HomeCummins/OnanCummins/Onan HGJAE

Cummins/Onan HGJAE Generator Set

The Cummins/Onan HGJAE is a generator set.

5
Document types

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Specifications

Ratings spec sheet not in our library yet — see the documents below.

Maintenance & consumables

ItemSpecCapacityPart #Interval
Air filter500 hr find
Fuel filter100 hr find
Oil filter50 hr find
Belt30000 hr find
Coolant3.7 L500 hr
OilEngine Oil Recommendations4.6 L50 hr

Troubleshooting

68

Fault codes

CodeMeaningCauseRemedy
2Low Oil Pressure Fault
3Service Check Fault
4Overcrank
12Overvoltage
13Undervoltage
14Overfrequency
15Underfrequency
17Fuel Pump Fault
19Governor Actuator (EFI Only)
22Governor Actuator Overload (EFI Only)
23Oil Pressure Switch Fault
27Voltage Sense Lost
29High Battery Voltage
31Overspeed Fault
32Low Cranking Speed Sense
33Fault Code 3 - Fault Code 33
35Control Card Failure
36Generator Set Stopped Without Fault Condition - Fault Code 36
37Invalid Set Configuration
38Field Overload (Overvoltage)
41Alternator Rotor Fault
42Processor Fault - Fault Code 42
43Processor Fault - Fault Code 43
45Speed Sense Fault
47Ignition Fault
48Field Sense Fault
51Processor Failure - Fault Code 51
52Fuel Injector Fault (EFI Only)
54MAT Sensor Fault (EFI Only)
56MAP Sensor Fault (EFI Only)
57Overprime Fault
CODE NO. 12OVERVOLTAGE SHUTDOWN—Controller unable to maintain rated voltageCorrective Action: See an authorized Onan dealer.
CODE NO. 13UNDERVOLTAGE SHUTDOWN—Controller unable to maintain rated voltageCorrective Action: Reduce the number of connected appliances, especially when air conditioners and battery chargers are running.
CODE NO. 14OVERFREQUENCY SHUTDOWN—Engine governor unable to maintain rated frequencyCorrective Action: See an authorized Onan dealer.
CODE NO. 15UNDERFREQUENCY SHUTDOWN—Engine governor unable to maintain rated frequencyCorrective Action: Reduce the number of connected appliances, especially when air conditioners and battery chargers are running.
CODE NO. 19GOVERNOR ACTUATOR SHUTDOWN—Controller sensed open or shorted circuitCorrective Action: See an authorized Onan dealer.
CODE NO. 22GOVERNOR ACTUATOR OVERLOAD SHUTDOWN—Duration of operation at or near full-duty cycle beyond design limitCorrective Action: Reduce the number of connected appliances, especially when air conditioners and battery chargers are running. Service the air cleaner (Page Section 4.5). Check for and repair a blocked exhaust system.
CODE NO. 23LOW OIL PRESSURE CUTOFF SWITCH SHUTDOWN—Controller sensed switch still open during start—not a running faultCorrective Action: See an authorized Onan dealer.
CODE NO. 27VOLTAGE SENSE SHUTDOWN—Controller unable to sense output voltageCorrective Action: See an authorized Onan dealer.
CODE NO. 29HIGH BATTERY VOLTAGE SHUTDOWN—Voltage across battery system greater than 19 voltsCorrective Action: 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). Select a lower battery boost charge rate.
CODE NO. 31OVERSPEED SHUTDOWN—Engine speed greater than 3400 rpmCorrective Action: See an authorized Onan dealer.
CODE NO. 32LOW CRANKING SPEED SHUTDOWN—Cranking speed less than 180 rpm for more than 2 secondsCorrective Action: Clean and tighten the positive (+) and negative (-) battery cable connections at the battery and at the genset. Recharge or replace the battery. Refer to the battery manufacturer's recommendations. Replace engine oil with oil of proper viscosity for ambient temperatures (Page Section 2.5). (High oil viscosity can slow down cranking speed.)
CODE NO. 35CONTROL CARD FAILURE SHUTDOWN—Microprocessor EEPROM error during self-testCorrective Action: See an authorized Onan dealer.
CODE NO. 36ENGINE STOPPED SHUTDOWN—Engine stopped without command by controller
CODE NO. 37INVALID GENSET CONFIGURATION SHUTDOWN—Wrong frequency/rpm ratioCorrective Action: See an authorized Onan dealer.
CODE NO. 38OVERCURRENT (FIELD OVERLOAD) SHUTDOWN—Low power factor loadsCorrective Action: Reduce the number of appliances running at the same time, especially those with high motor starting loads such as air conditioners. Have air conditioners and other appliances checked for proper operation. (A locked compressor rotor can cause very low power factor.)
CODE NO. 41GENERATOR ROTOR SHUTDOWN—Controller unable to sense field or output voltageCorrective Action: See an authorized Onan dealer.
CODE NO. 42PROCESSOR SHUTDOWN—Microprocessor ROM error during self-testCorrective Action: See an authorized Onan dealer.
CODE NO. 43PROCESSOR SHUTDOWN—Microprocessor RAM error during self-testCorrective Action: See an authorized Onan dealer.
CODE NO. 45SPEED SENSE SHUTDOWN—Controller unable to sense quadrature frequencyCorrective Action: See an authorized Onan dealer.
CODE NO. 47IGNITION SHUTDOWN—Controller unable to sense ignitionCorrective Action: See an authorized Onan dealer.
CODE NO. 48GENERATOR FIELD SENSE SHUTDOWN—Controller unable to sense field voltageCorrective Action: See an authorized Onan dealer.
CODE NO. 51PROCESSOR SHUTDOWN—Microprocessor malfunctionCorrective Action: See an authorized Onan dealer.
CODE NO. 52FUEL INJECTOR SHUTDOWN(Open or short circuit in fuel injector)See an authorized Onan dealer.
CODE NO. 54MAT SENDER SHUTDOWN(Open or short circuit in MAT sender)See an authorized Onan dealer.
CODE NO. 56MAP SENDER SHUTDOWN(Open or short circuit in MAP sender)See an authorized Onan dealer.
CODE NO. 57OVERPRIME SHUTDOWN(Prime mode exceeded 3 minutes)Check for and remove any object that may be holding either control switch (remote or local) in the prime position.
CODE NO. 58Exhaust Gas Temp Shutdown/Fault(Exhaust gas temperatures reach 650C (1202F) for 2 secs when the set is running)See an authorized Onan dealer
36Generator Set Stopped Without Fault Condition
42Processor Fault
51Processor Failure
58Exhaust Gas Temperature Shutdown
81Exhaust Gas Temperature Sensor Open
82Exhaust Gas Temperature Sensor Shorted

