 4 2014 5 Fuel Connections Do not connect the generator set fuel supply line to any appliance fuel supply line The generator set 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 generator set and other appliances at the expected temperature conditions lt may be necessary to use a separate fuel tank for the generator set if sufficient fuel cannot be supplied with a single tank system Mio INo Description No Description 2 Regulator Heating 4 Generatorset Op FIGURE
21. R RECIRCULATION TEST A035D005 Issue 7 51 7 Installation Review and Startup 4 2014 7 3 2 Test Requirement High ambient operating temperatures could reduce maximum generator set power output if the air temperature rise measured in this test is on the high end of the acceptable range The rise in inlet air temperature over ambient air temperature must not exceed 8 C 15 F in all modes of operation 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 52 A035D005 Issue 7 Appendix A Outline Drawings Table of Contents Figure 30 Outline Drawing HGJAA HGJAB 222222aaaaaaaan aaaass saans anannaanannnnaanannaanannnnanannaannannaanannnanaan naan A035D005 Issue 7 53 Appendix A Outline Drawings 4 2014 This page is intentionally blank 54 A035D005 Issue 7 4 2014 A 0 Outline Drawing 563 3 22 181 REMOTE CABLE CONNECTION AC OUTPUT CONNECTION 1 2 CONDUIT SEE NOTE 3 FUEL INLET CONNECTION SAE JI231 TYPE 1 HOSE BARB FOR 1 4 HOSE SEE NOTE 4 A035D005 Issue 7 B CONNECTION GENSET GROUNDING SCREW LOCATION REMOTE FUEL PUMP ELECTRICAL CONNECTION EFI ONLY 425 16 73 SERVICE ACCESS DOOR 10mm 39 HOLE FOR TAILPIPE HANGER APPROX 117 14 611 INBOARD 31 2 11 471 FUEL INLET FUEL RETURN EFI ONLY SAE J1231 T
22. RE 17 FUEL PUMP KIT FIGURE 18 REMOTE PUMP WIRING CONNECTOR 5 2 8 Fuel Supply Line Pump to Generator Set 1 Connect the 5 16 inch generator set hose barb to the vapor hose from the carbon canister 36 A035D005 Issue 7 4 2014 5 Fuel Connections 2 Connect the 1 4 inch generator set hose barb to the fuel supply hose from the fuel tank No Description we Description 5 16 inch Supply Hose Fitting 1 4 inch Return Hose Fitting FIGURE 19 FUEL FITTINGS LEFT END OF BASE 5 2 9 Generator Set 1 Connect the 5 16 inch generator set hose barb farthest from the corner of the base to the vapor purge hose from the carbon canister 2 Connect the other 5 16 inch hose barb to the fuel supply hose from the fuel pump 3 Connect the 1 4 inch hose barb to the fuel supply hose 5 3 LPG LPG is flammable and explosive and can cause asphyxiation NFPA 58 Section 1 6 requires all persons handling LPG to be trained in proper handling and operating procedures High LPG supply pressure can cause gas leaks which can lead to fire and severe personal injury or death LPG supply pressure must be adjusted to Specifications by trained and experienced personnel Sparks can ignite LPG leading to severe personal injury or death Do not run electrical wiring and fuel lines together Separate them with conduit or tubing if run through the same opening Do not tie them together LPG leaks from the vent hose can lead to explosive
23. VAC Volts Alternating Current VDC Volts Direct Current 14 Watts Width A035D005 Issue 7 3 1 Location Mounting and Ventilation The location mounting and ventilation of a generator set must be such that mounting is secure engine exhaust and fuel vapors are prevented from entering the vehicle rain and road debris are prevented from entering the generator set and ready access is afforded for operating the generator set and performing periodic maintenance Location Typical locations for generator set installation are shown below The location must provide Ready access for starting and stopping the generator set and performing all periodic maintenance Separation from sources of flammable vapors such as batteries and fuel tanks which the generator set could ignite Access for connecting and disconnecting fuel lines battery cables remote control wiring and AC wiring Access from below for draining engine oil and changing the oil filter Unobstructed space below the generator set for proper cooling air flow The generator set must not share a compartment or ventilation with batteries or fuel tanks An operating generator set can ignite flammable vapors Make sure the space below the generator set cooling outlet is unobstructed for at least 305 mm 12 in and open on at least 3 sides Locate or shield the generator set cooling air openings from direct rain road splash and debris thrown up by the road wheels
