Service parts for the HGJAA
Grouped by system, with how many of each the parts manual calls for.
Air intake
1 requiredFuel system
1 requiredOil system
1 requiredPrices captured from merchant listings; some links are affiliate links. Confirm against your serial number before ordering.
Specifications
| Fuel | gasoline |
|---|---|
| Frequency | 60.0 Hz |
| Controller | A1, EC-AGS+ |
| Oil capacity | 1.8 L |
| Voltage options | 120 V |
| Phase | 1 |
| Rated current | 58.3 A |
| Power factor | 1.0 |
| Battery cranking | 450 CCA |
| Battery voltage | 12 V |
| Dry weight | 127 kg |
| Sound level | 66.0 dBA @ 3 m |
Maintenance & consumables
| Item | Spec | Capacity | Part # | Interval | |
|---|---|---|---|---|---|
| Air filter | Air filter | 149-2629 | eBay | ||
| Fuel filter | Fuel filter | 167-1638 | eBay | ||
| Oil filter | Oil filter | 140-3116 | eBay $18.99 FridayParts $48.88 |
Service intervals
40| Item | Action | Hours | Months | Notes |
|---|---|---|---|---|
| Genset | Other | 2 hr | 1 mo | Exercise at least 2 hours each month at approximately 1/2 rated power; a single 2-hour period is better than several shorter ones |
| Carbon monoxide detector | Test | 8 hr | Inspect for exhaust leaks and test/confirm all CO detectors prior to every startup and after every 8 hours of running | |
| Carbon monoxide detectors | Test | 8 hr | Must be tested and confirmed working prior to every startup and after every eight hours of running. | |
| Cylinder Cooling Fins | Clean | 8 hr | Daily or every 8 hours; more often in dusty conditions | |
| Engine | Inspect | 8 hr | Daily or every 8 hours | |
| Engine oil level | Check | 8 hr | Section 4.2 | |
| Exhaust leaks / CO detectors | Inspect | 8 hr | Inspect for exhaust leaks and test/confirm all CO detectors are working prior to every startup and after every 8 hours of running. | |
| Exhaust system | Inspect | 24 hr | Inspect for exhaust leaks at every startup and after every eight hours of running. | |
| Fuel Lines | Inspect | 8 hr | Daily or every 8 hours | |
| General Inspection | Check | 8 hr | Every day or 8 hours | |
| General inspection | Inspect | 8 hr | Before first start of day and after every 8 hours of operation (Table 4) | |
| General inspections | Inspect | 8 hr | Every day or every 8 hours | |
| Genset | Inspect | 8 hr | Every day or every 8 hours; general inspections | |
| Oil Level | Check | 8 hr | Daily or every 8 hours | |
| Engine oil | Change | 50 hr | First service — Break-in: change engine oil after the first 20-50 hours of operation (RV QG/RV QG RM); perform at least once a year | |
| Spark arrestor | Clean | 150 hr | Table 3-1 Periodic Maintenance Schedule | |
| Air filter element | Replace | 150 hr | Perform more often when operating in dusty environments | |
| Engine Oil & Oil Filter | Change | 150 hr | 12 mo | First service — Perform more often in dusty environments, in hot weather, and at least once a year |
| Engine cooling fins | Clean | 500 hr | Perform more often when operating in dusty environments | |
| Engine oil and oil filter | Change | 150 hr | 12 mo | First service — Perform more often in dusty/hot environments; at least yearly |
| Carburetor and combustion chambers | Clean | 300 hr | Clean with Onan "4C"; Table 4 column inferred | |
| Engine air filter | Replace | 300 hr | Footnotes 2,4 — more often in dusty conditions, at least once a year | |
| Cylinder heads | Clean | 450 hr | Clean or replace; must be performed by a trained and experienced mechanic | |
| Fuel filter | Replace | 500 hr | 36 mo | Sooner if engine performance deteriorates; by trained mechanic |
| Choke vacuum sustain valve | Replace | 500 hr | Footnotes 5,6 — sooner if performance deteriorates; qualified mechanic | |
| Cylinder heads and combustion chambers | Clean | 500 hr | Remove cylinder heads and clean combustion chambers; footnote 6 | |
| Engine valve clearance | Adjust | 500 hr | First service — Footnote 6 — must be performed by an authorized Onan dealer | |
| Fuel filter(s) and fuel pump screen | Replace | 500 hr | Footnotes 5,6 — replace filter(s) and clean fuel pump screen | |
| Governor linkage | Inspect | 500 hr | Inspect and clean; footnote 6 | |
| Spark Plug(s) | Replace | 500 hr | Sooner if performance deteriorates | |
| Spark plugs | Replace | 500 hr | Sooner if performance deteriorates | |
| Valve lash | Adjust | 500 hr | Must be performed by trained mechanic (authorized Cummins dealer) | |
| Battery | Clean | 1 mo | Every Month; footnote 3 - perform more often when operating in hot weather | |
| Battery & connections | Clean | 1 mo | Clean & check battery & connections; perform more often in hot weather | |
| Battery and battery connections | Clean | 1 mo | Perform more often in hot weather | |
| Oil/oil filter - Quiet Diesel 10000/12500 | Change | First service — Break-in then repeat (footnotes 1-4, 2-4) | ||
