CUMMINS onan 7.0 HGJAD, onan onan 7.0 HGJAE, onan 5.5 HGJAD, onan 7.0 HGJAF, onan 5.5 HGJAE Operator's Manual
...
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by any means, is strictly prohibited.
!!
Redistribution or publication of this document
by any means, is strictly prohibited.
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
gasoline warnings
Table of Contents
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by any means, is strictly prohibited.
SAFETY PRECAUTIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About this Manual 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Genset 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Recommendations 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Recommendations 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Batteries 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Control Panel 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Panel 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conducting Pre-Start Checks 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming Gasoline Fuel Systems 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Genset 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Genset 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Restarting the Genset 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Only Operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Restarting the Genset 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Lockout Switch 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting Circuit Breakers 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Utility Power 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Cold Weather 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Hot Weather 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating at High Altitude 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in Dusty Environments 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Breaking In a New Engine 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercising the Genset 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storing the Genset 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC MAINTENANCE 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conducting General Inspections 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Engine Oil Level 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Engine Oil and Oil Filter 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining Battery and Battery Connections 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Air Filter Element 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Spark Plugs 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Spark Arrestor 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INFORMATION FOR CALIFORNIA GENSET USERS 31. . . . . . . . . . . . . . . . . . . . . . . . . . .
HOW TO OBTAIN SERVICE 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE RECORD 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
Safety Precautions
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by any means, is strictly prohibited.
Thoroughly read the OPERATOR’S MANUAL
before operating the genset. Safe operation and
top performance can be obtained only when
equipment is operated and maintained properly.
The following symbols in this manual alert you to potential hazards to the operator, service person and
equipment.
alerts you to an immediate hazard
which will result in severe personal injury or
death.
WARNING
practice which can result in severe personal
injury or death.
CAUTION
practice which can result in personal injury or
equipment damage.
Electricity, fuel, exhaust, moving parts and batteries
present hazards which can result in severe personal
injury or death.
alerts you to a hazard or unsafe
alerts you to a hazard or unsafe
GENERAL PRECAUTIONS
• Keep children away from the genset.
• Do not use evaporative starting fluids. They are
highly explosive.
• 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
state and federal agencies as causing cancer
or reproductive toxicity. Do not ingest, inhale, or
contact used oil or its vapors.
• Benzene and lead in some gasolines have
been identified by some state and federal
agencies as causing cancer or reproductive
toxicity. Do not to ingest, inhale or contact gasoline or its vapors.
• Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials such as wood and cloth; Class B fires,
combustible and flammable liquid fuels and
gaseous fuels; Class C fires, live electrical
equipment. (ref. NFPA No. 10)
• Genset installation and operation must comply
with all applicable local, state and federal codes
and regulations.
GENERATOR VOLTAGE IS DEADLY!
• Generator electrical output connections must
be made by a trained and experienced electrician in accordance with applicable codes.
• The genset must not be connected to shore
power or to any other source of electrical
power. Back-feed to shore power can cause
electric shock resulting in severe personal injury or death 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.
2
ENGINE EXHAUST IS DEADLY!
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by any means, is strictly prohibited.
• Learn the symptoms of carbon monoxide poisoning in this manual and never sleep in the
vehicle while the genset is running unless the
vehicle is equipped with a working carbon monoxide detector.
ments and other below-grade spaces. Prevent
leaks and the accumulation of gas.
BATTERY GAS IS EXPLOSIVE
• Wear safety glasses.
• Do not smoke.
• The exhaust system must be installed in accor-
dance with the genset Installation Manual.
Engine cooling air must not be used for heating
the working or living space or compartment.
• Inspect for exhaust leaks at every startup and
after every eight hours of running.
• Make sure there is ample fresh air when operating the genset in a confined area.
FUEL IS 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 flame, sparks, pilot lights, arc-producing equipment and switches 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-
• To reduce arcing when disconnecting or reconnecting battery cables, always disconnect the
negative (–) battery cable first and reconnect it
last.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
• Do not wear loose clothing or jewelry near 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.
HYDRAULIC FLUID UNDER PRESSURE
CAN CAUSE SEVERE PERSONAL INJURY
• Always shut down the engine that drives the hydraulic pump before loosening or tightening fittings.
• The high pressure spray from a leak or fitting in
a hydraulic line can penetrate the skin, leading
to possible blood poisoning. Wear safety
glasses. Do not delay getting proper medical
attention if exposed to spray.
Commercial Mobile-1
3
Introduction
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ABOUT THIS MANUAL
This manual covers the operation and maintenance
of the HGJAD, HGJAE and HGJAF Series of generator sets (gensets). Each operator should study this
manual carefully and observe all of its instructions
and safety precautions. Keep this manual and the
Installation Manual with the other vehicle manuals.
Operation, Periodic Maintenance and Troubleshooting provide the instructions necessary for
operating the genset and maintaining it at top performance. The owner is responsible for performing
maintenance in accordance with the PERIODIC
MAINTENANCE SCHEDULE (Page 15). This manual also includes genset specifications, information
on how to obtain service, and information for California users.
7HGJAD–1910A
D000012345
WARNING
This genset is not a life support system. It can stop without warning. Children, persons with physical or mental limitations, and
pets could suffer personal injury or death. A personal attendant, redundant power or an alarm
system must be used if genset operation is critical.
NAMEPLATE
Model and Serial Numbers: Have the model and
serial numbers handy (gray boxes, Figure 1) when
contacting an Onan dealer for parts, service or product information. Each character is significant. (The
last character of the model number is the specification letter, which is important for obtaining the right
parts.) Record these numbers in the boxes in Figure 1 so that they are handy when you need them.
Genuine Onan replacement parts are recommended for best performance and safety.
Federal Emissions Compliance Period: The
Federal Emissions Compliance Period referred to
on the nameplate indicates the number of operating
hours for which the engine has been shown to meet
Federal emissions requirements. Category
C = 250 hrs, B = 500 hrs, A = 1000 hrs.
[The engine family designation, engine displacement, statement of compliance with the applicable EPA and / or California
emissions regulations, including the compliance period or
category, appear in this block on the actual nameplate on the
genset.]
RECORD NUMBERS HERE
MODEL NUMBER:
SERIAL NUMBER:
FIGURE 1. TYPICAL NAMEPLATE
4
TYPICAL GENSET
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Figure 2 illustrates a typical self-enclosed genset
with the maintenance access cover removed.
CAUTION
Operating the genset with the access cover off can lead to overheating of components. Always secure the cover after starting
the genset.
FIGURE 2. TYPICAL SELF-ENCLOSED GENSET
5
FUEL RECOMMENDATIONS
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ENGINE OIL RECOMMENDATIONS
WARNING
Gasoline and LPG are highly flammable and explosive and can cause severe personal injury or death. Do not smoke or turn electrical switches ON or OFF where fuel fumes,
tanks or equipment are present or in areas
sharing ventilation. Keep flames, sparks, pilot
lights, arc-producing equipment and switches
and all other sources of ignition well away. Keep
a type ABC fire extinguisher in the vehicle.
Gasoline Models
Use clean, fresh unleaded gasoline having a minimum octane rating (Anti-Knock Index) of 87.
CAUTION
Do not use gasoline or gasoline additives containing methanol because methanol
can be corrosive to fuel system components.
Avoid using leaded gasoline because of the extra engine maintenance that will be required.
LPG Models
Use clean, fresh HD-5 grade liquified petroleum gas
(LPG) or equivalent product consisting of at least 90
percent propane. Commercial liquified petroleum
gas fuels may contain more than 2.5 percent butane
which can result in poor fuel vaporization and poor
engine starting in low ambient temperatures (below
32° F (0° C).
Satisfactory performance on low-pressure LPG
models requires that the LPG vapor be supplied at a
pressure within the range indicated in Specifica-
tions.
WARNING
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.