24. YPE HOSE BEAD FOR 1 4 1D HOSE SAE J1231 TYPE HOSE BEAD FOR 1 4 10 HOSE CONNECTION 1 2 CONDUIT NOTE 3 i SEE 853 4 33 6 EFI FUEL INLET CONNECTION SAE J1231 TYPE FOR 5 16 INCH ID HOSE SEE NOTE 4 OMBUSTION AIR NLET 730 9 28 18 FIGURE 30 OIL FILTER lOmm 1 39 HOLE FOR TAILPIPE HANGER EXHAUST CONNECTION 1 3 8 OD 4X CORED FOR 3 8 INCH THREAD FORMING SCREWS SEE NOTE 2 OUTLINE DRAWING HGJAA HGJAB Appendix A Outline Drawings NOTES CORED FOR 3 8 INCH 1 3 8 CONNECTION THREAD FORMING SCREWS SEE NOTE 2 He 818 8 34 6 SEE NOTE 646 125 43 INCLUDES 12 7MM 501 MINIMUM CLEARANCE AROUND GENSET TORQUE MOUNTING SCREWS TO 25 37 t lbs AC LEADS GREEN GROUND 2 WHITE NEUTRALS BLACK CBI LOAD BLACK W YELLOW STRIPE CB2 LOAD LP CONNECTIONS VAPOR 3 8 18 NPTF LIQUID 1 4 18 NPTF WEIGHT TKW 290 LBS 5 5KW 280 LBS 4X EXHAUST CLEARANCE HOLES FOR 3 8 INCH THD FORMING BOLTS SEE NOTE 2 AIR OUTLET 2 99 ACCESS HOLE TO FAN BOLT HANTOM LINES DENOTE GENSET LOCATION SER RVICE ACCESS ie 588 7 23 181 SEE NOTE 1 TE 1 6 25 18 66 40 5 1 59 COMPARTMENT FLOOR TEMPLATE VIEWED FROM TOP OF GENSET FOR LATEST DIMENSIONS AND REVISION SEE 0539 2057 55 Appendix A Outline Drawings 4 2014 This page is intentionally blank 56 A035D005 Issue 7 Cummins
25. accumulations inside the generator set compartment Route the LPG vent hose so that it vents to the outside or provide required openings A035D005 Issue 7 37 5 Fuel Connections 4 2014 38 The flameout of an unvented LPG appliance can lead to explosive accumulations of gas inside the vehicle and the danger of severe personal injury or death Do not connect the generator set fuel supply line to any vehicle appliance supply line 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 NFPA 58 the Standard for the Storage and Handling of Liquified Petroleum Gases NFPA 58 should be used as a guide for the installation of the LPG fuel system NFPA 1192 the Standard on Recreation Vehicles for Liquified Petroleum Gases should be used as a guide for the installation of the LPG fuel system in regard to the following sections e Propane Container e Propane Suppy Connection Connector e Regulated High Pressure Piping e Propane Systems e Propane Piping Systems e Propane Piping Design e Propane Pipe Sizing NOTICE Generator is included in pipe sizing calculations and testing e Special Requirement for High Pressure Testing e Testing Low Pressure Piping Systems for Propane Leakage After Appliances are Connected NOTICE Generator is considered connected as an appliance for testing e Testing Regulated High Pressure Piping System for
26. aeenensees 2 3 Installation Codes and Standards for Safety a aiaiaiaaasasas saaasaasnasaaanansaasanannasanaannnaani 2 4 Electromagnetic Compatibility Compliance aaaaaaaaasaaassass saaanaaaaananannnsaasanannnsaaaaannnanan 2 5 Specifications AA cc ide 2 5 1 Gasoline Model Specifications aaaaaaaaa aanaaannannasnnsanasnnnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnana 2 5 2 LPG Model Specifications aaaaaaaaaaaaannasnnasnnsnnsnannnannnannnannnanannnnnnnnnnnannnnnnnnnanuni 2 0 Bici OP iy ieee on MARAA T 3 LOCATION MOUNTING AND VENTILATION aaaiiaaaaiaaaaa vaaa saan naannnananaananananaaannnnnananaanaaananaaaaa Ohi ll LOGE THON sorna doaoadocoddainocote ht ee eee ace ee O 3 1 1 Typical Generator Set Locations Class A RV ooooooicccccccnccnooconcncnnnnnnanancnccnnnnnnnancnnnnos 3 1 2 Typical Generator Set Locations Class C RV cccccccessssectecceeeeesessencceseeeeeeeeecanee 3 1 3 Typical Generator Set Locations Class B Van aaaaaavaasaaaaaas sananaasasnanannasaana 3 1 4 Typical Generator Set Locations Pickup Truck Camper ainanvniassaassa saasaaaa LM re ds a deer ene SZI SOWIE OOF AO LIN UIA EEE AA A O an sd A 6 323 kire and Exhaust Barriers ie 3 3Ventilallo n FFF t YF a E A a EE E E 4 EXHAUSTEGONNEGCTIONS rers errat UT 07 TT Oo caer EU 4 1 Tailpipe Installation F U FEET A E FT A 4 2 Vehicle ClearancesisC asssRV rr 4 3 Vehicle Cl
27. arbs Secure the hoses with Oeitiker ear type clamps or equivalent Connect the 5 16 inch hose from the vent of the fuel tank identified as 5 16 inch Purge Hose Vapor to the 5 16 inch barb Canister Connection Connect the adjacent 3 8 inch hose barb on the canister to the generator set Do not vent the canister 5 8 inch line into the vehicle or other confined space where the vapors could accumulate to a flammable level Blockage of the canister vent or vent hose could lead to collapse of system components due to vacuum To prevent dirt from entering the canister vent when it is mounted in a dirty location connect the 5 8 inch hose barb to a hose terminated outside the living space of the vehicle at a location that is not exposed to road splash or dust Alternatively secure Onan Part Number 0148 1343 vent filter to the hose barb A035D005 Issue 7 4 2014 5 Fuel Connections No Description No Description HA G FIGURE 16 ACCEPTABLE CANISTER MOUNTING ORIENTATIONS 5 2 7 Remote Fuel Pump Kit The fuel injection system is supplied by a remote electric pump Install the pump kit made for the model of the vehicle in which the generator set is installed Follow the installation instructions in the pump kit A035D005 Issue 7 35 5 Fuel Connections 4 2014 COO AN Up Q e INo Description No Description 3 Pump Mounting Bracket 6 1 4 inch LD by 6 ft Pump Inlet ose FIGU