| Oil/oil filter - Quiet Diesel 5500 | Change | First service — Break-in then repeat (footnotes 1-4, 2-4) | ||
| Oil/oil filter - Quiet Diesel 7500/8000 | Change | First service — Break-in then repeat (footnotes 1-4, 2-4) | ||
| Spark arrester | Clean | 50 hr | 1 mo | Clean arrester; perform sooner if engine performance deteriorates |
| Starting Battery | Check | 1 mo | Monthly; see battery manufacturer instructions |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Service specifications
60| Type | Item | Value | Unit | Condition |
|---|---|---|---|---|
| Clearance | Crankshaft End Play | 0.005 - 0.012 | in | |
| Clearance | Crankshaft End Play | 0.127 - 0.305 | mm | |
| Clearance | Crankshaft Oil Seal depth below surface | 0.020 to 0.060 | in | |
| Clearance | Crankshaft end play | 0.005 – 0.012 | in (0.127 – 0.305 mm) | |
| Clearance | Crankshaft end play | 0.005-0.012 | in | |
| Clearance | Crankshaft oil seal press depth | 0.020 to 0.060 | in | below surface |
| Clearance | Cylinder head flatness max | 0.004 | in | |
| Clearance | Cylinder head flatness maximum | 0.004 | in (0.1 mm) | |
| Clearance | Minimum Free Air Inlet Area | 752.3 | cm2 (116.7 in2) | |
| Clearance | Minimum Free Air Inlet Area (LPG) | 752.3 | cm2 (116.7 in2) | |
| Clearance | Minimum clearance at top and any side of genset | 1/2 | in (12.7 mm) | |
| Clearance | Minimum distance from tail pipe termination to any opening into vehicle interior | 6 | in (153 mm) | |
| Clearance | Minimum distance from tail pipe to combustible material | 3 | in (76 mm) | unless insulated or shielded |
| Clearance | Minimum ground clearance | 12 | in (305 mm) | |
| Clearance | Minimum unobstructed space below genset, open on at least three sides | 6 | in (152 mm) | |
| Clearance | Piston-to-cylinder clearance at skirt max | 0.0098 | in | |
| Clearance | Tail pipe extension beyond perimeter of vehicle (minimum) | 1 | in (25 mm) | |
| Clearance | Tailpipe extension beyond perimeter of vehicle | at least 1 inch (25.4 mm) | ||
| Clearance | Valve guide inside diameter max | 0.242 | in | |
| Clearance | Valve guide inside diameter standard | 0.2376 – 0.2383 | in (6.035 – 6.053 mm) | |
| Gap | Magneto air gap | 0.012 | in (0.3 mm) | |
| Gap | Magneto air gap | 0.3 | mm (0.012 in) | |
| Gap | Spark Plug Gap | 0.035 inches (0.89 mm) | inches (mm) | |
| Gap | Spark plug gap | 0.025 | in (6-7 mm) | |
| Gap | Spark plug gap | 0.025 inches (0.64 mm) | ||
| Gap | Spark plug gap | 6-7 | mm (0.025 in) | |
| Injection timing | Ignition timing | 20° BTDC | degrees | non-adjustable |
| Injection timing | Ignition timing | 20° BTDC, non-adjustable magneto | ||
| Other | Battery electrolyte specific gravity — recharge below | 1.215 | ||
| Other | Battery electrolyte specific gravity — stop charging at | 1.260 | at approximately 80° F (27° C) | |
| Other | Bore | 3.15 | in (80 mm) | |
| Other | Compression ratio | 7.0 : 1 | ||
| Other | Compression ratio | 8.0 : 1 | ||
| Other | Cylinder bore | 3.250 inches (83 mm) | ||
| Other | Cylinder bore | 3.563 inches (90 mm) | ||
| Other | Displacement | 39.8 | in3 (653 cc) | |
| Other | Displacement | 48 inches3 (782 cc) | ||
| Other | Displacement | 60 inches3 (980 cc) | ||
| Other | EC-AGS+ gateway dimensions | 120 x 108 x 38 | mm | |
| Other | Engine Oil Capacity | 2.0 | quart (1.8 l) | |
| Other | Engine oil capacity (with filter) | 3.5 quarts (3.3 l) | ||
| Other | Fuse F1 (control circuit) | 5 amperes | ||
| Other | Fuse F2 (autochoke/fuel pump; fuel solenoid on LPG) | 10 amperes mini-bayonet | ||
| Other | Generator Speed | 3600 | rpm | |
| Other | Genset power (BGE LPG, 50 Hz) | 4800 watts; 120 volts; 40 amperes | ||
| Other | Genset power (BGE, 60 Hz) | 4000 watts; 120 volts; 33.3 amperes | ||
| Other | Genset power (NHE, 50 Hz, 1-phase) | 5000 watts; 110/220 or 120/240 volts; 45.5/22.7 or 41.7/20.8 amperes; 1500 RPM | ||
| Other | Genset power (NHE, 60 Hz, 1-phase) | 6500 watts; 110/220 or 120/240 volts; 54.2 amperes; 1800 RPM | ||
| Other | Ignition Timing | 20 | deg BTDC, non-adjustable | |
| Other | Ignition Timing | 23° BTDC | degrees BTDC | Non-adjustable, electronic, magneto ignition |
| Other | Ignition timing (electronic ignition) | 12° BTDC, non-adjustable | ||
| Other | LPG Liquid Connection Pressure | Tank Pressure | ||
| Other | LPG low-pressure supply (vapor) | 9-13 | in WC | |
| Other | Minimum battery cold cranking capacity above freezing | 360 amperes | above freezing | |
| Other | Minimum battery cold cranking capacity below freezing | 450 amperes | below freezing | |
| Other | Oil capacity | 2.0 | quart (1.8 l) | |
| Other | Power decrease with altitude | approximately 3.5 percent of rated power each 1000 feet (305 m) | ||
| Other | Power output change with altitude | 3.5 | % decrease per 1000 ft increase | typical power output change based on ambient conditions |