High LPG supply pressure can
Use API (American Petroleum Institute) performance Class SJ, SH or SG engine oil, which may be
in combination with performance Class CH-4, CG-4
or CF-4 (for example: SJ/CH-4). Also look for the
SAE (Society of Automotive Engineers) viscosity
grade. Referring to Table 1, choose the viscosity
grade appropriate for the ambient temperatures
expected until the next scheduled oil change.
Single-grade SAE 30 oil is preferable when temperatures are consistently above freezing. Multigrade
oils are better when wide temperature variations are
expected.
TABLE 1. OIL VISCOSITY VS. TEMPERATURE
EXPECTED AMBIENT
TEMPERATURES
32° F (0° C) and higher 30
10° F to 100° F (–12° C to 38° C)
0° F to 80° F (–18° C to 27° C)
–20° F to 50° F (–28° C to 10° C) 5W-30
SAE VISCOSITY
GRADE
15W-40
TM
(OnaMax
10W-30
10W-40
)
STARTING BATTERIES
The genset has a 12 volt, direct current (DC) engine
cranking and control system. See Specifications
(Page 29) regarding minimum battery ratings for
reliable genset cranking, especially in cold weather.
Also see PERIODIC MAINTENANCE SCHEDULE
(Page 15) and the battery manufacturer’s instructions regarding battery maintenance. Reliable genset starting and starter service life depend upon
adequate battery system capacity and proper maintenance.
The genset provides up to 10 amps of regulated battery charging current.
OnaMax is a trademark of Onan Corporation.
6
GENSET CONTROL PANEL
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by any means, is strictly prohibited.
The genset control panel (Figure 3) is located behind the maintenance access cover (Figure 2) and
has the following features:
Control Switch – This switch is used to prime the
fuel system, start and stop the genset and display
the shutdown code. Hold the switch in its START
position to crank and start the genset. Press the
switch to its STOP position to stop the genset. Hold
the switch in its STOP/PRIME position (starts in
2 seconds) to prime the fuel system (gasoline models only). See Troubleshooting (Page 22) about dis-
playing shutdown codes.
Status Indicator Light – This light is an LED (light
emitting diode) in the control switch which blinks
rapidly during cranking and comes on solid when
the starter disconnects, indicating that the genset is
running. If the genset shuts down abnormally, the
light will blink a code to indicate the cause of the
shutdown. See Troubleshooting (Page 22).
Line Circuit Breakers – The line circuit breakers
protect the AC power leads connected to the genset
from overloads and equipment short circuits.
Hour Meter – The hour meter records genset oper-
ating time in hours. It cannot be reset. See the Periodic Maintenance Schedule (Page 15).
REMOTE CONTROL PANEL
The vehicle probably has a control panel inside the
vehicle for remote control of the genset. Onan offers
three remote control kits as follows:
FIGURE 3. GENSET CONTROL PANEL
FIGURE 4. REMOTE SWITCH
• Remote switch / status lamp (Figure 4).
• Remote switch / status lamp and hour meter
(Figure 5).
• Remote switch / status lamp and DC voltmeter
(Figure 6).
The DC voltmeter indicates whether voltage across
the 12 VDC control system and battery is normal. If
the indicator consistently stays above or below the
normal zone, see MAINTAINING THE BATTERY
AND BATTERY CONNECTIONS (Page 19).
FIGURE 5. REMOTE SWITCH / HOUR METER
FIGURE 6. REMOTE SWITCH / DC VOLTMETER
7
Operation
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WARNING
Exhaust gases contain carbon monoxide, an odorless, colorless gas. Carbon monoxide is poisonous
and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning include:
• Dizziness • Throbbing in Temples • Nausea
• Muscular Twitching • Headache • Vomiting
• Weakness and Sleepiness • Inability to Think Clearly
IF YOU OR ANYONE ELSE EXPERIENCES ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH
AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the genset and do not operate it until it has been inspected and repaired.
Never sleep in the vehicle with the genset running unless the vehicle is equipped with a working carbon monoxide detector. Primary protection against inhaling carbon monoxide, however, is proper
installation of the exhaust system, daily (every eight hour) inspection for visible and audible exhaust
system leaks.
CONDUCTING PRE-START CHECKS
Before the first start of the day and after every eight
hours of operation, inspect the genset as instructed
under CONDUCTING GENERAL INSPECTIONS
(Page 16). Keep a log of maintenance and the hours
run and perform any maintenance that may be due.
See Returning the Genset to Service (Page 14) if
the vehicle has been in storage.
Before each start:
1. Make sure all vehicle CO detectors are working.
2. Check for signs of fuel and exhaust leaks and
for damage to the exhaust system.
3. To prevent overheating and to reduce fouling
with dust and debris, make sure the genset’s
normal ground clearance is not being reduced
by sloping ground, curbs, logs or other objects.
Repark the vehicle if necessary and/or remove
any objects blocking the air inlet or air outlet.
4. Turn off air conditioners and other large loads.
5. If the genset is equipped with an hydraulic
pump, check and refill the oil reservoir as necessary.
PRIMING GASOLINE FUEL SYSTEMS
If a gasoline genset ran out of fuel prime the fuel system by holding the control switch at STOP/PRIME
EXHAUST GAS IS DEADLY!
for 30 seconds. (The status indicator light will stay
on solid while the pump is on.)
STARTING THE GENSET
Start the genset from the genset control panel or remote control panel inside the vehicle (Page 7).
1. Push and hold the switch at START until the
genset starts. The status indicator light on the
switch flashes while cranking. It will come on
solid when the starter disconnects, indicating
that the genset is running. (Because the genset
control has to “wake up,” a slight delay might be
noticed before anything seems to happen. On
models with fuel injection, the delay could be up
to 3 seconds to pressurize the fuel injectors.)
2. The genset control will discontinue cranking if
the genset does not start within 30 seconds and
will cause the status indicator light to blink shutdown code No. 4. Wait 5 seconds for the control to reset before trying again. See Trouble-
shooting (Page 22) if the genset does not start
after two or three tries.
CAUTION
starter motor by continued attempts to
start. Find out why the genset is not starting
and repair as necessary.
3. For top performance and engine life, especially
in colder weather, let the engine warm up for
two minutes before connecting appliances.
Do not risk burning out the
8
4. Check for fuel and exhaust leaks. Stop the gen-
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set immediately if there is a fuel or exhaust leak
and have it repaired.
5. See Troubleshooting (Page 22) if the engine
shuts down and the status indicator light blinks.
6. Always secure the access cover after starting
the genset at the genset control panel.
WARNING
Operating the genset with the
access cover off can lead to severe burns
and overheating of components. Always
secure the cover after starting the genset.
STOPPING THE GENSET
Turn off air conditioners and other large loads and
let the genset run for two minutes to cool down before stopping. This reduces backfiring and run-on.
Then press the switch to STOP to stop the genset.
can be powered depends upon the genset power
rating. The genset will shut down or its circuit breakers will trip if the sum of the loads exceeds genset
power.
To avoid overloading the genset and causing shutdowns, compare the sum of the loads that are likely
to be used at the same time with the power rating of
the genset. It may be necessary to run fewer
loads at the same time—the sum of the loads
must not be greater than genset rating.
Note that the genset may shut down due to overload—even though the sum of the loads is less than
genset rating—when a large motor or air conditioner
is started last or cycles off and then on again. The
reason for this is that a motor’s startup load is much
larger than its running load. It may be necessary to
run fewer loads when large motors and air conditioners are cycling on and off.
RESTARTING THE GENSET
See Troubleshooting (Page 22) if the genset shuts
down abnormally.
ENGINE ONLY OPERATION
Shutdowns due to generator failure are bypassed
when the genset is restarted within one (1) minute.
While operating in this mode, the status indicator
lamp flashes at a high frequency. This feature allows the engine to run so that hydraulic systems
powered by the engine can be operated though AC
output has failed.
GENSET LOCKOUT SWITCH
The vehicle may be equipped with a genset lockout
switch in the cab and/or boom bucket that can be
used to prevent unauthorized starting of the genset.
The switch(s) must be in their unlocked positions to
start the genset.