28. ately for connections between the generator set and remote control panel To make connections to a remote control panel 1 Push the generator set remote control connector through the entrance hole in the side of the generator set housing and snap it together with the remote wiring harness connector mate Refer to the following table to fabricate the remote control panel and or wiring harness when not using the accessories available from Cummins Onan Mark the remote control end of each lead to identify the connector pin number at the generator set Use insulated 18 AWG copper conductors for distances up to 9 m 30 ft and heavier gauge conductors for greater distances Protect the wiring with full length flexible sheathing Route control leads separately from AC power leads to reduce the possibility of erratic operation due to false induced signals Seal the opening where the leads enter the vehicle interior with silicone rubber or equivalent sealant to keep out exhaust gas FIGURE 24 REMOTE CONTROL CONNECTOR A035D005 Issue 7 4 2014 6 Electrical Connections TYPICAL REMOTE CONTROL PANEL REMOTE CONTROL CONNECTOR GENERATOR SET CONNECTOR EEE WIRE END CONNECTOR END H WIRE END CONNECTOR END CONNECTOR END VIEW A A Description Pin Description Battery Ground LB Stop Prime Start LD Notused TT OOOO FIGURE 25 REMOTE CONTROL CONNECTOR PLUG AND TYPICAL CONNECTIONS 6 3 Start
29. ator Set HGJAA Spec J and HGJAB Spec J K A041X685 e Parts Manual for RV Generator Set HGJAA Spec J and HGJAB Spec J K 0983 0201 e Standard Repair Times AR Family 0900 0617 e Service Tool Manual A043D529 e Warranty Manual A040VV374 2 3 Installation Codes and Standards for Safety The Commercial Generator Set Warranty applies only when the generator set is installed in a commercial or recreational vehicle The RV Generator Set Warranty applies only when the generator set is installed in a recreational vehicle The installer bears sole responsibility for the selection of the appropriate generator set for its proper installation and for obtaining approvals from the authorities if any having jurisdiction over the installation The generator sets meet the basic requirements of the Standard for Safety for Engine Generator Sets for Recreational Vehicles ANSI RVIA EGS 1 and are suitable for installation in accordance with e ANSI A1192 NFPA No 501C Recreational Vehicles e NFPA No 70 Article 551 Recreational Vehicles and RV Parks e 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 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
30. d The entire length of the fuel lines must be visible for inspection and accessible for replacement NOTICE The fuel lines should be at or above the top of the fuel tank to reduce siphoning if a line breaks or a hose comes off 2 Support fuel lines to restrain movement and prevent chaffing or contact with sharp edges electrical wiring and hot exhaust parts Vapor and Fuel Return Line Requirements Electronic fuel injected EFI generater sets require a vapor line from the carbon canister to the generator set and a return fuel line from the generator set to the fuel tank Fuel Tank NOTICE 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 Modification must conform with application sectons of the Code of Federal Regulations Titles 40 and 49 and other standards Onan requires a separate fuel pickup tube or a separate fuel tank for the generator set The generator set must never by connected to the fuel supply line of the vehicle engine either to a high pressure system pump in tank that can overpressureize the generator set fuel system or a vacuum system pump in engine that can cause the generator set to starve for fuel Some vehicle chassis manufacturers allow connections to the fuel return line on hight pressure fuel systems Contact the vehicle chassis manufacturer fo
31. death Accidental starting of the generator set can cause severe personal injury or death Do not connect the starting battery until instructed in Chapter 7 on page 49 6 1 AC Power Output Connections The generator set is equipped with a circuit breaker and 3 m 120 in long 30 A 10 AWG leads for AC power output which exit through a rain tight 1 2 inch trade size conduit connector The leads can be terminated at the main AC distribution panel where individual breakers can be provided for vehicle trailer AC loads If longer AC cable is required or code stipulates a 4 x 4 inch junction box is mounted near the generator set Use a weather type junction box if it is exposed to the elements When extending this cable use the proper size wire for amperage and insulation temperature rated wire typically 10 AWG to the main AC distribution panel FIGURE 22 AC OUTPUT CONDUIT A035D005 Issue 7 41 6 Electrical Connections 4 2014 6 1 1 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 veh
