Specifications
| Fuel | gasoline/LPG |
|---|---|
| Frequency | 60.0 Hz |
| Controller | A1 |
| Oil capacity | 1.8 L |
| Voltage options | 120/240 V |
| Phase | 1 |
| Rated current | 45.8 A |
| Power factor | 1.0 |
| Battery cranking | 450 CCA |
| Battery voltage | 12 V |
| Dry weight | 104 kg |
| Sound level | 75.0 dBA @ 3 m |
Filters & service parts
model family| Item | Spec | Capacity | Part # | Interval | |
|---|---|---|---|---|---|
| Air filter | — | 1000 hr | |||
| Fuel filter | — | 500 hr | |||
| Oil filter | — | 500 hr | |||
| Battery | 12 V; Min. Battery CCA 450 @ 0°F (–18°C); genset provides up to 10 amps regulated charging | — | 1000 hr | ||
| Belt | — | 8 hr | |||
| Coolant | 3.5 L | — | 1000 hr | ||
| Oil | API Class SJ, SH or SG (may be combined with CH-4, CG-4 or CF-4) | — | 500 hr | ||
| Spark plug | Torque 18–25 lbs-ft (23–32 N-m); gap 0.025 in (6-7 mm); two spark plugs per genset | — | 5000 hr |
Compiled from this model's family documentation — may include parts for closely-related variants. Confirm the exact part for your serial number.
Service intervals
18| Item | Action | Hours | Months | Notes |
|---|---|---|---|---|
| Genset | Other | 1 hr | 1 mo | Exercise at least 1 hour each month at approximately 1/2 rated power if use is infrequent |
| Engine oil level | Check | 8 hr | First service — Section 4.2 | |
| Exhaust system | Inspect | 8 hr | Inspect for exhaust leaks at every startup and after every eight hours of running | |
| General inspections | Inspect | 8 hr | Every day or every 8 hours | |
| Genset | Inspect | 8 hr | Every day or every 8 hours; general inspections | |
| Genset general inspection | Inspect | 8 hr | Before first start of the day and after every 8 hours of operation | |
| Engine oil | Change | 50 hr | In dusty environments change engine oil every 50 hours | |
| Spark arrestor | Clean | 50 hr | Table 3-1 Periodic Maintenance Schedule | |
| Air filter element | Replace | 450 hr | Perform more often when operating in dusty environments | |
| Engine cooling fins | Clean | 450 hr | Perform more often when operating in dusty environments | |
| Engine oil & oil filter | Change | 150 hr | First service — Perform more often in dusty environments and hot weather; at least once a year | |
| Engine oil and oil filter | Change | 150 hr | 12 mo | First service — Perform more often in dusty/hot environments; at least yearly |
| Fuel filter | Replace | 500 hr | 36 mo | Sooner if engine performance deteriorates; by trained mechanic |
| Cylinder heads | Clean | 500 hr | Clean or replace; required for optimum performance | |
| 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 | Clean and check battery; perform more often in hot weather (footnote 3) | |
| Battery and battery connections | Clean | 1 mo | Perform more often in hot weather |
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 (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 | Piston-to-cylinder clearance at skirt max | 0.0098 | in | |
| 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 | Spark Plug Gap | 0.025 | in (0.6-0.7 mm) | |
| Injection timing | Ignition Timing | 20 deg BTDC | degrees BTDC | non-adjustable magneto |
| Other | LPG low-pressure supply (vapor) | 9-13 | in WC | |
| Other | Maximum exhaust back pressure | 35 | in WC | |
| Other | Spark plug kit torque specification | 18-25 | lb-ft | |
| Pressure | Crankcase Vacuum | 7 to 10 | inches of water column | measured through a tap in the oil fill cap |
| Pressure | Crankcase vacuum | 7-10 | inches water column | measured through oil fill cap tap |
| Pressure | Cylinder Compression Test | 153-188 | psi | |
| Pressure | Fuel Pump pressure (carburetor models) | 2.5 to 4 | psi (17 to 27 kPa) | |
| Pressure | Fuel Rail Pressure (EFI) | 43.5 psi (300 kPa) nominal | psi | |
| Pressure | Fuel rail pressure differential | 43.5 | psi | nominal |