LOADING THE GENSET
The genset can power AC motors, air conditioners,
AC/DC converters and other loads. How much load*
Note also that air density decreases as altitude increases, causing rated genset engine power to decrease—approximately 3.5 percent each increase
of 1000 feet (305 m) above the maximum elevation
at which the engine can maintain rated power
(Table 2). It may be necessary to run fewer loads
at higher altitudes.
De-rating for temperature usually is not necessary
because the engine can maintain rated power in
ambient air temperatures of up to 120° F (49° C).
TABLE 2. POWER VS. ALTITUDE
Genset Rated
7000 watts up to
3000 ft (914 m)
6755 watts @
4000 ft (1219 m)
6510 watts @
5000 ft (1524 m)
Subtract 245 watts
each additional
1000 ft (305 m)
1. – This table does not take into account the effect circuit
breakers may have in limiting maximum genset power. Also,
power decreases even though the altitude adjust knob is set
correctly (Page 11).
7.0 kW
1
Genset Rated
6500 watts up to
3000 ft (914 m)
6272 watts @
4000 ft (1219 m)
6044 watts @
5000 ft (1524 m)
Subtract 228 watts
each additional
1000 ft (305 m)
6.5 kW
1
Genset Rated
5500 watts up to
5000 ft (1524 m)
5307 watts @
6000 ft (1829 m)
5114 watts @
7000 ft (2134 m)
Subtract 193 watts
each additional
1000 ft (305 m)
5.5 kW
1
* Load and genset power are measured in terms of watts (W) or kilowatts (kW), where 1 kilowatt (kW) = 1000 watts (W).
9
RESETTING CIRCUIT BREAKERS
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by any means, is strictly prohibited.
If a circuit breaker in the main power distribution
panel of the vehicle or on the genset (Figure 7) trips,
either a circuit shorted or too many loads were running. Note that the genset may continue to run after
a circuit breaker trips.
If a circuit breaker trips, disconnect or turn off as
many loads as possible and reset the circuit
breaker. (Push the circuit breaker to OFF to reset it
and then to ON to reconnect the circuit.) If the circuit
breaker trips right away, either the electrical distribution system has a short circuit or the circuit
breaker is faulty. Call a qualified electrician.
If the circuit breaker does not trip, reconnect the
loads one by one up to a total that does not overload
the genset or cause the circuit breaker to trip. If a circuit breaker trips right away when an appliance is
connected, the appliance probably has a short.
Electrical appliances and tools must be used and
maintained properly and be properly grounded to
cause the line circuit breakers to trip when short circuits occur.
WARNING
Short circuits in electrical
appliances and tools can cause fire and electrical shock leading to severe personal injury or
death. Read and follow the equipment and tool
manufacturer’s instructions and warnings
regarding use, maintenance and proper
grounding.
CONNECTING UTILITY POWER
A vehicle with provisions for connecting utility power
must have an approved device to keep the genset
and utility from being interconnected. See the genset Installation Manual for more information.
FIGURE 7. LINE CIRCUIT BREAKER
WARNING
Interconnecting the genset and the
public utility (or any other power source) can
lead to electrocution of utility line workers,
equipment damage and fire. Use an approved
switching device to prevent interconnections.
10
OPERATING IN COLD WEATHER
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by any means, is strictly prohibited.
Pay particular attention to the following items when
operating the genset in cold weather:
1. Make sure engine oil viscosity is appropriate for
the ambient temperatures. Change oil if there
is a sudden drop in temperature. See ENGINE
OIL RECOMMENDATIONS (Page 6).
2. Perform spark plug maintenance (Page 20).
3. Perform battery maintenance (Page 19).
4. If so equipped, reset the carburetor for altitude
(Figure 8).
OPERATING IN HOT WEATHER
Pay particular attention to the following items when
operating the genset in hot weather:
1. Make sure nothing blocks airflow to and from
the genset.
2. Make sure engine oil viscosity is appropriate for
the ambient temperatures. See ENGINE OIL
RECOMMENDATIONS (Page 6).
3. Keep the genset clean.
4. Perform maintenance due. See PERIODIC
MAINTENANCE SCHEDULE (Page 15).
5. If so equipped, reset the carburetor for altitude
(Figure 8).
FIGURE 8. ALTITUDE ADJUST KNOB
(SERIES HGJAE / HGJAF GASOLINE ONLY)
OPERATING AT HIGH ALTITUDE
Series HGJAE / HGJAF Only – For best fuel econ-
omy and genset operation reset the carburetor for
the current altitude (Figure 8). Altitude may be found
on road maps and road signs. For the effect of altitude on maximum power, see LOADING THE GENSET (Page 9).
CAUTION
with a high altitude setting can cause power
loss, overheating and engine damage. Always
reset when returning to lower altitudes.
Operating the genset at low altitude
11
OPERATING IN DUSTY ENVIRONMENTS
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by any means, is strictly prohibited.
Pay particular attention to the following items when
operating the genset in dusty environments:
1. Do not let dirt and debris accumulate inside the
genset compartment. Keep the genset clean.
carburetor and removes oxides from electrical contacts and generator slip rings. The result is better
starting, more reliable operation and longer engine
life.
STORING THE GENSET
2. Perform air cleaner maintenance more often
(Page 19).
3. Change engine oil every 50 hours.
4. Keep containers of engine oil that have been
opened tightly closed to keep out dust.
BREAKING IN A NEW ENGINE
Proper engine break-in on a new genset or on one
with a rebuilt engine is essential for top engine performance and acceptable oil consumption. Run the
genset at approximately 1/2 rated power for the first
1 hour and then at 3/4 rated power for 1 more hour.
Proper engine oil and oil level are especially critical
during break-in because of the higher engine temperatures that can be expected. Change the oil if not
appropriate for the ambient temperatures during
break-in. See ENGINE OIL RECOMMENDATIONS
(Page 6). Check oil level twice a day or every
4 hours during the first 20 hours of operation and
change the oil after the first 20 hours of operation.
EXERCISING THE GENSET
Proper storage is essential for preserving top genset performance and reliability when the genset
cannot be exercised regularly and will be idle for
more than 120 days.
Storing Genset
1. Gasoline Models Only – Fill the fuel tank with
fresh fuel and add a fuel preservative (Ona-
TM
Fresh
), following the instructions on the container label. Unless a preservative (stabilizer) is
added, the gasoline in the fuel system will deteriorate causing fuel system corrosion, gum
formation and varnish-like deposits which can
lead to hard starting and rough operation.
Then run the genset for about 10 minutes at
approximately 1/2 rated power to fill the fuel
lines with the fresh fuel and preservative.
WARNING
Gasoline preservatives (stabilizers) are toxic. Follow the instructions on
the container. Avoid skin contact. Wash
hands with soap and water after using.
2. Change the engine oil (Page 18) and attach a
tag indicating grade of oil viscosity (Page 6).
Exercise the genset at least 1 hour each month if
use is infrequent. Run the genset at approximately
1/2 rated power. A single long exercise period is
better than several short periods.
Exercising a genset drives off moisture, re-lubricates the engine, replaces stale fuel in fuel lines and
OnaFresh and OnaGard are trademarks of Onan Corporation.
3. Remove the air filter (Page 19) and restart the
genset. While the genset is running, spray an
engine fogger (OnaGard
TM
) into the carburetor,
following the instructions on the container label, and stop the genset. The fogger leaves a
protective coat of oil on the internal surfaces of
the engine.
12
4. Gasoline Models with Carburetor – Shut off
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by any means, is strictly prohibited.
the fuel supply valve (if so equipped) and drain
the carburetor float bowl (Figure 9) into a container. Dispose of the fuel in accordance with local environmental regulations. Draining the
float bowl prevents deposits of gum from clogging the tiny passages in the carburetor as the
gasoline in the bowl evaporates during storage.
5. Disconnect the battery cables (negative [–]
cable first) from the starting battery and store
the battery according to the battery manufacturer’s recommendations. See MAINTAINING
THE BATTERY AND BATTERY CONNECTIONS (Page 19).