32. e of fuels electricity and machinery hazards should perform generator set installation or adjustment procedures or remove dismantle or dispose of the generator set Save these instructions 1 2 Warning Caution and Note Styles Used In This Manual The following safety styles and symbols found throughout this manual indicate potentially hazardous conditions to the operator service personnel or the equipment DANGER Indicates a hazardous situation that if not avoided will result in death or serious injury Indicates a hazardous situation that if not avoided could result in death or serious injury Indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE Indicates information considered important but not hazard related e g messages relating to property damage 13 General Safety Precautions Operation of equipment is unsafe when mentally of physically fatigued Do not operate equipment in this condition or after consuming any alcohol or drug A035D005 Issue 7 1 1 Important Safety Instructions 4 2014 Maintaining or installing a generator set can can severe personal injury Wear personal protective equipment such as safety glasses protective gloves hard hats steel toed boots and protective clothing when working on equipment Running the generator set wihtout the cover or service door can cause severe personal injury or equipment damage Do not operate
33. e vapor and fire resistance must be installed between the generator set and the interior of the vehicle if the generator set is mounted below the floor e If the generator set is mounted in a compartment on the floor of the vehicle the entire compartment must be lined with vapor and fire resistive materials e Use approved materials 26 gauge galvanized steel or equivalent See NFPA 1192 for details e All seams and openings in the barriers for wiring mounting screws etc must be sealed 3 3 Ventilation Generator set cooling air must not be obstructed e A free air inlet size of at least 232 cm 36 in is required Grilles louvers and other kinds of decorative treatments for air openings are restrictive Contact the manufacturer of the decorative assembly or material to find out how large of an opening is required to obtain the minimum free air inlet size 18 A035D005 Issue 7 4 2014 3 Location Mounting and Ventilation e Unless the compartment air inlet lines up directly with the generator set air inlet a clearance of at least 50 8 mm 2 in is required at the front of the generator set for air to get to the generator set inlet Staggering a compartment side opening or pulling the air up under the skirt of the vehicle will reduce line of sight noise but requires the extra clearance in front EO PAWS I a i Fl No Description Air Inlet Air Outlet FIGURE 5 GENERATOR SET COOLING AIR INLET AND OUTLET
34. earances Class ENa 4 4 Vehicle Clearances Pickup Truck Camper aaiaaaaaaaaaanaaanaannasansanasaaaaaaaaaaaaannaanaaanannaaaa 5 FUEL CONNECTIONS ui added 51 Gasoline Motorized o A035D005 Issue 7 wow SR aa OO JJ CIC amp Ww N O O O O ON NN Sy La Sk oar E E E ES EE ea CO CO CO Y Y Y O O OO NNNNDN OOOO NN SJ N Table of Contents 4 2014 O NN 28 A A A ston ba st TA Teas anion a ga dab laa aras daa 29 O k s n llk aaa f i gm ren ente a a Da A da kag ag 29 5 2 Gasoline EFD 0 ita 30 5 21 Fuel HOSES ii e 32 5 2 2 Fuel Lines sr l QUES NT 32 5 2 3 Route EEES 33 5 2 4 Vapor and Fuel Return Line Requirement cocccccccccncccnccnnconconnnnnnonnonnnnnnnnnnncnnncnnnnos 33 O PUE ET coorooosormoncocoruororcconioronnc A coco coc e cocisocododouccbene 33 29 CEA ANS O SPEER Roce oGonooaqqqeqondaHnoqqb000 34 DEZA REMOS US RUN A a MU o AO 35 5 2 8 Fuel Supply Line Pump to Generator Set ooococconccicccinicccocoooononnnonononcnnnonnnnnnncnnnnininos 36 LG NETAS Cor O 37 A te O A a ES DR COSES CEIC Ga 37 6 EREGIRICAEGONNEGNONSE RE lt lt cc Ma E 41 GuleAG RowemOutputGonnectiomS 339 O 41 OMEV MENO St Teg EEES DS EO a E a Se seagate a 42 GG enpecting to Shore Powis AAA A Te eer er ee 42 6 2 Remote Control Connections aaaaaaaaaaaaanaasnasanasansaasasasaaaaaannannnannannnnnnnnnnnnnnnnnnnnnnnananuna 44 Soo OE ue E as AA 45
35. ecommended fuels and Section 2 5 on page 9 for fuel consumption Unauthorized modifications or replacement of fuel exhaust air intake or speed control system components that affect engine emissions are prohibited by law in California 5 1 Gasoline Motorized The maximum fuel pump lift is 914 mm 36 in The generator set and propulsion engine fuel supply and return lines must not be interconnected Connections meet the requirements of the following SAE standards when applicable e J1231 Fromed Tube Ends for Hose Connections and Hose Fittings e J1508 Hose Clamp Spectifications e J2260 Nonmetallic Fuel System Tubing with One or More Layers e J2044 Quick Connector Specification for Liquid Fuel and Vapor Emissions Systems Terminate the generator set fuel pickup above the vehicle engine pickup in the supply tank to keep the generator set from running the vehicle out of fuel Connect 1 4 inch fuel line from the vehicle fuel tank to the generator set A035D005 Issue 7 27 5 Fuel Connections 4 2014 No Description 1 4 inch Fuel Supply Hose Fitting and Fuel Filter Type 1 Hose Beads Hose Clamp and Type 3 Hose Bead FIGURE 13 GASOLINE MOTORIZED FUEL CONNECTION 5 1 1 Fuel Hoses The fuel hoses used inside the generator set are low permeation fuel hoses which meet Federal 50 state standards for gasoline evaporative emissions Low permeation fuel hose is required to meet the requirements for gasoline generator set