| Pressure | Hydraulic Pump Inlet Conditions | 5 | in Hg Vacuum or 20 psi Pressure max | |
| Pressure | Hydraulic Pump Inlet Conditions | Not to exceed 5 in Hg Vacuum or 20 psi | in Hg / psi | |
| Pressure | Hydraulic pump | 1.6 | gpm @ 2500 psi | 5.5 model pumps |
| Pressure | Hydraulic pump | 1.8 | gpm @ 2500 psi | HGJAD/HGJAE pumps |
| Pressure | LPG Vapor Supply Pressure | 9-13 | in (228-330 mm) WC | |
| Pressure | LPG supply pressure (low-pressure) | 9-13 | in (228-330 mm) WC | all loads |
| Pressure | Low Oil Pressure Cutoff | less than 17 | psi | |
| Pressure | Low oil pressure fault threshold | 17 | psi | less than 17 psi |
| Pressure | Low oil pressure switch opens | 14.2 | psi | |
| Pressure | Low-pressure LPG lock-off pressure | 0.20 to 0.35 | inches WC (5.1 to 8.9 mm) | |
| Pressure | Max Exhaust Back Pressure (HGJAF models) | 35 | in (889 mm) WC | |
| Pressure | Max exhaust back pressure | 35 | in (889 mm) WC | |
| Pressure | Nominal Engine Oil Pressure | 43 | psi | |
| Pressure | Nominal oil pressure | 43 | psi | |
| Pressure | Oil pressure (nominal) | 43 | psi | |
| Resistance | Fuel injector electrical resistance | approximately 12.5 | ohms | |
| Resistance | Governor actuator stator winding | 4.5 and 5.5 | ohms | |
| Resistance | Ignition Coil LEFT (No. 1 Cyl) maximum | 33,000 | Ohms | |
| Resistance | Ignition Coil LEFT (No. 1 Cyl) minimum | 13,700 | Ohms | |
| Resistance | Ignition Coil RIGHT (No. 2 Cyl) maximum | 27,000 | Ohms | |
| Resistance | Ignition Coil RIGHT (No. 2 Cyl) minimum | 11,500 | Ohms | |
| Resistance | Ignition coil secondary resistance left (No.1) | 13,700 to 33,000 | Ohms | |
| Resistance | Ignition coil secondary resistance right (No.2) | 11,500 to 27,000 | Ohms | |
| Resistance | MAP sensor A-C (GND-5V) | 4.0-4.2 | Kilo-ohms | Room Temperature & Pressure |
| Resistance | MAT sensor resistance | 2600 to 3000 | ohms | |
| Resistance | Min. Battery CCA | 450 | CCA | @ 0 deg F (-18 deg C) |
| Resistance | Rotor resistance (80 mm stack, 5.5 kW) | 29.34 | Ohms | 77 F (25 C) |
| Resistance | Rotor resistance at 77 F (25 C) +/- 10% (95 mm stack) | 31.97 | Ohms | 77 F (25 C) |
| Resistance | Rotor winding (HGJAA, HGJAB, HGJAC) | 31.97 | ohms @ 77 F (25 C) +/-10% | |
| Resistance | Rotor winding (HGJAD, HGJAE, HGJAF) | 31.97 | ohms @ 77 F (25 C) +/-10% | |
| Resistance | Rotor winding 5.5 kW (80 mm Stack) | 29.34 | ohms @ 77 F (25 C) +/-10% | |
| Resistance | Rotor winding resistance HGJAA/B/C (5.5 kW, 80 mm stack) | 29.34 | ohms @ 77° F (25° C) ± 10% | |
| Resistance | Rotor winding resistance HGJAA/B/C (6.5-7.0 kW, 95 mm stack) | 31.97 | ohms @ 77° F (25° C) ± 10% | |
| Resistance | Rotor winding resistance HGJAD/E/F | 31.97 | ohms @ 77° F (25° C) ± 10% | |
| Resistance | Starter solenoid / battery charge regulator B1-B2 output | 15 to 20 | VAC | |
| Resistance | Stator B1-B2 (120 V 1-ph) | 0.124 | Ohms | 77 F (25 C) |
| Resistance | Stator B1-B2 (120 V, 1-Ph) | 0.124 | ohms @ 77 F (25 C) +/-10% | |
| Resistance | Stator L1-L2, L1-L3, L2-L3 (3-Ph Delta) | 1.05 | ohms @ 77 F (25 C) +/-10% | |
| Resistance | Stator Q1-Q2 (120 V 1-ph) | 2.42 | Ohms | 77 F (25 C) |
| Resistance | Stator Q1-Q2 (120 V, 1-Ph) | 2.42 | ohms @ 77 F (25 C) +/-10% |
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 |
|---|---|---|---|---|---|
| Engine oil | API Class SJ, SH or SG | 2.0 quart (1.8 l) | Oil capacity | ||
| Engine oil | 5W-30 | API SJ, SH or SG (may combine with CH-4, CG-4 or CF-4) | -28°C to 10°C | –20° F to 50° F (–28° C to 10° C) | |
| Engine oil | SAE 5W-30 | API Class SJ, SH or SG (may be combined with CH-4, CG-4 or CF-4) | -28°C to 10°C | –20°F to 50°F | |
| Engine oil | 10W-30 | API SJ, SH or SG (may combine with CH-4, CG-4 or CF-4) | -18°C to 27°C | 0° F to 80° F (–18° C to 27° C) | |
| Engine oil | 10W-30 10W-40 | API SJ, SH or SG (with CH-4, CG-4 or CF-4) | -18°C to 27°C | 1.8 l | 0 deg F to 80 deg F (-18 deg C to 27 deg C) |