6. Plug the exhaust tail pipe to keep out dirt, moisture, bugs, rodents, etc. Use a plug that will
completely blow out on next startup.
7. LPG Models – Check the local ordinances if
the vehicle is to be garaged. Generally, ordinances require that the LPG system be leakfree, that the LPG container not be filled beyond
specified limits, that the container shutoff valve
be closed and that the vehicle not be parked
near sources of heat or ignition.
FIGURE 9. DRAINING CARBURETOR FLOAT BOWL
WARNING
LPG leaks can lead to explosive
accumulations in pits, sumps or other
below-grade locations. Comply with all local ordinances regarding the garaging of
vehicles with LPG engine fuel systems.
8. Push the genset line circuit breaker OFF
(Page 10).
13
Returning Genset to Service
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by any means, is strictly prohibited.
1. Check the oil tag on the genset and change the
oil if the viscosity indicated is not appropriate for
the temperatures expected. See ENGINE OIL
RECOMMENDATIONS (Page 6).
2. Reconnect the starting battery (negative [–] cable last). See MAINTAINING THE BATTERY
AND BATTERY CONNECTIONS (Page 19).
3. Remove the plug from the exhaust tailpipe.
4. Change the air filter element if it is dirty
(Page 19).
5. Open the fuel supply valve (if so equipped).
6. Inspect the genset. See CONDUCTING GENERAL INSPECTIONS (Page 16).
7. Gasoline Models – Prime the genset fuel sys-
tem by holding the control switch at STOP/
PRIME for 30 seconds. (The status indicator
light will stay on solid while the pump is on.)
8. Start the genset. There may be smoke and
rough operation for a few minutes until the oil
from the fogger burns off. If the engine does not
start, clean or replace the spark plugs, which
may have been fouled by the fogger.
9. Push the genset line circuit breaker ON
(Page 10) when the genset is ready to power
appliances.
14
Periodic Maintenance
MAINTENANCE
PROCEDURE
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by any means, is strictly prohibited.
Periodic maintenance is essential for top performance and long genset life. Use Table 3 as a guide
for normal periodic maintenance. In hot and dusty
environments some maintenance procedures
should be performed more frequently, as indicated
by the footnotes in the table. Keeping a log of maintenance performed and hours run will help you keep
genset maintenance regular and provide a basis for
supporting warranty claims (Page 33).
Maintenance, replacement or repair of emission
control devices and systems may be performed by
any engine repair establishment or individual. However, warranty work must be completed by an
authorized Onan dealer.
TABLE 3. PERIODIC MAINTENANCE SCHEDULE
MAINTENANCE FREQUENCY
Every Day
or Every 8
Hours
General Inspections X 16
Check Engine Oil Level X 17
Clean and Check Battery X
Clean Spark Arrestor X 21
After First
20 Hours
Every
Month
3
Every 50
Hours
Every 150
Hours
Every 450
Hours
P
a
g
e
19
Change Engine Oil & Oil Filter X
Replace Air Filter Element X
Replace Spark Plugs X
Clean Engine Cooling Fins X
Replace Fuel Filter X
Adjust Valve Lash X
Clean or Replace Cylinder Heads X
1 – As a part of engine break-in, change the engine oil after the first 20 hours of operation.
2 – Perform more often when operating in dusty environments.
3 – Perform more often when operating in hot weather.
4 – Perform at least once a year.
5 – Perform sooner if engine performance deteriorates.
6 – Must be performed by a qualified mechanic (authorized Onan dealer).
1
X
2, 3, 4
2
5
2
5, 6
6
6
18
19
20
–
–
–
–
15
CONDUCTING GENERAL INSPECTIONS
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by any means, is strictly prohibited.
Inspect the genset before the first start of the day
and after every eight hours of operation.
Oil Level
Check engine oil level (Page 17).
Exhaust System
Look and listen for exhaust system leaks while the
genset is running. Shut down the genset if a leak is
found and have it repaired before operating the genset again.
WARNING
Do not park the vehicle in high grass
or brush. Contact with the exhaust system can
cause a fire.
Fuel System
Check for leaks at the hose, tube and pipe fittings in
the fuel supply and return systems while the genset
is running and while it is stopped. Do not use a flame
to check for LPG leaks. Check flexible fuel hose
sections for cuts, cracks, and abrasions. Make sure
the fuel line is not rubbing against other parts.
Replace worn or damaged fuel line parts before
leaks occur.
Look for openings or holes between the genset
compartment and vehicle cab or living space if the
genset engine sounds louder than usual. Have all
such openings or holes closed off or sealed to prevent exhaust gases from entering the vehicle.
Replace dented, bent or severely rusted sections of
the tailpipe and make sure the tailpipe extends at
least 1 inch (25.4 mm) beyond the perimeter of the
vehicle.
Park the vehicle so that genset exhaust gases disperse away from the vehicle. Barriers such as walls,
snow banks, high grass and brush and other vehicles can cause exhaust gases to accumulate in
and around the vehicle.
Do not operate power ventilators or exhaust fans
while the vehicle is standing with the genset running. The ventilator or fan can draw exhaust gases
into the vehicle.
Check all CO monitors to assure proper operation.
WARNING
EXHAUST GAS IS DEADLY! Do not
operate the genset if there is an exhaust leak or
any danger of exhaust gases entering or being
drawn into the vehicle.
If you smell gas, close the LPG container shutoff
valve and have the genset serviced before using it
again.
WARNING
Gasoline and LPG are highly flammable and explosive and can cause severe personal injury or death. Shut down the genset and
repair leaks immediately.
Battery Connections
Check the battery terminals for clean, tight
connections. Loose or corroded connections have
high electrical resistance which makes starting
harder. See MAINTAINING THE BATTERY AND
BATTERY CONNECTIONS (Page 19).
WARNING
Arcing at battery terminals or light
switch or other equipment or flames and sparks
can ignite battery gas causing severe personal
injury—Ventilate battery area before working on
or near battery—Wear safety glasses—Do not
smoke—Switch trouble light ON / OFF away
from battery—Do not disconnect battery cables
while genset is running or vehicle battery charging system is on—Always disconnect negative (–) cable first and reconnect it last.
16
Mechanical
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by any means, is strictly prohibited.
Look for mechanical damage. Start the genset and
look, listen and feel for any unusual noises and
vibrations.
Check the genset mounting bolts to make sure they
are secure.
Check to see that the genset air inlet and outlet
openings are not clogged with debris or blocked.
Clean accumulated dust and dirt from the genset.
Do not clean the genset while it is running or still hot.
Protect the generator, air cleaner, control panel, and
electrical connections from water, soap and cleaning solvents.
WARNING
Always wear safety glasses when
using compressed air, a pressure washer or a
steam cleaner to avoid severe eye injury.
CHECKING ENGINE OIL LEVEL
Park the vehicle on level ground and shut off the
genset before checking the engine oil level.
FIGURE 10. OIL FILL/DIPSTICK AND DRAIN VALVE
WARNING
Crankcase pressure can blow hot
engine oil out the fill opening causing severe
burns. Always stop the genset before removing
the oil fill cap.
1. Unscrew the oil fill cap and wipe oil off the dipstick (Figure 10). Screw the cap back on,
remove it and check the oil level on the dip stick.
2. Add or drain oil as necessary. See ENGINE OIL
RECOMMENDATIONS (Page 6). Keep the
oil level between the FULL and ADD marks.
The oil fills slowly because it takes time for the
air in the crankcase to escape. Recheck the
level in a few minutes to make sure.
CAUTION
Too much oil can cause high oil
consumption. Too little oil can cause severe
engine damage. Keep the oil level between
the FULL and ADD marks.
3. Screw the oil fill cap back on securely.
17
CHANGING ENGINE OIL AND OIL FILTER
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by any means, is strictly prohibited.
WARNING
termined that contact with used engine oil can
cause cancer or reproductive toxicity. Try to
avoid skin contact and breathing of vapors. Use
rubber gloves and wash exposed skin.