36. icle interior to keep out exhaust gas Apply silicone rubber or an equivalent type of 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 Faulty grounding can lead to fire and electrocution resulting in severe personal injury or death Grounding must be in accordance with applicable codes 6 Bond the generator set and all connected AC and DC equipment and controls to a common grounding point in accordance with applicable codes 6 1 2 Connecting to Shore Power Interconnecting the generator set and shore power can lead to electrocution of utility line workers equipment damage and fire Use an approved switching device to prevent interconnections A vehicle with provisions for connecting to utility power must have an approved device to keep the generator set and utility from being interconnected 42 A035D005 Issue 7 4 2014 6 Electrical Connections GND Li N Description No Description Generator Set La ere 8 Blak S O 3 write 2 6 3 Pole Transfer Swith 42 2PoleTramsferSwiteh FIGURE 23 TYPICAL CONNECTIONS WITH TRANSFER SWITCH AND UTILITY A035D005 Issue 7 43 6 Electrical Connections 4 2014 6 2 44 Remote Control Connections The generator set has an 8 pin connector for remote control connections Wiring harnesses in several lengths are available separ
37. ing Battery Connections Accidental starting of the generator set can cause severe personal injury or death Do not connect the starting battery until instructed in Chapter 7 on page 49 The generator set has a 12 VDC negative ground engine control and cranking system See Section 2 5 on page 9 for the requirements for cranking batteries 6 3 1 Battery Compartment 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 A035D005 Issue 7 45 6 Electrical Connections 4 2014 6 3 2 6 3 3 46 Batteries must be mounted in a separate compartment from that of the generator set and away from spark producing equipment A compartment must have openings of at least 11 cm 1 7 in at the top and bottom for ventilation of battery gasses It should be mounted such that spills and leaks will not drip acid on fuel lines wiring and other equipment that could be damaged e Stand alone applications will require a starting battery and a battery charger e RVs often connect house batteries to the generator set All RVs should be equipped with a battery charger to charge the batteries Battery Cable Sizes TABLE 7 BATTERY CABLE SIZES FOR TEMPERATURES DOWN TO 29 C 20 F Total Cable Length Cable Size 0 to 13 7 m 0 to 45 ft 2 AWG 14 to 18 3 m 46 to 60 ft 0 AWG
38. ing on or around the generator set e Inspect for exhaust leaks and test and confirm that all carbon monoxide detectors are working in accordance with the manufacturer s instructions or owner s manual prior to every startup and after every 8 hours of running Never occupy the vehicle while the generator set is running unless the vehicle is equipped with a working carbon monoxide detector Never operate the generator set when the vehicle is in a confined space such as a garage basement or building of any kind Make sure the exhaust system is installed in accordance with the generator set installation manual Never use engine cooling air for heating a working or living space compartment Carbon Monoxide CO is odorless colorless tasteless and non irritating It cannot be seen or smelled Exposure even to low levels of CO for a prolonged period can lead to asphyxiation lack of oxygen Mild effects of CO poisoning include e headache e dizziness e drowsiness e fatigue e chest pain e confusion More extreme symptoms include vomiting seizure e loss of consciousness A035D005 Issue 7 4 2014 1 Important Safety Instructions 1 8 Fuel ls Flammable and Explosive Fuel and fuel vapor is highly explosive Adhere to the following bullets to avoid igniting fuel and fuel vapors Do not smoke or turn electrical switches on or off where fuel fumes are present or in areas sharing ventilation with fuel tanks or equip
39. inning with Spec J EPA Phase 3 and CARB Tier 3 product incorporates a catalyst exhaust system which leads to subsequent higher exhaust gas temperatures and higher cooling air outlet temperatures Due to these higher exhaust gas temperatures and higher cooling air outlet temperatures the installer must review and follow all guidelines for the installation Care must be taken to ensure that all installation requirements are met in Installation Review and Startup The muffler is mounted inside the generator set and has a flange to which the tailpipe adapter available from Cummins Onan is bolted or a collar to which the tailpipe is clamped or a short adapter bolted to its outlet flange Flexible pipe is not gas tight or durable and can cause exhaust gas leaks Do not use flexible pipe for tailpipe 1 Use 18 gauge 1 3 8 inch I D aluminized steel tubing or material of equivalent heat and corrosion resistance for the tailpipe 2 Support a tailpipe longer than 457 mm 1 1 2 ft near its end and at intervals of 900 mm 3 ft or less Use automotive type tailpipe hangers Do not attach the hangers to combustible material such as wood A035D005 Issue 7 21 4 Exhaust Connections 4 2014 Use U bolt muffler clamps to connect sections of tailpipe Overlapping pipe should be slotted 4 Do not route the tailpipe near fuel lines or fuel tanks 5 Do not route the tailpipe closer than 76 mm 3 in to combustible material wood felt