| 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-40 | API SJ, SH or SG (may combine with CH-4, CG-4 or CF-4) | -18°C to 27°C | 0° F to 80° F (–18° C to 27° C) | |
| Engine oil | SAE 10W-30 / 10W-40 | API Class SJ, SH or SG (may be combined with CH-4, CG-4 or CF-4) | -18°C to 27°C | 0°F to 80°F | |
| Engine oil | 15W-40 (OnaMax) | API SJ, SH or SG (may combine with CH-4, CG-4 or CF-4) | -12°C to 38°C | 10° F to 100° F (–12° C to 38° C) | |
| Engine oil | SAE 15W-40 (OnaMax) | API Class SJ, SH or SG (may be combined with CH-4, CG-4 or CF-4) | -12°C to 38°C | 10°F to 100°F | |
| Engine oil | SAE 30 | API SJ, SH or SG (may combine with CH-4, CG-4 or CF-4) | above 0°C | 32° F (0° C) and higher; single-grade SAE 30 preferable when temperatures consistently above freezing | |
| 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) | |||
| Fuel | HD-5 grade LPG or equivalent, at least 90 percent propane | LPG models; commercial LPG may contain more than 2.5% butane | |||
| Fuel | HD-5 grade liquefied petroleum gas (LPG) | at least 90 percent propane | LPG models. Commercial LPG may contain more than 2.5 percent butane causing poor vaporization below 32 F (0 C). | ||
| Fuel | HD-5 grade liquified petroleum gas (LPG), at least 90 percent propane | Commercial LPG may contain more than 2.5 percent butane | LPG models; low-pressure LPG vapor pressure per Specifications | ||
| Fuel | Unleaded gasoline | minimum octane rating (Anti-Knock Index) of 87 | Gasoline models. Do not use gasoline containing methanol. | ||
| Fuel | Unleaded gasoline, min octane 87 (Anti-Knock Index) | Max 10% ethanol; max 5% methanol with solvents/corrosion inhibitors | Gasoline models | ||
| Fuel | Unleaded gasoline, min. octane rating (Anti-Knock Index) 87 | Ethanol blend not more than 10% ethanol; methanol blend not more than 5% methanol with solvents and corrosion inhibitors | Gasoline models | ||
| Fuel | Unleaded gasoline, minimum octane rating (Anti-Knock Index) 87 | Do not use gasoline/additives containing methanol; avoid leaded gasoline | |||
| Hydraulic oil | Transmission or Petroleum-Based Hydraulic Fluid | Operating Viscosity: 80-1000 SSU; Maximum Start-Up Viscosity: 4000 SSU | |||
| Hydraulic oil | Transmission or petroleum-based hydraulic fluid | Operating viscosity 80-1000 SSU; maximum start-up viscosity 4000 SSU | Optional hydraulic pump models HGJAD/HGJAE/HGJAF |
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 | Status indicator light blinks 1 time - shutdown due to high engine coolant temperatures | Shutdown | Allow engine to cool; inspect cooling system |
| 12 | Overvoltage Shutdown | Instantaneous: AC voltage S1-S2 greater than 150 VAC. Delayed: greater than 138 VAC but less than 150 VAC for 3 continuous minutes | Shutdown | See an authorized Onan dealer. |
| 13 | Undervoltage Shutdown | Controller unable to maintain rated voltage | Shutdown | Reduce the number of connected appliances, especially when air conditioners and battery chargers are running. |
| 14 | Overfrequency Shutdown | Instantaneous: frequency greater than 70 Hz. Delayed: greater than 66 Hz but less than 70 Hz for 3 continuous seconds | Shutdown | See an authorized Onan dealer. |
| 15 | Underfrequency Shutdown | Engine governor unable to maintain rated frequency | Shutdown | Reduce the number of connected appliances, especially when air conditioners and battery chargers are running. |
| 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 Shutdown | 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 Shutdown | First-level shutdown code—Low oil pressure cutoff switch did not open (2 blinks) | Shutdown | Measure oil level; measure oil pressure with mechanical gauge; repair or replace relief valve and oil pump |
| 22 | Governor Actuator Overload Shutdown | Only active prior to 2001 - maximum governor output (PWM) for 10 continuous seconds | Shutdown | Reduce the number of connected appliances; service the air cleaner; check for and repair a blocked exhaust system. |