State and federal agencies have de-
3. Spin off the old oil filter and thoroughly wipe off
the filter mounting surface. Remove the old
gasket if it does not come off with the filter.
4. Apply a film of oil to the filter gasket and spin the
new filter on by hand until the gasket just
touches the mounting pad. Then turn it 1/2 to
3/4 turn—not more.
Refer to Table 3 for scheduled engine oil change.
Change oil more often in hot or dusty environments.
1. Place a pan underneath the oil drain hose and
filter (Figure 11). (The genset may have been
installed with a remote oil filter.) Run and then
stop the engine when it is warm.
WARNING
Crankcase pressure can blow
hot engine oil out the fill opening causing
severe burns. Always stop the genset before removing the oil fill cap.
2. Remove the oil fill cap, open the oil drain valve
(Figure 10), let all oil drain from the engine and
then close the drain valve.
5. Refill with 2 quarts (1.8 l) of oil. See ENGINE
OIL RECOMMENDATIONS (Page 6). Check
and add or drain oil as necessary.
CAUTION
Too much oil can cause high oil
consumption. Too little oil can cause severe
engine damage. Keep the oil level between
the FULL and ADD marks.
OIL FILLS VERY SLOWLY. TAKE YOUR
TIME AND CHECK LEVEL OFTEN WHILE
FILLING. IT TAKES TIME FOR THE AIR IN
THE CRANKCASE TO ESCAPE AND ALLOW OIL TO ENTER.
6. Dispose of the used oil and oil filter in accordance with local environmental regulations.
FIGURE 11. OIL FILTER AND DRAIN HOSE—VIEW FROM BELOW OF FRONT EDGE OF GENSET
18
MAINTAINING BATTERY AND BATTERY
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by any means, is strictly prohibited.
CONNECTIONS
WARNING
switch or other equipment or flames and sparks
can ignite battery gas causing severe personal
injury—Ventilate battery area before working on
or near battery—Wear safety glasses—Do not
smoke—Switch trouble light ON / OFF away
from battery—Do not disconnect battery cables
while genset is running or vehicle battery charging system is on—Always disconnect negative (–) cable first and reconnect it last.
Arcing at battery terminals or light
2. Remove battery cables with a battery terminal
puller.
3. Make sure which terminal is positive (+) and
which is negative (–) before making battery
connections, always removing the negative (–)
cable first and reconnecting it last to reduce
arcing.
REPLACING THE AIR FILTER ELEMENT
Refer to Table 3 for scheduled air filter element
replacement. In dusty environments the filter element should be inspected and changed more frequently. To change the filter element (Figure 12):
Refer to Table 3 for scheduled battery maintenance,
and follow the battery manufacturer’s instructions.
Have the battery charging system serviced if DC
system voltage is consistently low or high. Always:
1. Keep the battery case and terminals clean and
dry and the terminals tight.
1. Unlatch the three spring clips and rotate the
cover out and away from the hooks on top. Remove the air filter element.
2. Wipe the filter element sealing surfaces clean
and reassemble the air filter with a new filter
element.
FIGURE 12. REPLACING THE AIR FILTER ELEMENT
19
REPLACING SPARK PLUGS
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by any means, is strictly prohibited.
Refer to Table 3 for scheduled spark plug replacement. (The genset has two spark plugs, Figure 13.)
The spark plugs must be in good condition for
proper engine starting and performance. A spark
plug that fouls frequently or has heavy soot deposits
indicates the need for engine service. See Trouble-
shooting (Page 22).
To prevent cross threading, always thread a spark
plug in by hand until it seats and then torque to
10 lbs-ft (13 N-m).
FIGURE 13. SPARK PLUGS
20
CLEANING THE SPARK ARRESTOR
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by any means, is strictly prohibited.
Refer to Table 3 for scheduled cleaning of the spark
arrestor muffler. Cleaning is required for maximum
genset performance. Park the vehicle away from
grass, brush or debris that could be ignited by
sparks expelled during this procedure.
WARNING
A hot muffler can cause severe
burns. Let the muffler cool down before removing or installing cleanout plugs or screens.
Series HGJAD: A double-drum muffler is mounted
inside the genset. The cleanout plug is in the top
drum, but accessible from below, though not readily
visible. In Figure 14 a portion of the lower drum is
cut out so that the location of the plug is visible.
1. Locate the square-headed cleanout plug by
hand and solidly seat a 7/16 inch, eight point,
3/8 inch drive socket wrench with 3 inch extension on the plug. Then add a swivel section and
6 inch extension and turn with a ratchet to remove the plug.
2. Start and load the genset to near full power. Let
the genset run for about five minutes to expel
the soot in the muffler.
3. Stop the genset, allow the muffler to cool down
and then reinstall the plug.
Series HGJAE: See Figure 14 if double-drum or
Figure 15 if single-drum. On a single-drum muffler
the cleanout plug is accessible from below as
shown in Figure 15.
FIGURE 14. HJGAA CLEANOUT PLUG—VIEW
FROM BELOW
1. Remove the plug with a 7/16 inch, eight point
socket wrench.
2. Start and load the genset to near full power. Let
the genset run for about five minutes to expel
the soot in the muffler.
3. Stop the genset, allow the muffler to cool down
and then reinstall the plug.
Series HGJAF: The muffler is externally mounted.
If it has a clean out plug like the one shown in Figure 15, use the instructions for Series HGJAE as a
guide. Alternatively, the end of the tail pipe may
have a spark screen (Figure 16). If so, remove the
screw that secures the spark screen, clean the
screen with a wire brush and re-install it.
FIGURE 15. HJGAB CLEANOUT PLUG—VIEW
FROM BELOW
FIGURE 16. TYPICAL SPARK SCREEN
21
Troubleshooting
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by any means, is strictly prohibited.
WARNING
Hot engine parts can cause severe
burns. Always allow the engine time to cool
before performing any maintenance or service.
TABLE 4. TROUBLESHOOTING lists the shutdown
codes in numerical order along with step-by-step
corrective actions. If you are unable to resolve the
problem after taking the corrective actions suggested, contact an authorized Onan dealer. See
How to Obtain Service (Page 32).
First note the following:
• Maintaining engine oil level, keeping battery
connections clean and tight, watching the fuel
gauge, not overloading the genset, keeping
the air inlet and outlet openings clear, etc. will
prevent most shutdowns.
• When the genset and vehicle engine share a
common fuel tank the fuel dip tubes are usually arranged so that the genset will run out of
fuel first. Marking the genset empty point on
the fuel gauge will make it easier to tell when
to stop the genset before running it out of fuel.
• Two blinks indicates a low oil pressure fault.
• Three blinks indicates a service fault. Press
Stop once to cause the two-digit, secondlevel shutdown code to blink. (Pressing Stop
again will stop the blinking.)The two-digit
code consists of 1, 2, 3, 4 or 5 blinks, a brief
pause, and then 1 to 9 blinks. The first set of
blinks represents the tens digit and the second set of blinks the units digit of the shutdown code number. For example, shutdown
code No. 36 appears as:
blink-blink-blink—pause—blink-blink-blink-blink-blink-blink—
long pause—repeat
• Four blinks indicates that cranking
exceeded 30 seconds without the engine
starting.
•
Note: shutdown code Nos. 3 and 4 are first
level faults. Avoid interpreting them as second-level shutdown code Nos. 33 and 44,
which have not been assigned as shutdown
codes.
SHUTDOWN CODES
Restoring shutdown code Blinking – The shut-
The genset controller provides extensive diagnostics by causing the status indicator light on the Control Switch to blink in a coded fashion. Following a
fault shutdown, the indicator light will repeatedly
blink 2, 3 or 4 blinks at a time.
TABLE 4. TROUBLESHOOTING
WARNING
Some genset service procedures present hazards that can result in severe per-
down code stops blinking after five minutes (15 minutes, Series HGJAD). Press Stop three times within
five seconds to restore blinking. Note that the last
fault logged will blink, even after the condition
that caused the shutdown has been corrected.