40. ment Keep flame sparks pilot lights arc producing equipment and all other sources of ignition well away from fuel lines and sources Fuel lines must be secured free of leaks and separated or shielded from electrical wiring Leaks can lead to explosive accumulations of gas e LPG sinks when released and can accumulate inside housings and basements and other below grade spaces NOTICE Natural gas is identifiable by a rotten egg smell 1 9 Battery Gas Is Explosive Battery gas is highly explosive and may cause personal injury or death if ignited Take the proper precautions to avoid personal injury e For personal safety wear appropriate PPE when working on or around the generator set e To make sure battery gas is not ignited do not smoke around the generator set e To reduce arcing when disconnecting or reconnecting battery cables always disconnect the negative battery cable first and reconnect it last 1 10 Moving Parts Can Cause Severe Personal Injury or Death Moving parts can cause severe personal injury or death and hot exhaust parts can cause severe burns Make sure all protective guards are properly in place before starting the generator set Hot moving and electrically live parts can cause severe personal injury or death Keep children away from the generator set A035D005 Issue 7 5 1 Important Safety Instructions 4 2014 Hot moving and electrically live parts can cause severe personal
41. og fuel jets Only use soap free lubricants such as WD40 which runs through with the fuel without leaving residues that can clog fuel jets Fuel Lines Tubing e Use 5 16 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 e Tubing must meet requirements for 150 psi operating pressure Ref ASTM A 539 99 and have corrosion resistance equal to or better than hot dipped zinc galvanized Hose Beads e Use suitable tooling to form tubing ends into SAE J1231 Type 1 or Type 3 double flare hose beads e Required for all tubing and fittings When connecting fuel hoses only use soap free lubricants such as WD 40 which runs through fuel without leaving residues that can clog fuel jets A035D005 Issue 7 4 2014 5 2 3 5 2 4 5 2 5 5 Fuel Connections Flexible Hose Use 5 16 inch I D fuel hose that meets SAE J30R9 standards for working pressure and applicable standards for evaporative emissions Hose Clamps Use stainless steel ear clamps NOTICE Onan part number 0503 1951 11 and Oetiker part number 16700011 or equivalent worm screw type clamps are no longer allowed Routing Fuel Lines Electric arcs can ignite gasoline leading to severe personal injury or death Do not run wiring and fuel lines together 1 Route the supply and return lines side by side along bulkheads and frame members such that they are protecte
42. quid 4 FuelTank 9 1 4 in Fuel Return Line liquid 10 FIGURE 15 GASOLINE EFI CONNECTIONS A035D005 Issue 7 31 5 Fuel Connections 4 2014 5 2 1 5 2 2 32 Fuel Hoses The fuel hoses used inside the generator set are low permeation fuel hoses which meet Federal 50 state standards for gasoline evaporative emissions The vapor and liquid hoses connecting the fuel tank to the generator set the fuel tank to the carbon canister and the carbon canister to the generator set must also be low permeation fuel hoses Low permeation fuel hose is required to meet the requirements for gasoline generator sets sold in or used for commerce in all 50 states The following hose materials are acceptable Avon Automotive Greenbar EO G 05 018 SAE J30R7 Avon Automotive Greenbar 1200 EO C U 05 009 SAE J30R12 e Gates 4219D EO C U 06 002 SAE J30R9 e Gates Barricade EO Q 09 019 e Kubota EO C U 05 003 SAE J30R7 e Mark IV Automotive Gen2 EO C U 05 002 SAE J30R7 e Mark IV Automotive Fluoroperm EO C U 07 017 SAE J30R9 e Mark IV Automotive Dayperm EO C U 06 030 SAE J30R7 e Mark IV Automotive Dayperm EO G 05 016 e Mold Ex Division of SETI Inc SETiFLEX II EO G 05 17A SAE J30R7 e Parker Hannifin Corp Super Flex FL 7 series 389XX EO Q 08 013 e Veyance Technologies Inc Goodyear Flexshield EO Q 09 022 Lubricants used when connecting fuel hoses can leave residues that can cl