| Other | Power output change with temperature | 1 | % decrease per 10 degF increase | typical power output change based on ambient conditions |
| Other | Spark plug kit torque specification | 18-25 | lb-ft |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Recommended fluids
| Fluid | Grade | Standard | Ambient | Capacity | Notes |
|---|---|---|---|---|---|
| Coolant | 50/50 ethylene glycol based antifreeze and water | Mix thoroughly before adding; use clean soft tap water, distilled water or pure rain; select high quality antifreeze with corrosion inhibitors | |||
| Engine oil | API Class SJ, SH or SG | 2.0 quart (1.8 l) | Oil capacity | ||
| Engine oil | OnaMax 10W-30 (A063E183) | API SM, SN, or better | 1.8 l | Recommended for temperatures above 0 °F | |
| Engine oil | SAE 10W-30 / 10W-40 / 0W-30 / 5W-30 | Use viscosity chart to select grade for expected ambient temperature range; avoid mixing grades or brands | |||
| Engine oil | SAE 15W-40 | API CF, CF-4, CG-4, CH-4, CI-4 or CJ-4 (diesel) | OnaMax 15W-40 #326-5336; multi-grade recommended year-round in liquid-cooled engines; synthetic oil not recommended | ||
| Engine oil | SAE-30 | API SJ, SL or SM (gasoline) | OnaMax SAE-30 #326-5339; preferred summer grade for optimum oil consumption control in air-cooled engines | ||
| Engine oil | 5W-30 | API SJ, SH or SG (may be combined with CH-4, CG-4 or CF-4) | -28°C to 10°C | 2.0 quart (1.8 l) | -20°F to 50°F |
| Engine oil | SAE 5W-30 | API SJ, SH or SG | -28°C to 10°C | 2.0 quart | -20 F to 50 F |
| Engine oil | 10W-30 | API Class SG or SH (also SG/CD, SG/CE, SH/CD or SH/CE) | -18°C to 27°C | 3.5 | 0° F to 80° F |
| Engine oil | 10W-30 (OnaMax), 10W-40 | API SM, SN, or better | -18°C to 38°C | -18 to 38 °C (0 to 100 °F) | |
| Engine oil | 10W-30 / 10W-40 | API SJ, SH or SG; may be combined with CH-4, CG-4 or CF-4 | -18°C to 27°C | 2.0 quart (1.8 l) | 0° F to 80° F (−18° C to 27° C) |
| Engine oil | 10W-30 10W-40 | API SJ, SH or SG (may be combined with CH-4, CG-4 or CF-4) | -18°C to 27°C | 2.0 quart (1.8 l) | 0°F to 80°F |
| Engine oil | 10W-30, 10W-40 | API SJ/SH/SG (may combine CH-4, CG-4, CF-4) | -18°C to 27°C | ||
| Engine oil | 10W-30/10W-40 | -18°C to 27°C | 1.8 liters | ||
| Engine oil | 10W-40 | API Class SG or SH (also SG/CD, SG/CE, SH/CD or SH/CE) | -18°C to 27°C | 3.5 | 0° F to 80° F |
| Engine oil | SAE 10W-30 / 10W-40 | API SJ, SH or SG | -18°C to 27°C | 2.0 quart | 0 F to 80 F |
| Engine oil | 15W-40 (OnaMax) | API SJ, SH or SG (may be combined with CH-4, CG-4 or CF-4) | -12°C to 38°C | 2.0 quart (1.8 l) | 10°F to 100°F |
| Engine oil | SAE 15W-40 (OnaMax) | API SJ, SH or SG | -12°C to 38°C | 2.0 quart | 10 F to 100 F |
| Engine oil | 30 | API SM, SN, or better | above 0°C | 0 °C (32 °F) and higher | |
| Engine oil | API SJ, SH or SG | 0°C to 38°C | 1.8 liters | SAE 30 preferred when consistently above freezing | |
| Engine oil | SAE 30 | API SJ, SH or SG (may be combined with CH-4, CG-4 or CF-4) | above 0°C | 2.0 quart (1.8 l) | 32°F (0°C) and higher; single-grade SAE 30 preferable when temperatures consistently above freezing |
| Fuel | ASTM No.2-D / No.1-D / No.2-DLS / No.1-DLS / B5 Biodiesel | minimum Cetane number 45 | No.2-D or No.2-DLS above 23 degF; No.1-D or No.1-DLS below 23 degF; B5 Biodiesel above 50 degF; use No.1 diesel below 32 degF and during long light-load periods; cloud point at least 10 degF below lowest expected fuel temperature | ||
| Fuel | Clean, fresh HD-5 grade liquified petroleum gas (LPG) or equivalent, at least 90 percent propane | LPG models. Commercial LPG may contain more than 2.5 percent butane causing poor vaporization/starting below 32° F (0° C). | |||
| Fuel | Clean, fresh unleaded gasoline, minimum octane rating (Anti-Knock Index) of 87 | Gasoline models. Do not use gasoline or additives containing methanol; avoid leaded gasoline. | |||
| Fuel | Gasoline | Type 304L stainless or AISI 1008−1010 low carbon steel tubing; SAE J30R9 hose | Fuel line pressure must not exceed 1-1/2 psi (HGJAB / HGJAC); maximum fuel pump lift 36 inches (914 mm) | ||
| Fuel | Gasoline (EFI or carburetor) or LPG (vapor or liquid withdrawal) | See the Operator's Manual for recommended fuels. Evaporative fuel system requires low-permeation fuel hose. | |||
| Fuel | Gasoline (Type 1 SAE J1231 fuel supply connection) | SAE J1231, J1508, J2260, J2044, J2599 | Low permeation fuel hose required; 1/4 in I.D. fuel line from vehicle fuel tank | ||
| Fuel | HD-5 LPG | At least 90% propane | Supply pressure 228-330 mm WC | ||
| Fuel | HD-5 grade LPG (at least 90 percent propane) | Commercial LPG may contain more than 2.5 percent butane causing poor vaporization/starting below 32° F (0° C) | |||
| Fuel | HD-5 grade LPG (min 90% propane) | LPG models; butane >2.5% prevents vaporization below 32 °F (0 °C) |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Fault codes
35| Code | Name | Meaning | Severity | Action |
|---|---|---|---|---|
