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Onan
Portable Generator
HGJAB
Onan HGJAB Service Manual
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HGJAA, HGJAB, HGJAC,
HGJAD, HGJAE, HGJAF
Printed
in
U.S.A.
983-0501D
01-06
1
3
Table of Contents
Default Chapter
4
Table of Contents
4
Section Page
5
Safety Precautions
8
1 Introduction
10
2 Operation
11
Fuel Recommendations
11
Engine Oil Recommendations
11
Starting Batteries
11
Genset Control Panel
12
Remote Control Panel
12
Conducting Pre-Start Checks
13
Priming Gasoline Fuel Systems
13
Starting the Genset
13
Stopping the Genset
14
Restarting the Genset
14
Engine Only Operation
14
Genset Lockout Switch
14
3 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
4 Preparing for Service
22
Troubleshooting
22
Safety
22
Special Tools
22
Removing the Genset
23
Installing the Genset
24
Controller A1
25
Other Control Components
28
6 Generator
33
Generator Description
33
Generator Service
33
Brushes and Slip Rings
35
Generator Testing
36
Voltage Adjustments-HGJAD, HGJAE, HGJAF
37
Generator Connections
37
7 Fan, Drive Belt, Flywheel, Ignition, Exhaust
39
Fan, Belt, Pulleys and Flywheel
39
Ignition System
42
Exhaust System
44
8 Fuel System
49
Testing Compression / Leakdown
69
Testing Crankcase Vacuum
69
Adjusting Valve Lash
72
Cylinder Heads and Valves
73
Crankcase Assembly
74
10 Hydraulic Pump
88
Installing the Hydraulic Pump
88
Connecting Hydraulic Hoses
88
Troubleshooting
89
Fault Codes
89
Genset Starts or Stops Without Command – no Fault Code
90
No Response – Status Indicator Light Dead
91
Starting Batteries Run down
91
Starter Engages – Disengages
92
Undervoltage – Fault Code
97
Overfrequency – Fault Code
98
Underfrequency – Fault Code
100
Governor Actuator Overload (Efi Only) – Fault Code
103
Control Card Failure (Faultcode 35)
111
Genset Stopped Without Fault (Faultcode 36)
111
Genset Stopped Without Fault Condition – Fault Code
111
Invalid Set Configuration – Fault Code
113
Field Overload (Overvoltage) – Fault Code
114
Service Checklist
124
Specifications
126
Torque Specifications
130
4
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Onan HGJAB Specifications
General
Fuel Type
Gasoline
Power Output
5500 Watts
Voltage
120/240V
Starting
Electric
Engine Type
OHV
Noise Level
68 dB
Outlet Types
1 x 120/240V 30A Locking
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