Symptoms & remedies

SymptomRemedy
STATUS INDICATOR LIGHT DEAD (Genset locked out, faulty connections, no battery voltage)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.
STARTING BATTERIES RUN DOWN (Marginal batteries, connections, or charging system or, parasitic loads)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)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)1. Turn on or reset the line circuit breaker on the genset (Page Section 3.10). 2. Turn on or reset the line circuit breakers on the main distribution panel in the vehicle.

Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing.

Parts

8
Part #DescriptionQtySystem
0541-1287Harness Kit for InPower Diagnostic Service Tool1Hose PartsGeek
0541-1374InPower Harness Kit (Spec J and later)1Hose PartsGeek
0541-1389Harness Kit for InPower Diagnostic Service Tool1Hose PartsGeek
121-0122-02Hydraulic PumpPump PartsGeek
A065U664Temperature Sensor (with Mounting Screws)1Temperature sensor PartsGeek
0420-0603Bypass Control Board Tester1Service part / kit PartsGeek
0541-1143Bypass Control Board Tester Adapter Kit1Service part / kit PartsGeek
500-3449OUTLINE DRAWING—HGJAD / HGJAEService part / kit PartsGeek

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

RatingLoadL/hgal/h
Full load4.31.13
Half load2.70.7
No load1.60.43
Prime
Standby

Available documents

Installation manual — 983-0601 Onan HGJAD (spec A-E) HGJAE (spec A-E) HGJAF (spec A-D) Mobile Genset Installation Manual (11-2014) (Cummins/Onan)Operator's manual — 6758 Owners Manual (Cummins/Onan)Reference — 900-0617D Onan HGJAx Repair Times (Cummins/Onan)Parts manual — HGJAD, HGJAE, HGJAF Parts Manual (Cummins/Onan)Service manual — 983-0102 Onan HGJA Series (spec A-E) Mobile Genset Operators manual (07-2011) (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 — 983-0601B Onan HGJAD HGJAE HGJAF Mobile Genset Installation Manual (07-2005) (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)