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
STATUS INDICATOR LIGHT DEAD
(Genset locked out, faulty connections, no battery voltage)
Corrective Action:
1. Unlock the genset with the lockout switch in the cab and/or boom bucket.
2. Try the genset Start Switch if the remote Start Switch does not work, and vice versa.
3. Clean and tighten the positive (+) and negative (–) battery cable connections at the battery, vehicle
frame and genset.
4. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
22
TABLE 4. TROUBLESHOOTING (CONT.)
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by any means, is strictly prohibited.
WARNING
Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
STARTING BATTERIES RUN DOWN
(Marginal batteries, connections, or charging system or, parasitic loads)
Corrective Action:
1. Clean and tighten the positive (+) and negative (–) battery cable connections at the battery, vehicle
frame and genset.
2. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
3. Have a battery charging system installed or serviced in the vehicle.
STARTER ENGAGES-DISENGAGES
(Cranking voltage dips below 6 volts—low battery charge, poor connections, long cables)
Corrective Action:
1. Have the vehicle propulsion engine running while trying to start the genset—the battery charging
alternator may be able to maintain starting voltage high enough to get the genset started.
2. Clean and tighten the positive (+) and negative (–) battery cable connections at the battery, vehicle
frame and genset.
3. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
4. Increase battery cable size or run parallel cables.
NO POWER—GENSET RUNNING, STATUS LIGHT ON
(Line circuit breaker OFF, or tripped due to short circuit or overload)
Corrective Action:
1. Turn on or reset the line circuit breaker on the genset (Page 10).
2. Turn on or reset the line circuit breakers on the main distribution panel in the vehicle.
LOW OIL PRESSURE SHUTDOWN—CODE NO. 2
(First-level shutdown code—Low oil pressure cutoff switch did not open)
Corrective Action:
1. Check engine oil level and add oil as necessary (Page 17).
2. Drain excess oil (above dipstick Full mark.)
SERVICE CHECK SHUTDOWN—CODE NO. 3
(First-level shutdown code—Indicates fault with second-level shutdown code)
Corrective Action: Check the second-level shutdown code by pressing STOP once. The second-level
shutdown code will have two-digits. The faults are listed in numerical order in this table.
23
TABLE 4. TROUBLESHOOTING (CONT.)
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by any means, is strictly prohibited.
WARNING
Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
OVERCRANK SHUTDOWN—CODE NO. 4
(First-level shutdown code—Cranking exceeded 30 seconds without engine starting)
Corrective Action:
1. Gasoline Models – Check and fill the fuel tank, as necessary. (Note: The genset fuel pickup tube
is probably higher up in the fuel tank than the vehicle engine pickup.)
2. Prime the engine fuel system by holding the control switch at Stop/Prime for 30 seconds.
3. Low Pressure LPG Models – Check and fill the LPG container, as necessary. On cold days the LPG
container may have to be kept at least half full to provide the rate of vaporization necessary to keep
up with the genset fuel demand.
4. Open any closed fuel valves.
5. Secure the spark plug leads on the spark plugs (Page 20).
6. Replace the spark plugs (Page 20).
7. Service the air cleaner (Page 19).
OVERVOLTAGE SHUTDOWN—CODE NO. 12
(Controller unable to maintain rated voltage)
Corrective Action: See an authorized Onan dealer.
UNDERVOLTAGE SHUTDOWN—CODE NO. 13
(Controller unable to maintain rated voltage)
Corrective Action: Reduce the number of connected appliances, especially when air conditioners and
battery chargers are running.
OVERFREQUENCY SHUTDOWN—CODE NO. 14
(Engine governor unable to maintain rated frequency)
Corrective Action: See an authorized Onan dealer.
UNDERFREQUENCY SHUTDOWN—CODE NO. 15
(Engine governor unable to maintain rated frequency)
Corrective Action:
1. Reduce the number of connected appliances, especially when air conditioners and battery chargers
are running.
GOVERNOR ACTUATOR SHUTDOWN—CODE NO. 19
(Controller sensed open or shorted circuit)
Corrective Action: See an authorized Onan dealer.
24
TABLE 4. TROUBLESHOOTING (CONT.)
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by any means, is strictly prohibited.
WARNING
Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
GOVERNOR ACTUATOR OVERLOAD SHUTDOWN—CODE NO. 22
(Duration of operation at or near full-duty cycle beyond design limit)
Corrective Action:
1. Reduce the number of connected appliances, especially when air conditioners and battery chargers
are running.
2. Service the air cleaner (Page 19).
3. Check for and repair a blocked exhaust system.
LOW OIL PRESSURE CUTOFF SWITCH SHUTDOWN—CODE NO. 23
(Controller sensed switch still open during start—not a running fault)
Corrective Action: See an authorized Onan dealer.
VOLTAGE SENSE SHUTDOWN—CODE NO. 27
(Controller unable to sense output voltage)
Corrective Action: See an authorized Onan dealer.
HIGH BATTERY VOLTAGE SHUTDOWN—CODE NO. 29
(Voltage across battery system greater than 19 volts)
Corrective Action:
1. Check battery bank connections and reconnect if necessary so that the 12 volt batteries serving the
genset are connected in parallel (12 volt) rather than in series (24 volt).
2. Select a lower battery boost charge rate.
OVERSPEED SHUTDOWN—CODE NO. 31
(Engine speed greater than 3400 rpm)
Corrective Action: See an authorized Onan dealer.
LOW CRANKING SPEED SHUTDOWN—CODE NO. 32
(Cranking speed less than 180 rpm for more than 2 seconds)
Corrective Action:
1. Clean and tighten the positive (+) and negative (–) battery cable connections at the battery and at
the genset.
2. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
3. Replace engine oil with oil of proper viscosity for ambient temperatures (Page 6). (High oil viscosity
can slow down cranking speed.)
25
TABLE 4. TROUBLESHOOTING (CONT.)
Redistribution or publication of this document
by any means, is strictly prohibited.
WARNING
Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
CONTROL CARD FAILURE SHUTDOWN—CODE NO. 35
(Microprocessor EEPROM error during self-test)
Corrective Action: See an authorized Onan dealer.
ENGINE STOPPED SHUTDOWN—CODE NO. 36
(Engine stopped without command by controller)
Corrective Action:
1. Gasoline Models – Check and fill the fuel tank, as necessary. (Note: The genset fuel pickup tube
is probably higher up in the fuel tank than the vehicle engine pickup.)
2. Low Pressure LPG Models – Check and fill the LPG container, as necessary. On cold days the LPG
container may have to be kept at least half full to provide the rate of vaporization necessary to keep
up with the genset fuel demand.
3. Secure the spark plug leads on the spark plugs (Page 20).
4. Replace the spark plugs (Page 20).
5. Service the air cleaner (Page 19).=
6. Check for mechanical damage.
INVALID GENSET CONFIGURATION SHUTDOWN—CODE NO. 37
(Wrong frequency/rpm ratio)
Corrective Action: See an authorized Onan dealer.
OVERCURRENT (FIELD OVERLOAD) SHUTDOWN—CODE NO. 38
(Low power factor loads)
Corrective Action:
1. Reduce the number of appliances running at the same time, especially those with high motor starting
loads such as air conditioners.
2. Have air conditioners and other appliances checked for proper operation. (A locked compressor
rotor can cause very low power factor.)
GENERATOR ROTOR SHUTDOWN—CODE NO. 41
(Controller unable to sense field or output voltage)
Corrective Action: See an authorized Onan dealer.
PROCESSOR SHUTDOWN—CODE NO. 42
(Microprocessor ROM error during self-test)
Corrective Action: See an authorized Onan dealer.
26
TABLE 4. TROUBLESHOOTING (CONT.)
Redistribution or publication of this document
by any means, is strictly prohibited.
WARNING
Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
PROCESSOR SHUTDOWN—CODE NO. 43
(Microprocessor RAM error during self-test)
Corrective Action: See an authorized Onan dealer.