| 1 | High Engine Coolant Temperature | 1 blink indicates shutdown due to high engine coolant temperatures. | Shutdown | Allow engine to cool; inspect cooling system |
| 12 | Overvoltage Fault | Instantaneous: AC voltage S1-S2 greater than 150 VAC. Delayed: greater than 138 VAC but less than 150 VAC for 3 continuous minutes | Shutdown | Verify FC12; measure AC voltage; cycle loads; reduce battery charge rate; balance loads; run in ERO mode; measure winding resistances; check brush alignment. |
| 13 | Undervoltage Fault | Controller unable to maintain rated voltage | Shutdown | Verify FC13; measure AC voltage in/out of sense transformer; cycle loads; reduce charger rate; measure winding resistances; check brush alignment. |
| 14 | Overfrequency Fault | Instantaneous: frequency greater than 70 Hz. Delayed: greater than 66 Hz but less than 70 Hz for 3 continuous seconds | Shutdown | Verify FC14; measure AC current and load capability; check governor, fuel supply, air filter, exhaust, choke, magnetos; run ERO test. |
| 15 | Underfrequency Fault | Engine governor unable to maintain rated frequency | Shutdown | Verify FC15; measure AC current; check governor, fuel supply, air filter, exhaust, choke, magnetos; run ERO test. |
| 17 | Fuel Pump Fault | Open fuel pump circuit at control (active prior to 2001) | Shutdown | Verify pump in prime mode; check fuse F1; replace pump |
| 19 | Governor Actuator Fault | Shorted or open connection between governor leads after pressing start; P1-17 | Shutdown | Verify actuator function with DC voltage; measure actuator terminal resistance; check P1-28 continuity |
| 2 | Low Oil Pressure Fault | Low oil pressure cutoff switch did not open | Shutdown | Verify FC2; measure oil level; inspect P1 pins per PSB-676; measure continuity; measure oil pressure with a mechanical gauge; repair/replace relief valve and oil pump. |
| 22 | Governor Actuator Overload Fault | Only active prior to 2001; maximum governor output (PWM) for 10 continuous seconds. | Shutdown | Verify FC22; measure AC current, load capability; check air filter, intake manifold gaskets, exhaust, fuel pump pressure; verify actuator; check magnetos. |
| 23 | Oil Pressure Switch Fault | Only active prior to 2001 - continuous open on oil pressure switch input before cranking | Shutdown | Verify harness lead connected; measure continuity to ground at switch and through harness at P1 |
| 27 | Voltage Sense Lost | No sense voltage (0 VAC across S1-S2) for 1 continuous second after start disconnect. | Shutdown | Verify FC27; measure AC voltage; inspect P1 pins; check air filter and exhaust; run ERO test; check fuel and ignition systems. |
| 29 | High Battery Voltage Fault | Voltage across battery system greater than 19 volts | Warning | Verify FC29; measure DC voltage at battery, generator set and P1; check grounds; replace controller if needed. |
| 3 | Service Check Fault | Single-digit fault indicating shutdown due to a two-digit fault | Shutdown | While LED flashing three times, press stop once (1 second) and troubleshoot the two-digit fault code. |
| 31 | Overspeed Fault (HGJAD, E, F Models Only) | Engine speed greater than 3400 rpm | Shutdown | Verify FC31; measure frequency and droop; check governor, air filter, exhaust, fuel, magnetos; run ERO test. |
| 32 | Low Cranking Speed Sense | Quadrature frequency less than or equal to 3 Hz and engine RPM less than or equal to 100 RPM for 12 continuous seconds after pressing start. | Shutdown | Verify FC32; measure battery voltage; verify engine rotation; check starter, air filter, spark plug, exhaust; check magnetos. |
| 33 | Fault Code 33 | There is a single-digit fault which indicates a shutdown due to a two-digit fault code; Fault Code 3 interpreted as a non-assigned Fault Code 33. | Shutdown | While LED flashing three times, press stop once (1 second); troubleshoot the two-digit fault code. |
| 35 | Control Card Failure Fault | Microprocessor EEPROM error during self-test | Shutdown | Verify FC35; replace the control. |
| 36 | Stopped Without Fault Condition | RPM less than 500 and sense voltage S1-S2 at 0 VAC with no other fault | Shutdown | Verify FC36; check AGS; verify engine rotation; inspect P1 pins; check air filter, spark plug, exhaust; run ERO test. |
| 37 | Invalid Set Configuration | Wrong frequency/rpm ratio | Shutdown | Verify FC37; if alternating with FC47 reset magneto gap; run ERO test; measure winding resistances; verify magnetos and board. |
| 38 | Overcurrent (Field Overload) Fault | Low power factor loads | Shutdown | Verify FC38; measure F1-F2 DC voltage and AC current; reduce charger rate; inspect P1 pins; measure winding resistances; check brush alignment. |
| 4 | Overcrank Fault | First-level fault code—Cranking exceeded 30 seconds without engine starting | Shutdown | Verify FC4; measure battery voltage; check start/stop switch and P1; check air filter, spark plug, exhaust system, fuel supply, ignition and magnetos. |