43. r approval A035D005 Issue 7 33 5 Fuel Connections 4 2014 5 2 6 34 Excessive fuel pressure can flood the generator set causing a fire Generator set fuel supply line pressure must not exceed 1 1 2 psi under any condition Fuel line pressure at the point where the generator set is connected must not exceed 1 1 2 psi under any condition The EFI fuel pump can pump fuel significantly better than it can draw fuel out of the main tank For this reason locate the high pressure EFI pump as close to the tank pickup as possible Terminate the generator set fuel pickup above the vehicle engine pickup in the supply tank to keep the generator set from running the vehicle out of fuel Carbon Canister Gasoline vapors in the fuel tank accumulate in the carbon canister when the generator set is not running Vapors are drawn into the engine combustion chamber and burned while the generator set is operating Use a Delphi carbon canister shown below No other carbon canisters are acceptable Part Number Description Onan Part Number 17208238 3 1L 196g working capacity 0159 1755 17208262 3 3L 233 8g working capacity 0159 1754 Mount the canister in one of three orientations shown in the figure below in accordance with its instructions NOTICE Use 5 16 inch hose for vapor lines Use an SAE J2044 quick connect fuel fitting on the canister hose barb or use a soap free lubricant such as WD40 to slip the hoses on the canister hose b
44. requirements for generator set system grounding Coat all battery cable connections with a battery terminal oxidation inhibitor Routing battery cables with fuel lines can lead to fire and severe personal injury or death Keep battery cables away from fuel lines 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 A035D005 Issue 7 4 2014 6 Electrical Connections No Description No Description Generator Set Cable size per table Battery sss FIGURE 26 FULL LENGTH CABLE FROM BATTERY NEGATIVE TERMINAL No Description No Description Generator Set Cable size per table Battery IS FIGURE 27 VEHICLE FRAME AS PATH FROM BATTERY NEGATIVE TERMINAL A035D005 Issue 7 A7 6 Electrical Connections 4 2014 6 3 4 Battery Cable Connections at the Generator Set Terminate the battery cables with ring terminals sized for 5 16 inch screws and connect them to the generator set 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 6 Nm 4 5 ft lbs Torque the negative cable terminal to 11 Nm 8 ft lbs No Description No Description Negative Cable Screw Grounding Screw Postive
45. s sold in or used for commerce in all 50 states The following hose materials are acceptable Avon Automotive Greenbar EO G 05 018 SAE J30R7 Avon Automotive Greenbar 1200 EO C U 05 009 SAE J30R12 e Gates 4219D EO C U 06 002 SAE J30R9 e Gates Barricade EO Q 09 019 e Kubota EO C U 05 003 SAE J30R7 e Mark IV Automotive Gen2 EO C U 05 002 SAE J30R7 e Mark IV Automotive Fluoroperm EO C U 07 017 SAE J30R9 e Mark IV Automotive Dayperm EO C U 06 030 SAE J30R7 e Mark IV Automotive Dayperm EO G 05 016 e Mold Ex Division of SETI Inc SETiFLEX II EO G 05 17A SAE J30R7 e Parker Hannifin Corp Super Flex FL 7 series 389XX EO Q 08 013 e Veyance Technologies Inc Goodyear Flexshield EO Q 09 022 28 A035D005 Issue 7 4 2014 5 Fuel Connections Lubricants used when connecting fuel hoses can leave residues that can clog fuel jets Only use soap free lubricants such as WD40 which runs through with the fuel without leaving residues that can clog fuel jets 5 1 2 Fuel Lines Tubing e Use 1 4 inch I 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 e Tubing must meet requirements for 150 psi operating pressure Ref ASTM A 539 99 and have corrosion resistance equal to or better than hot dipped zinc galvanized Hose Beads e Use suitable tooling to form tubing ends into SAE J1231 Type 1 or Type 3
46. set support structure must be designed and installed to support and restrain the dynamic weight of the generator set Failure to do so can result in the generator set dropping onto the roadway causing property damage severe personal injury or death A035D005 Issue 7 17 3 Location Mounting and Ventilation 4 2014 e Support the generator set on a structure able to resist the dynamic weight of the generator set 3 g force vertical and 1 g force horizontal See Section 2 5 on page 9 for the weight of the generator set See the outline drawings in Appendix A on page 53 for mounting bolt hole locations TABLE 6 MOUNTING SCREWS Quantity 3 8 inch thread forming bolts 42 Nm 31 ft lbs 3 2 1 Below Floor Mounting Mounting kits are available for below floor mounting Follow the instructions in the kit Do not mount the generator set within the approach or departure angles of the vehicle or below the axle line 3 2 2 Insulating Materials Acoustic thermal insulation and adhesive must be classified as Self Extinguishing at not less than 90 C 200 F Do not line the bottom of a compartment with insulation since it absorbs fuel and oil 3 2 3 Fire and Exhaust Barriers Exhaust gas and fire are deadly Install a vapor tight and fire resistant barrier of approved materials between the generator set and the vehicle interior Do not duct generator set cooling air into the vehicle for heating e Barriers to provid