SPEED SENSE SHUTDOWN—CODE NO. 45
(Controller unable to sense quadrature frequency)
Corrective Action: See an authorized Onan dealer.
IGNITION SHUTDOWN—CODE NO. 47
(Controller unable to sense ignition)
Corrective Action: See an authorized Onan dealer.
GENERATOR FIELD SENSE SHUTDOWN—CODE NO. 48
(Controller unable to sense field voltage)
Corrective Action: See an authorized Onan dealer.
PROCESSOR SHUTDOWN—CODE NO. 51
(Microprocessor malfunction)
Corrective Action: See an authorized Onan dealer.
FUEL INJECTOR SHUTDOWN—CODE NO. 52
(Open or short circuit in fuel injector)
Corrective Action: See an authorized Onan dealer.
MAT SENDER SHUTDOWN—CODE NO. 54
(Open or short circuit in MAT sender)
Corrective Action: See an authorized Onan dealer.
27
TABLE 4. TROUBLESHOOTING (CONT.)
Redistribution or publication of this document
by any means, is strictly prohibited.
WARNING
Some genset service procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
MAP SENDER SHUTDOWN—CODE NO. 56
(Open or short circuit in MAP sender)
Corrective Action: See an authorized Onan dealer.
OVERPRIME SHUTDOWN—CODE NO. 57
(Prime mode exceeded 3 minutes)
Corrective Action: Check for and remove any object that may be holding either control switch (remote
or local) in the prime position.
28
Specifications
Redistribution or publication of this document
by any means, is strictly prohibited.
GASOLINE MODELS
7.0 HGJAD 7.0 HGJAE 7.0 HGJAF 5.5 HGJAD 5.5 HGJAE 5.5 HGJAF
GENERATOR: 2-Pole Revolving Field, 2-Bearing, Self-Excited, 1-Phase, Vertical Shaft, Capped Digital Voltage Regulation
Power (1.0 PF) 7000 watts 5500 watts
Frequency 60 Hertz 60 Hertz
1-Ph, 4-Wire V/A 120 / 240 Volts, 29.2 Amps 120 / 240 Volts, 22.9 Amps
1-Ph, 2-Wire V/A 120 Volts, 58.3 Amps 120 Volts, 45.8 Amps
3-Ph V/A 120 / 240 Volts, 16.8 Amps 120 / 240 Volts, 12 Amps
Speed 3600 rpm 3600 rpm
FUEL CONSUMPTION:
No load 0.43 gph (1.6 l/h) 0.43 gph (1.6 l/h) 0.43 gph (1.6 l/h) 0.34 gph (1.3 l/h) 0.35 gph (1.3 l/h) 0.35 gph (1.3 l/h)
Half load 0.70 gph (2.7 l/h) 0.73 gph (2.8 l/h) 0.73 gph (2.8 l/h) 0.58 gph (2.2 l/h) 0.60 gph (2.3 l/h) 0.60 gph (2.3 l/h)
Full load 1.13 gph (4.3 l/h) 1.22 gph (4.6 l/h) 1.22 gph (4.6 l/h) 0.89 gph (3.4 l/h) 0.95 gph (3.6 l/h) 0.95 gph (3.6 l/h)
ENGINE: Air-Cooled, 4-Cycle Spark-Ignited, OHV, 90° V Twin Cyl, Vertical Shaft
Fueling Method SFI
Governor Digital Mechanical Mechanical Digital Mechanical Mechanical
Speed 2880 rpm 2400 rpm
Bore 3.15 in (80 mm) 3.15 in (80 mm)
Stroke 2.56 in (65 mm) 2.56 in (65 mm)
Displacement 39.8 in3 (653 cc) 39.8 in3 (653 cc)
Comp. Ratio 8.0 : 1 8.0 : 1
Oil Capacity 2.0 quart (1.8 l) 2.0 quart (1.8 l)
Valve Lash (Cold) 0.004 in (0.10 mm), Intake & Exhaust 0.004 in (0.10 mm), Intake & Exhaust
Spark Plug 18–25 lbs-ft (23–32 N-m) 18–25 lbs-ft (23–32 N-m)
Ignition Timing 20° BTDC, non-adjustable magneto 20° BTDC, non-adjustable magneto
Magneto Air Gap 0.012 in (0.3 mm) 0.012 in (0.3 mm)
Spark Plug Gap 0.025 in (6-7 mm) 0.025 in (6-7 mm)
HYDRAULIC PUMP: Fixed-displacement gear pump—1.8 gpm @ 2500 psi Fixed-displacement gear pump—1.6 gpm @ 2500 psi
DC SYSTEM:
Battery Voltage 12 volts 12 volts
Battery Charging 10 amps regulated 10 amps regulated
Min. Battery CCA 450 @ 0° F (–18° C) 450 @ 0° F (–18° C)
INSTALLATION:
Exhaust O. D. 1-1/4 in 1-1/4 in
Max. Exhaust Back
Pressure
Fuel Supply
Connection
Fuel Return
Connection
Hydraulic Fluid
Hydraulic Pump Inlet
Conditions
Hydraulic Pump Connections
Outlet
Inlet
Noise dB(A)
Weight 290 lb (132 Kg) 290 lb (132 Kg) 239 lb (107 Kg) 279 lb (127 Kg) 279 lb (127 Kg) 228 lb (104 Kg)
Compartment
(H x D x W)
1. Sequential Multiport Fuel Injection
2. Measurements @ 10 ft (3 m) in a typical installation, under an 4 kW load.
3. With 1/2 in. clearances. See the Installation Manual for additional considerations when sizing the genset compartment.
2
3
5/16 in. SAE J1231
5/16 in. SAE J1231
Viscosity: 80-1000 SSU—Maximum Start-Up Viscosity: 4000 SSU
1
– – 35 in (889 mm) WC – – 35 in (889 mm) WC
Type 1
Type 1
Transmission or Petroleum-Based Hydraulic Fluid—Operating
Not to exceed 5 in Hg Vacuum or 20 psi Pressure Not to exceed 5 in Hg Vacuum or 20 psi Pressure
66 67 75 66 67 75
Carburetor Carburetor SFI
1/4 in. SAE J1231
Type 1
– –
3/4-16 UNF-2B SAE
7/8-14 UNF-2B SAE
HGJAD/HGJAE: 17.2 in x 23.2 in x 34.6 in (438 mm x 589 mm x 879 mm)
HGJAF: 16.5 in x 22.8 in x 27.9 in (420 mm x 579 mm x 709 mm)
1/4 in. SAE J1231
Type 1
5/16 in. SAE J1231
5/16 in. SAE J1231
Viscosity: 80-1000 SSU—Maximum Start-Up Viscosity: 4000 SSU
1
Type 1
Type 1
Transmission or Petroleum-Based Hydraulic Fluid—Operating
Carburetor Carburetor
1/4 in. SAE J1231
Type 1
– –
3/4-16 UNF-2B SAE
7/8-14 UNF-2B SAE
1/4 in. SAE J1231
Type 1
29
LPG MODELS
Redistribution or publication of this document
by any means, is strictly prohibited.