| 41 | Generator Rotor Fault | Only active after 2003; field voltage F1-F2 at 0 VDC and sense voltage S1-S2 at 0 VAC for 1 continuous second. | Shutdown | Verify FC41; measure F1-F2 DC voltage and AC current; inspect P1 pins; run ERO test; measure winding resistances; check brush alignment. |
| 42 | Processor Fault (ROM) | ROM error during self-test | Shutdown | Verify FC42; replace the control. |
| 43 | Processor Fault (RAM) | RAM error during self-test | Shutdown | Verify FC43; replace the control. |
| 45 | Speed Sense Fault | While running, the quadrature frequency dropped to 0 Hz for 1 continuous second. | Shutdown | Verify FC45; check AGS; verify engine rotation; inspect P1 pins; check air filter, exhaust, loads; run ERO test; check magnetos. |
| 47 | Ignition Fault | No ignition signal at P1 (P1-15 for HGJAB/C; P1-5 for HGJAA/D/E/F) for 1 continuous second | Shutdown | Verify FC47; if alternating with FC37 reset magneto gap; test magnetos; run ERO test; measure winding resistances. |
| 48 | Generator Field Sense Fault | The controller is unable to sense field voltage. | Shutdown | Verify FC48; replace the control. |
| 51 | Processor Fault | Processor error; faulty control | Shutdown | Verify FC51; use breakout board per Instruction Sheet R1098; replace the control. |
| 52 | Fuel Injector Fault (EFI) | Open or shorted fuel injector; P1-17; wire connections | Shutdown | Verify FC52; inspect injector connector and P1 pins; measure continuity between P1-23 INJ1 and P1-35 INJ2; replace injector. |
| 54 | MAT Sensor Fault (EFI) | The MAT sender input is greater than 300k Ohms. | Shutdown | Verify FC54; inspect sender connector and P1 pins; measure continuity between P1-25 MAT(A) and P1-20 MAT(B); replace sender. |
| 56 | MAP Sensor Fault (EFI) | The MAP sensor input is less than 50 kPa at start. | Shutdown | Verify ambient pressure; test sender; replace sender |
| 57 | Overprime Fault | The generator set has been priming for 3 consecutive minutes. | Shutdown | Verify FC57; check for an object holding the switch in stop position; inspect P1 pins; check start/stop switch. |
| 58 | Exhaust Gas Temperature Shutdown | Exhaust gas temperatures above 650 °C (1202 °F) for 2 seconds when the generator set is running. | Shutdown | Verify FC58; check spark plugs and cables; test magnetos; check carburetor/LP mixer/regulator/EFI injector; check EGT sensor and wiring; check compression and leakdown. |
| 81 | Exhaust Gas Temperature Sensor Open | While running, the EGT falls below 60 °C (140 °F) for 2 minutes or is not above 60 °C 2 minutes after starting. | Shutdown | Verify FC81; check connector at muffler and harness; check wiring; measure resistance between EGT sensor connector and J1-15/J1-21; use InPower; replace the EGT sensor. |
| 82 | Exhaust Gas Temperature Sensor Shorted | With the set running and/or startup - control reads 1000C (1832F) for 1 second | Shutdown | Verify FC82; measure resistance between ground and J1-21; use InPower; replace the EGT sensor if a short exists. |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Procedures
12Adjusting Governor (Mechanical) adjustment
⚠ Voltage/frequency-sensitive equipment may be damaged by power line frequency variations; disconnect them before adjustments.
Tools: Variable load bank up to 7 kW, Frequency meter (within 0.3%), Voltmeter (within 0.5%), AC ammeter
- Warm up the genset for at least 5 minutes at 1/2 to 3/4 rated load with the choke fully open.
- Adjust frequency close to the Table 8-3 value with the speed adjusting nut.
- With the engine warm, remove all loads and adjust the idle stop screw to 51-53 Hz (60 Hz genset) or 41-43 Hz (50 Hz genset).
- Let the throttle lever go and recheck/adjust No-Load frequency to Table 8-3; bump the governor arm to check stabilization.
- Connect rated load; if droop is out of spec move the governor spring hook one or two notches and recheck.
- Confirm the governor does not hunt under the loading sequence.
Adjusting Governor (Mechanical, HGJAB and HGJAE) adjustment
⚠ Disconnect all voltage/frequency-sensitive devices before making carburetor/governor adjustments.
Tools: Variable load bank up to 7 kW, Frequency meter (within 0.3%), Voltmeter (within 0.5%)
- Warm up generator set for at least 5 minutes at 1/2 to 3/4 rated load.
- Adjust frequency with the speed adjusting nut toward the Table 11 value.
- With engine warm, remove all loads; adjust idle stop screw to 51-53 Hz (60 Hz) or 41-43 Hz (50 Hz).
- Let throttle lever go.
- Recheck and re-adjust no-load frequency per Table 11.
- Bump governor arm to see frequency stabilizes.
- Connect a rated load.
- If droop is greater than specified, move governor spring hook one or two notches toward governor shaft; recheck.
- If droop is less or set hunts, move spring hook one or two notches away from governor shaft.