47. t connections can cause equipment damage severe personal injury or death Electrical connections must be made by a trained and experienced electrician in accordance with applicable codes Improper installations can cause equipment damage severe personal injury or death All installations must be conducted by trained and experienced personnel in accordance with the installation instructions and all applicable codes Back feed to shore power can cause electrocution and damage to equipment The generator set must not be connected to shore power or to any other source of electrical power An approved switching device must be used to prevent interconnections A035D005 Issue 7 3 1 Important Safety Instructions 4 2014 1 7 Live electrical equipment can cause electrocution 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 Engine Exhaust Carbon Monoxide Is Deadly Substances in exhaust gases have been identified by some state and federal agencies to cause cancer or reproductive toxicity Do not breathe in or come into contact with exhaust gases Carbon monoxide is a poisonous gas Inhalation of this gas can cause severe personal injury or death Adhere to the following bullet points to make sure carbon monoxide is not being inhaled by occupants of the vehicle as well as others work
48. ting remove the barb fitting and weld a patch over the test port hole A035D005 Issue 7 4 2014 4 Exhaust Connections FIGURE 7 EXHAUST TAILPIPE CONNECTIONS A035D005 Issue 7 23 24 4 Exhaust Connections no Description No Description 153 mm 6 in No opening into the vehicle interior may be closer than 153 mm 6 in to the end of the tail pipe within area 2 identified in this image FIGURE 8 MINIMUM DISTANCES TO OPENINGS A035D005 Issue 7 4 2014 4 2014 4 Exhaust Connections No Description No Description 25 mm 1 inch Straight on view 2 The last tailpipe hanger must be as close to the end as possible FIGURE 9 TERMINATING THE EXHAUST TAILPIPE 4 2 Vehicle Clearances Class A RV INo Description No Description Approach Angle Departure Angle 2 Axle Clearance Line La FIGURE 10 VEHICLE CLEARANCES CLASS A RV A035D005 Issue 7 25 4 Exhaust Connections 4 2014 43 Vehicle Clearances Class B Van INo Description No Deseription Approach Angle Departure Angle Axle Clearance Line HM FIGURE 11 VEHICLE CLEARANCES CLASS B VAN 4 4 Vehicle Clearances Pickup Truck Camper No Description No Description Approach Angle Departure Angle Axle Clearance Line FIGURE 12 VEHICLE CLEARANCES PICKUP TRUCK CAMPER 26 A035D005 Issue 7 5 Fuel Connections See the Operator Manual for r
49. to ensure that all installation requirements are met in Chapter 7 Test Method EXHAUST GAS IS DEADLY Do not operate the generator set when the vehicle is parked indoors or where exhaust can accumulate 1 Complete a representative installation 2 Set up a load bank to run the generator set at rated full load 3 Conduct the test at a location where the ambient air temperature will remain between 16 C and 38 C 60 F and 100 F A035D005 Issue 7 4 2014 7 Installation Review and Startup 4 Measure temperatures with thermocouples not heavier than 0 21 mm 24 AWG a Measure ambient air temperature with a shielded thermocouple within 1 2 m 4 ft of the generator set and approximately the same height Make sure the thermocouple will not be affected by warm air discharged from the generator set or by sunlight Use 50 8 mm 2 in diameter white PVC piping at least 152 4 mm 6 in long as a thermocouple shield 5 Close all compartment doors and run the generator set 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 3 consecutive readings The following table illustrates how the data can be arranged for recording and analysis TABLE 8 TEMPERATURE DATA TEMPERATURE C F THERMOCOUPLE Time of Reading No Description No Description inlet Air ED WWW FIGURE 29 THERMOCOUPLE LOCATIONS FOR HOT AI
50. x 879 mm 17 2 in x 23 2 in x 34 6 in Size H x D x W 1 60 Hz models are listed by CSA and the US Testing Company 2 Sequential Multiport Fuel Injection 3 See the Installation Manual for additional considerations when sizing the generator set compartment 2 5 2 LPG Model Specifications TABLE 3 LPG MODEL SPECIFICATIONS v 6 5 HGJAA 6 5 HGJAB 5 5 HGJAA 5 5 HGJAB GENERATOR 2 Pole Revolving Field Self Excited 1 Phase Capped Digital Voltage Regulated 2 Bearing Vertical Shaft EE g 60 Hz Voltage 120 Volts 54 2 Amps 45 8 Amps 3600 RPM FUEL CONSUMPTION 1 0 kg h 2 2 Ibs h 0 8 kg h 1 8 Ibs h 10 A035D005 Issue 7 4 2014 2 Introduction llo GSHEAA 65HGJAB 5 5HGJAA 5 5HGJAB ENGINE 90 V Twin Cylinder 4 Cycle Spark Ignited OHV Air Cooled Vertical Shaft 80 mm 3 15 in 65 mm 2 56 in Displacement 653 cm 39 8 in 8 0 1 O IJO amp 93 sl 8 o o lt o 1 8 liters 2 0 qt Intake Valve Lash Cold 0 10 mm 0 004 in Exhaust Valve Lash Cold 0 10 mm 0 004 in 6 7 mm 0 025 in 23 32 Nm 18 25 ft lbs Ignition Timing 20 BTDC non adjustable Magneto Air Gap 0 3 mm 0 012 in 3 9 kgf cm 55 47 Ibf in 500 RPM Spark Plug Gap Spark Plug Torque DC SYSTEM Battery Voltage 12 Volts Minimum Battery o o INSTALLATION Exhaust O D 31 75 mm 1 25 in Minimum Free 4 Air Inlet Area 232 cm 36 in LPG Vapor Connection 3 8 18 NPTF 228 3
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