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Onan HGJAB Service Manual

Onan HGJAB
139 pages
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Table of Contents

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Onan HGJAB Specifications

General IconGeneral
Fuel TypeGasoline
Power Output5500 Watts
Voltage120/240V
StartingElectric
Engine TypeOHV
Noise Level68 dB
Outlet Types1 x 120/240V 30A Locking

Summary

1. Introduction

Safety Precautions

Essential safety guidelines and warnings for operating and servicing the genset.

2. Operation

Fuel Recommendations

Guidance on selecting appropriate gasoline and LPG fuels for optimal genset performance.

Engine Oil Recommendations

Recommendations for engine oil types and viscosity grades based on ambient temperature.

Genset Control Panel

Description of the features and functions of the genset's main control panel.

Starting the Genset

Step-by-step instructions for safely starting the genset from the control panel or remote panel.

3. Periodic Maintenance

Conducting General Inspections

Procedures for daily and pre-operation inspections of the genset's various systems.

Checking Engine Oil Level

Instructions for checking the engine oil level, including safety warnings.

Changing Engine Oil and Oil Filter

Detailed steps for performing an engine oil and filter change.

Replacing Spark Plugs

Guidance on replacing spark plugs for optimal engine starting and performance.

4. Preparing for Service

Safety

Comprehensive safety guidelines and hazard awareness for performing genset service.

Troubleshooting

Guidance on initial troubleshooting steps before commencing service work.

Removing the Genset

Procedures and considerations for safely removing the genset from its installation.

Installing the Genset

Steps and checks required for the proper installation of the genset.

5. Control

Controller A1

Description of the Controller A1, its functions, and connections.

Other Control Components

Overview of other control components like switches, circuit breakers, and meters.

6. Generator

Generator Description

Detailed description of the generator's construction, including stator, rotor, and brush block.

Generator Service

Procedures for servicing the generator, including stator removal and reassembly.

Generator Testing

Methods for testing the generator's rotor and stator windings for faults.

Voltage Adjustments

Procedure for adjusting voltage on specific genset models (HGJAD, HGJAE, HGJAF).

Generator Connections

Information on generator output connections and wiring diagrams.

7. Fan, Drive Belt, Flywheel, Ignition, Exhaust

Fan, Belt, Pulleys and Flywheel

Details on the fan shroud, drive belt system, pulleys, and flywheel.

Ignition System

Explanation of the ignition system components and troubleshooting steps.

Exhaust System

Information on the exhaust system, including manifold removal and installation.

8. Fuel System

Gasoline Fuel System

Details on the gasoline fuel system, including EFI and carburetor models.

LPG Fuel System

Information on the LPG fuel system for low-pressure and high-pressure models.

Mechanical Governor

Description and adjustment procedures for the mechanical governor.

9. Engine

Testing Compression / Leakdown

Procedures for testing engine compression and leakdown to assess wear.

Removing and Installing Generator / Engine Assembly

Steps for removing and installing the complete generator and engine assembly.

Starter Motor

Procedures for replacing the starter motor and its solenoid.

Adjusting Valve Lash

Step-by-step guide for adjusting engine valve lash.

Cylinder Heads and Valves

Procedures for removing, disassembling, and reassembling cylinder heads and valves.

Dimensions and Clearances

Table of standard and maximum dimensions and clearances for engine components.

10. Hydraulic Pump

Installing the Hydraulic Pump

Instructions for the correct installation of the hydraulic pump.

Connecting Hydraulic Hoses

Guidelines for connecting hydraulic hoses and starting the system.

11. Troubleshooting

Fault Codes Overview

Explanation of how the genset controller uses fault codes indicated by blinking lights.

Genset Starts or Stops Without Command

Troubleshooting steps for issues where the genset starts/stops unexpectedly.

No Response – Status Indicator Light Dead

Diagnosis and repair for a dead status indicator light on the control panel.

Low Oil Pressure Fault – Fault Code 2

Diagnosis and repair procedures for the low oil pressure fault code.

Service Check Fault – Fault Code 3

Troubleshooting for service check fault indicated by code 3.

Overcrank – Fault Code 4

Steps to resolve the overcrank fault code, indicating start failure.

Overvoltage – Fault Code 12

Diagnosis and repair for overvoltage fault code 12.

Undervoltage – Fault Code 13

Troubleshooting steps for undervoltage fault code 13.

Overfrequency – Fault Code 14

Diagnosis and repair for overfrequency fault code 14.

Underfrequency – Fault Code 15

Steps to resolve underfrequency fault code 15.

Fuel Pump Fault – Fault Code 17

Troubleshooting steps for fuel pump fault code 17.

Governor Actuator (EFI Only) – Fault Code 19

Diagnosis for governor actuator fault code 19 in EFI models.

Governor Actuator Overload (EFI Only) – Fault Code 22

Troubleshooting for governor actuator overload fault code 22 in EFI models.

Oil Pressure Switch Fault – Fault Code 23

Diagnosis and repair for oil pressure switch fault code 23.

Voltage Sense Lost – Fault Code 27

Troubleshooting steps for voltage sense lost fault code 27.

High Battery Voltage – Fault Code 29

Diagnosis and repair for high battery voltage fault code 29.

Overspeed Fault (HGJAD, E, F Models Only) – Fault Code 31

Troubleshooting for overspeed fault code 31 specific to certain models.

Low Cranking Speed Sense – Fault Code 32

Diagnosis and repair for low cranking speed sense fault code 32.

Invalid Set Configuration – Fault Code 37

Troubleshooting steps for invalid set configuration fault code 37.

Field Overload (Overvoltage) – Fault Code 38

Diagnosis and repair for field overload (overvoltage) fault code 38.

Generator Rotor Fault – Fault Code 41

Troubleshooting for generator rotor fault code 41.

Processor Fault – Fault Code 42

Diagnosis and solution for processor fault code 42 (ROM error).

Processor Fault – Fault Code 43

Diagnosis and solution for processor fault code 43 (RAM error).

Speed Sense Fault – Fault Code 45

Troubleshooting steps for speed sense fault code 45.

Ignition Fault – Fault Code 47

Diagnosis and repair for ignition fault code 47.

Field Sense Fault – Fault Code 48

Troubleshooting for field sense fault code 48.

Processor Failure – Fault Code 51

Diagnosis and solution for processor failure fault code 51.

Fuel Injector Fault – Fault Code 52

Troubleshooting steps for fuel injector fault code 52.

MAT Sensor Fault – Fault Code 54

Diagnosis and solution for MAT sensor fault code 54.

MAP Sensor Fault – Fault Code 56

Troubleshooting steps for MAP sensor fault code 56.

Overprime Fault – Fault Code 57

Diagnosis and repair for overprime fault code 57.

12. Service Checklist

General Checks

Pre-service checks for genset mounting, wiring, exhaust, and fuel systems.

Fuel System Checks

Procedures for checking fuel system connections, priming, and leak detection.

Startup Procedure

Instructions and checks for safely starting the genset and verifying operation.

13. Specifications

Gasoline Models Specifications

Technical data and performance specifications for various gasoline models.

LPG Models Specifications

Technical data and performance specifications for various LPG models.

14. Torque Specifications

Engine Torque Specifications

Table of torque values for key engine components during assembly.

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