Adjusting Mechanical Governor adjustment
⚠ Voltage/frequency-sensitive equipment may be damaged; disconnect before adjusting
Tools: load bank, frequency meter, voltmeter
- Warm up genset five minutes at 1/2 to 3/4 rated load.
- Adjust frequency to Table 8-4 value with speed adjusting nut.
- With engine warm and no loads, set idle stop screw to 51-53 Hz (60 Hz).
- Recheck no-load frequency and bump governor arm for stability.
- Connect rated load; move governor spring hook to correct droop.
- Check for hunting under the specified load sequence.
Adjusting Valve Lash adjustment
Tools: Socket wrench, Feeler gauge, Torque wrench
- Adjust when the engine is at room temperature.
- Remove the spark plugs so the engine is easier to turn over.
- Use a socket wrench on the generator pulley nut to turn the engine clockwise; remove the snap-in cover.
- Remove the valve covers with rags in place to catch oil.
- Turn engine until No. 2 intake valve is at max lift; adjust No. 1 intake valve lash.
- Turn engine until No. 2 exhaust valve is at max lift; adjust No. 1 exhaust valve lash.
- Turn engine until No. 1 intake valve is at max lift; adjust No. 2 intake valve lash.
- Turn engine until No. 1 exhaust valve is at max lift; adjust No. 2 exhaust valve lash.
- Secure valve covers using new gaskets and torque cover screws to 5.5 lb-ft (8 N-m).
- Replace the spark plugs and pulley nut cover.
Adjusting Voltage adjustment
⚠ HAZARDOUS VOLTAGE! Touching uninsulated live parts can result in severe personal injury or death.
Tools: AC voltmeter, frequency meter
- Make sure fuel, exhaust and battery connections made and engine has proper oil level.
- Disconnect all generator loads and connect accurate AC volt and frequency meters.
- Start the genset and let voltage and frequency stabilize for 5 to 10 seconds.
- Rapidly press the control switch to START 6 times within 10 seconds.
- To adjust voltage up, press control switch to START and release quickly.
- To adjust voltage down, press control switch to START and release in approximately 2 seconds.
- Normal operation will resume in 20 seconds after the last adjustment.
Engine Speed Adjustments adjustment
⚠ Adjusting engine speed above equipment manufacturer's specification could cause equipment to operate at speeds in violation of Federal and State Standards for Safety.
⚠ Moving parts can cause severe personal injury or death. Take care when measuring engine speed with tachometer. Must be qualified mechanic.
Tools: Accurate tachometer
- Adjust only by qualified mechanic using accurate tachometer.
- Set low-idle and high-idle speeds to values in equipment Operator's Manual. If absent, adjust low-idle to 1400 RPM and high-idle to 3400 RPM.
- Start engine and move throttle lever to lowest speed position.
- Adjust low-idle speed stop screw on carburetor to obtain specified low-idle speed.
- For cable controlled engines: move throttle lever to highest speed position. Loosen high-idle speed stop plate clamping screw and rotate stop plate while holding throttle control arm against it until
- For lever controlled engines: adjust lever stop screw while holding throttle lever against it until specified high-idle speed is obtained.
- Check for full, smooth movement of throttle control arm between stop positions.
Operating at High Altitude (Series HGJAB/HGJAC gasoline only) adjustment
⚠ Operating at low altitude with a high altitude setting can cause power loss, overheating and engine damage.
- Reset the carburetor for the current altitude using the altitude adjust knob.
- For best fuel economy and genset operation, always reset when returning to lower altitudes.
Reconnecting and Reclamping the Choke and Throttle Cables adjustment
⚠ Accidental starting can cause severe injury or death. Always disconnect spark plug and battery before resetting engine control cables.
- Stop engine and disconnect spark plug and battery (negative cable).
- Push choke knob in to full open-choke position and throttle lever to lowest speed position.
- Loosen cable clamp at engine bracket if necessary and hook cable wires into hook holes in choke and throttle control arms.
- Rotate choke and throttle control arms clockwise, hold against stops, pull slack out of cables and tighten cable clamp.
- Check for smooth movement and full travel of choke knob and throttle lever. Remove air cleaner element to see choke plate opens and closes fully. Check throttle control arm touches stop plate and thro
- Reassemble air cleaner and reconnect spark plug and battery.
Resetting Governor Arm adjustment
Tools: Battery terminal puller, Torque wrench
- Loosen the governor shaft nut by turning it clockwise and remove the arm.
- Use a battery terminal puller to break the taper fit of the shaft in the arm hub.
- Reattach arm and hub making sure the pins and holes engage; thread the shaft nut on counterclockwise.
- Check free rotation of the arm and let the governor spring take up all play; linkage must push throttle against the wide open throttle stop.
- Torque the shaft nut to 8 lb-ft (11 N-m) counterclockwise.
- Push the governor arm down and check for binding or interference.
Setting Ignition Coil Air Gaps adjustment
Tools: Feeler gauge, Torque wrench
- Bar the engine until the lands on the flywheel directly face the coils.
- Place a 0.012 inch (0.03 mm) thick feeler gauge between the coil and the land.
- Hold the coil tight against the feeler gauge and land and torque the two mounting bolts to 5 lb-ft (7 N-m).
Setting Magneto Air Gaps adjustment
Tools: feeler gauge, torque wrench
- Bar the engine until the flywheel lands directly face the coils.
- Place a 0.012 inch (0.3 mm) feeler gauge between coil and land.
- Hold coil tight against gauge and land.
- Torque the two mounting bolts to 5 lb-ft (7 N-m).