6.5 HGJAE 6.5 HGJAF 5.5 HGJAE 5.5 HGJAF
GENERATOR: 2-Pole Revolving Field, 2-Bearing, Self-Excited, 1-Phase, Vertical Shaft, Capped Digital Voltage Regulation
Power (1.0 PF) 6500 watts 5500 watts
Frequency 60 Hertz 60 Hertz
1-Ph, 4-Wire V/A 120 / 240 Volts, 27 Amps 120 / 240 Volts, 22.9 Amps
Speed 3600 rpm 3600 rpm
FUEL CONSUMPTION:
No load
Half load
Full load
ENGINE: Air-Cooled, 4-Cycle Spark-Ignited, OHV, 90° V Twin Cyl, Vertical Shaft
Fueling Method Air/Fuel Mixer Air/Fuel Mixer
Governor Mechanical Mechanical
Speed 2880 rpm 2400 rpm
Bore 3.15 in (80 mm) 3.15 in (80 mm)
Stroke 2.56 in (65 mm) 2.56 in (65 mm)
Displacement 39.8 in3 (653 cc) 39.8 in3 (653 cc)
Comp. Ratio 8.0 : 1 8.0 : 1
Oil Capacity 2.0 quart (1.8 l) 2.0 quart (1.8 l)
Valve Lash (Cold) 0.004 in (0.10 mm), Intake & Exhaust 0.004 in (0.10 mm), Intake & Exhaust
Spark Plug 18–25 lbs-ft (23–32 N-m) 18–25 lbs-ft (23–32 N-m)
Ignition Timing 20° BTDC, non-adjustable magneto 20° BTDC, non-adjustable magneto
Magneto Air Gap 0.012 in (0.3 mm) 0.012 in (0.3 mm)
Spark Plug Gap 0.025 in (6-7 mm) 0.025 in (6-7 mm)
HYDRAULIC PUMP: Fixed-displacement gear pump—1.8 gpm @ 2500 psi Fixed-displacement gear pump—1.6 gpm @ 2500 psi
DC SYSTEM:
Battery Voltage 12 volts 12 volts
Battery Charging 10 amps regulated 10 amps regulated
Min. Battery CCA 450 @ 0° F (–18° C) 450 @ 0° F (–18° C)
INSTALLATION:
Exhaust O. D. 1-1/4 in 1-1/4 in
Max. Exhaust Back
Pressure
LPG Vapor:
Connection
Pressure
LPG Liquid:
Connection
Pressure
Hydraulic Fluid
Hydraulic Pump Inlet
Conditions
Hydraulic Pump Connections
Outlet
Inlet
Noise dB(A)
Weight 290 lb (132 Kg) 239 lb (107 Kg) 279 lb (127 Kg) 228 lb (104 Kg)
Compartment
(H x D x W)
1. Measurements @ 10 ft (3 m) in a typical installation, under an 4 kW load.
2. With 1/2 in. clearances. See the Installation Manual for additional considerations when sizing the genset compartment.
1
2
2.2 lbs/h (1.0 kg/h) 2.2 lbs/h (1.0 kg/h) 1.8 lbs/h (0.8 kg/h) 1.8 lbs/h (0.8 kg/h)
3.9 lbs/h (1.8 kg/h) 3.9 lbs/h (1.8 kg/h) 3.3 lbs/h (1.5 kg/h) 3.3 lbs/h (1.5 kg/h)
5.3 lbs/h (2.4 kg/h) 5.3 lbs/h (2.4 kg/h) 4.6 lbs/h (2.1 kg/h) 4.6 lbs/h (2.1 kg/h)
– 35 in (889 mm) WC – 35 in (889 mm) WC
3/8–18 NPTF
9-13 in (228-330 mm) WC
1/4–18 NPTF
Tank Pressure
Transmission or Petroleum-Based Hydraulic Fluid—Operating
Viscosity: 80-1000 SSU—Maximum Start-Up Viscosity: 4000 SSU
Not to exceed 5 in Hg Vacuum or 20 psi Pressure Not to exceed 5 in Hg Vacuum or 20 psi Pressure
3/4-16 UNF-2B SAE
7/8-14 UNF-2B SAE
67 75 67 75
HGJAD/HGJAE: 17.2 in x 23.2 in x 34.6 in (438 mm x 589 mm x 879 mm)
HGJAF: 16.5 in x 22.8 in x 27.9 in (420 mm x 579 mm x 709 mm)
Transmission or Petroleum-Based Hydraulic Fluid—Operating
Viscosity: 80-1000 SSU—Maximum Start-Up Viscosity: 4000 SSU
3/8–18 NPTF
9-13 in (228-330 mm) WC
1/4–18 NPTF
Tank Pressure
3/4-16 UNF-2B SAE
7/8-14 UNF-2B SAE
30
Information for California Genset Users
Redistribution or publication of this document
by any means, is strictly prohibited.
This genset meets the requirements of California’s
Exhaust Emissions Standards as stated on the
nameplate. Figure 1 (Page 4) illustrates where
this information appears on the nameplate.
As a California user of this genset, please be aware
that unauthorized modifications or replacement of
fuel, exhaust, air intake, or speed control system
components that affect engine emissions are prohibited. Unauthorized modification, removal or replacement of the genset label is prohibited.
TABLE 5. EMISSIONS CONTROL INFORMATION
The California emissions control warranty statement is located in
Genset Warranty Information
Engine Valve Lash See Specifications (Page 29).
Engine Ignition Timing See Specifications (Page 29).
Engine Fuel Requirements
the same packet of information as this manual when the genset is
shipped from the factory.
Gasoline Models: The engine is certified to operate on unleaded
gasoline. See Fuel Recommendations (Page 6).
LPG Models: The engine is certified to operate on LPG. See Fuel
Recommendations (Page 6).
You should carefully review Operator (Owner),
Installation and other manuals and information you
receive with your genset. If you are unsure that the
installation, use, maintenance or service of your
genset is authorized, you should seek assistance
from an approved Onan dealer.
California genset users may use Table 5 as an aid in
locating information related to the California Air Resources Board requirements for emissions control.
Engine Lubricating Oil Requirements See ENGINE OIL RECOMMENDATIONS (Page 6).
Gasoline Models—Fuel Injection: The precision-manufactured fuel injection system is not adjustable.
Engine Fuel Mixture Settings
All Other Models: The precision-manufactured carburetor is not
adjustable.
Gasoline Models—Fuel Injection: Not applicable
Engine Adjustments
Engine Emission Control System
Gasoline Models—Carburetor: See Figure 8 (Page 11).
LPG Models: Not applicable.
Gasoline Models—Fuel Injection: The engine emissions con-
trol system consists of Sequential Multiport Fuel Injection (SFI).
All Other Models: The engine emissions control system consists of inherent engine design.
31
How to Obtain Service
Redistribution or publication of this document
by any means, is strictly prohibited.
When you need service, parts, or product literature
(such as the Service Manual) for your genset, contact the nearest authorized distributor. Onan has
factory-trained representatives to handle your
needs for genset parts and service.
Call 1-800-888-ONAN to contact the nearest Cummins/Onan or Onan-only distributor in the United
States or Canada. (This automated service utilizes
touch-tone phones only). Select OPTION 1
(press 1) to be automatically connected to the distributor nearest to you.
If you are unable to contact a distributor using the
automated service, consult the Yellow Pages. Typically, our distributors are listed under:
GENERATORS – ELECTRIC,
ENGINES – GASOLINE OR DIESEL, or
RECREATIONAL VEHICLES – EQUIPMENT,
PARTS AND SERVICE.
If you are outside North America, call Onan Corporation at 1–763–574–5000 from 7:30 AM to
4:00 PM, Central Standard Time, Monday through
Friday, or fax 1–763–528–7229.
Before calling for service, have the following information available:
1. The complete genset model number and serial
number. See Model Identification (Page 4).
2. The date of purchase.
3. The nature of the problem. See Troubleshoot-
ing (Page 22).
If you have difficulty in arranging service or resolving a problem, please contact the Service Manager
at the nearest Cummins/Onan distributor for assistance.
WARNING
parts can result in severe personal injury, death,
and/or equipment damage. Service personnel
must be trained and experienced in performing
electrical and/or mechanical service.
Improper service or replacement of
32
Maintenance Record
Redistribution or publication of this document
by any means, is strictly prohibited.
Record all periodic and unscheduled maintenance and service. See Periodic Maintenance (Page 15).
HOUR
DATE
METER
READING
MAINTENANCE OR SERVICE PERFORMED
Record the name, address, and phone number of your authorized Onan service center.
33
Cummins Power Generation
Redistribution or publication of this document
by any means, is strictly prohibited.
1400 73rd Avenue N.E.
Minneapolis, MN 55432
763-574-5000
Fax: 763-528-7229
Cummins and Onan are registered trademarks of Cummins Inc.
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