Installation Manual - Cummins

1 InstallationManualRV GeneratorSetHGJAA(SpecA-E)HGJAB(SpecA-E) HGJAC(SpecA-D)English7-2011983-0600(Issu e10)OriginalInstructionsTable of Contents1. SAFETY PRECAUTIONS .. Gasoline and Propane Are Flammable and Engine Exhaust is Generator Voltage is Moving Parts Can Cause Severe Personal Injury or Death .. Battery Gas is General Precautions .. 22. About this Installation Codes and Standards for Safety .. Outline Lifting and Handling Genset .. 63. LOCATION, MOUNTING AND Location .. Heat, Fire and Exhaust Barriers .. Insulating Fire and Exhaust Thermal Insulation for Model HGJAC Below-Floor Mounted .. Thermal Insulation for Model HGJAC Above-Floor Mounting .. Mounting Structure and Below-Floor Ventilation .. 114. EXHAUST Muffler Models HGJAA / Muffler Model HGJAC .. Tail 155. FUEL Gasoline Model HGJAA (EFI) .. Remote Fuel Pump Fuel Fuel Supply Line Pump to 20983-0600 (Issue 10)iTable of Vapor and Fuel Return Line Requirements.

2 Routing Fuel Gasoline Models HGJAB/HGJAC .. Fuel Fuel Lines .. Routing Fuel Evaporative system Installation .. System Fuel Carbon Carburetor Fuel System Generator Sets .. Fuel Injection (EFI) System Generator Fuel Low Pressure Propane Supply (Vapor Withdrawal) .. High Pressure Propane Supply (Liquid Withdrawal) .. 336. ELECTRICAL AC Power Output Wiring Connecting Shore Remote Control Battery Battery Battery Cables .. Battery Cable Connections at Genset .. Genset (Equipment) Grounding 427. Installation REVIEW AND Hot Air Recirculation Test Test Requirement .. Installation Startup .. 478. SPECIFICATIONS .. 49 APPENDIX A. WIRING 53 Wiring 55 APPENDIX B. OUTLINE DRAWINGS .. 57ii983-0600 (Issue 10)7-2011 Table of ContentsOutline 59983-0600 (Issue 10)iiiTable of Contents7-2011 This page is intentionally (Issue 10)1 Safety PrecautionsThoroughly read the OPERATOR'S Manual before operating the genset.

3 Safe operationand top performance can only be obtained when equipment is properly operated following symbols in this Manual alert you to potential hazards to the operator, serviceperson and : alerts you to an immediate hazard that will result in severe personalinjury or : alerts you to a hazard or unsafe practice that can result in severe personalinjury or : alerts you to a hazard or unsafe practice that can result in personal injury orequipment , fuel, exhaust, moving parts and batteries present hazards which can result in severepersonal injury or Gasoline and Propane Are Flammable andExplosive Do not smoke or turn electrical switches ON or OFF where fuel fumes are present or inareas 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.

4 LPG sinks when released and canaccumulate inside housings and basements and other below-grade spaces. Prevent leaksand the accumulation of Engine Exhaust is Deadly Inspect for exhaust leaks at every startup and after every eight hours of running. Prior to every startup and after every eight hours of running, all carbon monoxide detectorsmust be tested and confirmed to be working in accordance with the manufacture'sinstructions or owners Manual . Learn the symptoms of carbon monoxide poisoning in the genset Operator's Manual . Never occupy the vehicle while the genset is running unless the vehicle is equipped with aworking carbon monoxide detector. Do not operate the genset when the vehicle is parked in a confined space, such as agarage. Disable the automatic genset starting feature (AGS) of an inverter-charger or otherautomatic starting device before storing the vehicle or parking it in a garage or otherconfined space. The exhaust system must be installed in accordance with the genset Installation (Issue 10)11.

5 Safety Precautions7-2011 Engine cooling air must not be used for heating the Generator Voltage is Deadly Disable the automatic genset starting feature (AGS) of an inverter-charger or otherautomatic starting device before servicing the genset. Generator electrical output connections must be made by a trained and experiencedelectrician in accordance with applicable codes. The genset must not be connected to shore power (utility). Back-feed to shore power cancause electrocution and damage to equipment. An approved switching device must beused to prevent interconnections. Use caution when working on live electrical equipment. Remove jewelry, make sureclothing and shoes are dry, stand on a dry wooden platform or rubber insulating mat anduse tools with insulated Moving Parts Can Cause Severe Personal Injury orDeath Disable the automatic genset starting feature (AGS) of an inverter-charger or otherautomatic starting device before servicing the genset. Do not wear loose clothing or jewelry near moving parts such as PTO shafts, fans, beltsand pulleys.

6 Keep hands away from moving parts. Keep guards in place over fans, belts, pulleys, and other moving Battery Gas is Explosive Wear safety glasses. Do not smoke. To reduce arcing when disconnecting or reconnecting battery cables, always disconnectthe negative (-) battery cable first and reconnect it General Precautions Keep children away from the genset. To prevent accidental or remote starting while working on the genset, disconnect thenegative (-) battery cable at the battery. Keep the genset and its compartment clean. Excess oil and oily rags can catch fire. Do notstore gear in the compartment it 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 alcoholor (Issue 10)7-20111. Safety Precautions You must be trained and experienced to make adjustments while the genset isrunning hot, moving or electrically live parts can cause severe personal injury or death. Used engine oil has been identified by some U.