Valve Lash Adjustment adjustment
⚠ Adjust valve lash only when engine is at room temperature
Tools: Feeler gauge, Socket wrench, Torque wrench
- Adjust valve lash with engine at room temperature.
- Remove spark plugs and valve covers.
- Turn engine until No. 2 intake valve is at maximum lift.
- Adjust No. 1 intake valve lash to 0.004 in (0.10 mm).
- Turn engine until No. 2 exhaust valve at maximum lift; adjust No. 1 exhaust.
- Turn engine until No. 1 intake valve at maximum lift; adjust No. 2 intake.
- Turn engine until No. 1 exhaust at maximum lift; adjust No. 2 exhaust.
- Torque lock nuts to 6.5 lb-ft (8.5 Nm) and install valve covers.
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Voltage reconnection
| Voltage | Phase | Connection | Leads | Notes |
|---|---|---|---|---|
| Remote control connector pin A | Battery Ground | 8-pin remote control connector | ||
| Remote control connector pin B | Stop/Prime | 8-pin remote control connector | ||
| Remote control connector pin C | Start | 8-pin remote control connector | ||
| Remote control connector pin E | Hour Meter | 8-pin remote control connector | ||
| Remote control connector pin F | Status Light | 8-pin remote control connector; pins D, G, H not used | ||
| These generator sets are not reconnectable for voltages other than stated on the nameplate | AC output through rain-tight 1/2 inch conduit connector; 12 AWG leads, 125 °C rated wire | |||
| 100-120 | 1-Phase | 2-Wire | T1-T2 and T3-T4 in phase, neutral L0 and ground | The two generator windings marked T1-T2 are in phase; neutral conductors must carry the sum of the currents |
| 100-120V | 1 | "2-wire" | CB1-LOAD (L1), CB2-LOAD (L2), NEUTRAL (L0) | Not reconnectable; generator windings T1-T2 are in phase so neutral conductors must be sized to carry the sum of the currents |
| 100/200 | 1-Phase | standard 3-Wire | T1-T2, T3-T4 with neutral L0 | Not reconnectable |
| 100/200V, 115/230V, 120/240V | 1 | Standard 3-wire | CB1-LOAD (L1), CB2-LOAD (L2), NEUTRAL (L0) | These are not reconnectable generators; 12 AWG AC output leads through rain-tight 1/2 inch trade size conduit connector |
| 110/120 | 3-Phase | standard 3-phase | T1-T2, T3-T4, T5-T6 with neutral L0 | Not reconnectable for voltages other than stated on the nameplate |
| 110/120V, 115/230V, 120/240V | 3-phase | 3-phase | CB1-LOAD (L1), CB2-LOAD (L2), CB3-LOAD (L3), NEUTRAL (L0) | These are not reconnectable generators |
| 115/230 | 1-Phase | standard 3-Wire | T1-T2, T3-T4 with neutral L0 | Not reconnectable |
| 115/230 | 3-Phase | standard 3-phase | T1-T2, T3-T4, T5-T6 with neutral L0 | 12 AWG leads exit through rain-tight 1/2 inch trade size conduit connector |
| 120 | 1 | 2-wire 120 VAC; alternator leads T2 and T4, green AC output lead and two white (L0, L0) leads secured to base with alternator neutral ground screw | T2, T4, L0, L0, green | 2-wire 120 VAC configuration only |
| 120/240 | 1-Phase | standard 3-Wire | T1-T2, T3-T4 with neutral L0 | Not reconnectable |
| 120/240 | 3-Phase | standard 3-phase | T1-T2, T3-T4, T5-T6 with neutral L0 | Not reconnectable |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Common questions
What fuel does the Cummins/Onan HGJAA use?
The Cummins/Onan HGJAA runs on gasoline.
What is the oil capacity of the Cummins/Onan HGJAA?
The Cummins/Onan HGJAA has an engine oil capacity of 1.8 liters (1.9 US quarts), per the manufacturer specification sheet.
What is the sound level of the Cummins/Onan HGJAA?
The Cummins/Onan HGJAA is rated at 66.0 dBA at 3 m, per the manufacturer specification sheet.
How much does the Cummins/Onan HGJAA weigh?
The Cummins/Onan HGJAA has a dry weight of 127 kg (279 lb).
What voltages is the Cummins/Onan HGJAA available in?
The Cummins/Onan HGJAA is offered in 120 V, 1-phase.
What size battery does the Cummins/Onan HGJAA need?
The Cummins/Onan HGJAA uses 12 V each, 450 CCA, per the manufacturer specification sheet.
Which oil filter part number does the Cummins/Onan HGJAA take?
The Cummins/Onan HGJAA uses oil filter part number 140-3116.
What fuel filter does the Cummins/Onan HGJAA use?
The Cummins/Onan HGJAA uses fuel filter part number 167-1638.
What air filter does the Cummins/Onan HGJAA use?
The Cummins/Onan HGJAA uses air filter part number 149-2629.
Troubleshooting
6Fault codes
| Code | Meaning |
|---|---|
| 2 | Low Oil Pressure Fault |
| 3 | Service Check Fault |
| 4 | Overcrank |
| 12 | Overvoltage |
| 13 | Undervoltage |
| 14 | Overfrequency |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing. Full Cummins/Onan HGJAA troubleshooting guide (37 entries) →
Repair guides
36- AC Wiring Methods
- Adjusting Governor (Mechanical)
- Adjusting Governor (Mechanical, HGJAB and HGJAE)
- Adjusting Voltage
- Battery Cable Connections at Genset
- Battery Cable Connections at the Generator Set
- Carbon Canister Connection
- Conducting General Inspections
- Connect LPG Fuel System
- Cylinder Head Reassembly and Torque Sequence
- Exercising the Genset
- Fuel Line Installation and Routing
- Fuel Pump Flow Test (EFI Gasoline Models)
- Fuel Pump Flow Test (Gasoline EFI)
- Fuel Pump Pressure Test (Carburetor Models)
- Hot Air Recirculation Test
- Hot Air Recirculation Test Method
- Ignition Coil (Magneto) Installation
- Loading the Genset
- Lock-Off Pressure Test (Low-Pressure LPG Demand Regulator)
Step-by-step procedures compiled from the Cummins/Onan service manual for this model.
Parts
23| Part # | Description | Qty | System | |
|---|---|---|---|---|
| 0122-0836 | Oil Filter | 1 | Oil filter | Amazon eBay $10.59 |
| 0140-3116 | Element, Air Cleaner | 1 | Air filter | Amazon eBay $9.95 |
| 0147-0860 | Fuel Filter, EFI | 1 | Fuel filter | Amazon eBay $16.99 NAPA $4.68 |
| 0149-2341-01 | Fuel Filter, Gasoline | 1 | Fuel filter | Amazon eBay $13.50 |
| 0149-2648 | Fuel Filter, LPG (Inline) | 1 | Fuel filter | Amazon eBay $55.00 |
| 0167-1638 | Spark Plug | 1 | Spark plug | Amazon eBay $11.95 |
| 0187-6268 | Oil Pump Filter | 1 | Oil filter | eBay |
| 140-3116 | Oil filter | Oil filter | eBay $18.99 FridayParts $48.88 | |
| 147-0860 | Filter, Fuel for HDKAK and HDKAH (Beginning Spec N) | 1 | Fuel filter | Amazon eBay $19.99 KuduParts $12.00 |
| 147-0870 | Remote Fuel Pump Kit | Pump | Amazon eBay | |
| 149-2629 | Air filter | Air filter | eBay | |
| 149-2648 | Fuel filter (LP) | Fuel filter | eBay $20.00 | |
| 167-1638 | Fuel filter | Fuel filter | eBay | |
| 0148-1343 | vent filter | 1 | Service part / kit | Amazon eBay |
| 0159-1754 | 3.3L, 233.8g working capacity | Service part / kit | Amazon eBay | |
| 0159-1755 | 3.1L, 196g working capacity | Service part / kit | Amazon eBay | |
| 122-0836 | Tune-up kit (electronic ignition) | Service part / kit | eBay $18.99 FridayParts $20.28 | |
| A030C589 | Retainer, Insulation | 1 | Service part / kit | Amazon eBay $48.00 |
| A030T897 | Cover, Enclosure (Green) | 1 | Service part / kit | Amazon eBay |
| A030W739 | Door, Enclosure | 1 | Service part / kit | Amazon eBay $272.65 |
| A030W745 | Assy, Housing (Green) (Includes Enclosure and Door Assy) | 1 | Service part / kit | Amazon eBay |
| A032Y912 | (HGJAA & HGJAB) (Begin Spec J) | 1 | Service part / kit | Amazon eBay $350.00 |
| A035H749 | Insulation, Cover | 1 | Service part / kit | Amazon eBay |
Service, wear & replacement parts referenced for this model and its engine — confirm the exact part for your serial number. See the full parts catalog to search and cross-reference.
Fuel consumption
| Rating | Load | L/h | gal/h |
|---|---|---|---|
| 1.6 | 0.43 | ||
| 50% | 2.7 | 0.7 | |
| 100% | 4.3 | 1.13 | |
| Continuous | 1.6 | 0.43 | |
| Continuous | 50% | 2.7 | 0.7 |
| Continuous | 100% | 4.3 | 1.13 |
Available documents
Operator's manual (Cummins/Onan)Operator's manual — 0983-0101 (Cummins/Onan)Operator's manual — 965-0179 Onan E125H E140H Elite series Engine Operator's manual (07-1997) (Cummins/Onan)Operator's manual — 983-0101 Onan HGJAA HGJAB HGJAC RV GenSet Operator's manual (01-2009) (Cummins/Onan)Owner's manual — 965-0176 Onan BGE NHE RV Genset Operator's manual (07-1997) (Cummins/Onan)Owner's manual — Onan-EC-AGS Manual (Cummins/Onan)Parts manual — F-1123 Cummins-Onan RV Generator Handbook (08-2007) (Cummins/Onan)Parts manual — HGJAA, HGJAB, HGJAC Parts Manual (Cummins/Onan)Service manual (Cummins/Onan)Service manual — 0983-0600 (Cummins/Onan)Service manual — 983-0501 Onan HGJAA to HGJAF (spec A-D) RV Genset Service manual (02-2010) (Cummins/Onan)Service manual — 983-0501D Onan HGJAA HGJAB HGJAC HGJAD HGJAE HGJAF Mobile Genset Service manual (01-2006) (Cummins/Onan)Service manual — 983-0600B Onan HGJAA HGJAB HGJAC Mobile Genset Installation manual (07-2006) (Cummins/Onan)Service manual — A035D005 (Cummins/Onan)Service manual — A035D011 SERVICE i23-HGJAA HGJAB HGJAD HGJAE(Spec J-M)7-22 (Cummins/Onan)Service manual — HGJAA, HGJAB, HGJAC, HGJAD, HGJAE, HGJAF Service Manual (Cummins/Onan)
This page was generated from the 16 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.