7 S. state and federal agencies as causingcancer or reproductive toxicity. Do not ingest, inhale, or contact used oil or its vapors. Benzene and lead in some gasoline have been identified by some state and federalagencies as causing cancer or reproductive toxicity. Do not ingest, inhale or contactgasoline or its vapors. Keep multi-class ABC fire extinguishers readily at hand. Class A fires involve ordinarycombustible materials such as wood and cloth. Class B fires involve combustible andflammable liquids and gaseous fuels. Class C fires involve live electrical equipment. ( No. 10) Genset Installation and operation must comply with all applicable local, state and federalcodes and (Issue 10)31. Safety Precautions7-2011 This page is intentionally (Issue 10)2 About this ManualWARNING: Improper Installation can result in severe personal injury, death andequipment damage. The installer must be trained and experienced in theinstallation of electrical, mechanical, fuel and exhaust : This genset is not a life support system.

8 It can stop without , persons with physical or mental limitations, and pets could sufferpersonal injury or death. A personal attendant, redundant power or an alarmsystem must be used if genset operation is : Unauthorized modifications or replacement of fuel, exhaust, air intake or speedcontrol system components that affect engine emissions are prohibited by law inthe State of Manual is a guide for the Installation of the HGJAA and HGJAB Series of generator sets(gensets). Proper Installation is essential for top performance. Read through this Manual beforestarting the Installation . Leave this Manual with the Manual addresses the following aspects of the Installation : Location, Mounting and Ventilation Exhaust Connections Fuel Connections Electrical Connections StartupSee the Operator's Manual for operation and maintenance :Manuals are updated from time to time to reflect changes in the equipmentand its specifications. For this reason, only the copy of the installationmanual supplied with the genset should be used as a guide for Installation Codes and Standards for SafetyCAUTION: The Warranty applies only when this genset is installed in a Recreational installer bears sole responsibility for the selection of the appropriate genset, for its properinstallation and for obtaining approvals from the authorities (if any) having jurisdiction over theinstallation.

9 These sets meet the basic requirements of the Standard for Safety for EngineGenerator Sets for Recreational Vehicles, ANSI/RVIA EGS-1. They are suitable for installationin accordance with: NFPA No. 1192 Recreational Vehicles NFPA No. 70, Article 551 Recreational Vehicles and RV Parks NFPA No. 58 Liquefied Petroleum Gas Code983-0600 (Issue 10)52. Introduction7-2011 CSA Electrical Bulletin 946 Requirements for Internal Combustion Engine-Driven ElectricGenerators for Use in Recreational VehiclesFederal, State and local codes, such as the California Administrative Code Title 25 (RVinstallation), might also be applicable. Installation codes and recommendations can change fromtime-to-time and are different in different countries, states and municipalities. It is recommendedthat the standards inTable 1be obtained for 1. REFERENCE CODES AND STANDARDSCode of FederalRegulations, TitleSuperintendent of Documents P. O. Box 371954 Pittsburgh, PA 15250-795449: Chapter IIIand Chapter VNFPA No 58, 70,National Fire Protection Association 470 Atlantic Avenue Boston, MA 022101192 ANSI/RVIA-EGS-Recreational Vehicle Industry Association 14650 Lee Road Chantily, VA 220211 CaliforniaAdministrativeState of California Documents Section Box 1015 North Highlands, CA 95660 Code Title 25,Chapter 3 CAN/CSA-Z240 RecreationalCanadian Standards Association Housing and Construction Materials Section 178 Rexdale BulletinRexdale, Ontario, Canada M9W Outline DrawingsSee theAppendix B on page 57at the end of the Manual for Installation details: mounting bolthole locations, connection points (fuel, battery, exhaust, remote control, AC output), sizes andtypes of fittings, cooling air openings, weight, and overall dimensions.

10 See your Onan dealer fora large-scale Outline Drawing and full-size floor cutout Lifting and Handling GensetFigure 1illustrates the four lift hook slots for genset lifting. A lifting rig must spread the hookstraps such that they do not crush or bend parts such as the control box, air filter and fuel lineswhile lifting. SeeSpecifications(Chapter 8) for the weight of the genset and make provisionsaccordingly for safe : Avoid tipping the front (service side) down while handling the genset. Engine oilcould drain into and soak the air filter to cause hard starting and poor underside of the genset can be damaged by protruding objects Always restthe genset on a flat surface that has been cleared off Always extend the liftingarms of a forklift beyond the base of the genset to prevent them from protrudinginto the underside (Issue 10)7-20112. IntroductionFIGURE 1. GENSET LIFT-HOOK SLOTS MOUNTING BOLT HOLES AREA THAT CAN BEDAMAGEDFIGURE 2. LIFTING HOOK SLING - EXAMPLE ONLYC ontact local sling or rigging supplier for specifications983-0600 (Issue 10)72.