| 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 Shutdown | No sense voltage (0 VAC across S1-S2) for 1 continuous second after start disconnect | Shutdown | See an authorized Onan dealer. |
| 29 | High Battery Voltage Shutdown | Voltage across battery system greater than 19 volts | Shutdown | Measure DC voltage; reduce boost charge rate; verify grounds |
| 3 | Service Check Shutdown | Single-digit fault indicating shutdown due to a two-digit fault | Shutdown | While LED flashes three times press Stop once (1 second) to read the two-digit fault code |
| 31 | Overspeed Shutdown | Engine speed greater than 3400 rpm | Shutdown | See an authorized Onan dealer. |
| 32 | Low Cranking Speed Shutdown | Quadrature frequency <=3 Hz and engine RPM <=100 for 12 continuous seconds | Shutdown | Measure battery voltage; verify engine rotation; measure DC voltage at starter; check air filter and exhaust |
| 33 | Fault Code 33 | Single-digit fault indicating shutdown due to two-digit fault code | Shutdown | While LED flashes three times press stop once (1 second) to troubleshoot the two-digit fault code |
| 35 | Control Card Failure Shutdown | Microprocessor EEPROM error during self-test | Shutdown | See an authorized Onan dealer. |
| 36 | Stopped Without Fault Condition | RPM less than 500 and sense voltage S1-S2 at 0 VAC with no other fault | Shutdown | Verify AGS; verify engine rotation; check air filter, exhaust, loads and frequency response |
| 37 | Invalid Set Configuration | Wrong frequency/rpm ratio | Shutdown | See an authorized Onan dealer. |
| 38 | Overcurrent (Field Overload) Shutdown | Low power factor loads | Shutdown | Reduce the number of appliances running at the same time; have air conditioners and other appliances checked for proper operation. |
| 4 | Overcrank Shutdown | First-level shutdown code—Cranking exceeded 30 seconds without engine starting (4 blinks) | Shutdown | Gasoline: check and fill fuel tank; prime fuel system 30 seconds at Stop/Prime; LPG: check and fill container; open closed fuel valves; secure spark plug leads; replace spark plugs; service air cleaner |
| 41 | Generator Rotor Shutdown | Only active after 2003 - field voltage F1-F2 at 0 VDC and sense voltage S1-S2 at 0 VAC for 1 continuous second | Shutdown | See an authorized Onan dealer. |
| 42 | Processor Shutdown | ROM error during self-test | Shutdown | See an authorized Onan dealer. |
| 43 | Processor Shutdown | RAM error during self-test | Shutdown | See an authorized Onan dealer. |
| 45 | Speed Sense Shutdown | While running, quadrature frequency dropped to 0 Hz for 1 continuous second | Shutdown | Verify AGS; verify engine rotation; check air filter and exhaust; measure frequency and droop |
| 47 | Ignition Shutdown | No ignition signal at P1 (P1-15 for HGJAB/C; P1-5 for HGJAA/D/E/F) for 1 continuous second | Shutdown | See an authorized Onan dealer. |
| 48 | Generator Field Sense Shutdown | Controller unable to sense field voltage; faulty control | Shutdown | See an authorized Onan dealer. |
| 51 | Processor Shutdown | Processor error; faulty control | Shutdown | Use breakout board per Instruction Sheet R1098; replace control |
| 52 | Fuel Injector Shutdown | Open or shorted fuel injector; P1-17; wire connections | Shutdown | See an authorized Onan dealer. |
| 54 | MAT Sensor Fault (EFI) | Open or short circuit in MAT sender | Shutdown | See an authorized Onan dealer. |
| 56 | MAP Sensor Fault (EFI) | Open or short circuit in MAP sender | Shutdown | Verify ambient pressure; test sender; replace sender |
| 57 | Overprime Shutdown | Prime mode exceeded 3 minutes | Shutdown | Check for object holding switch in stop; test switch continuity |
| 58 | Exhaust Gas Temp Shutdown/Fault | Exhaust gas temperatures reach 650C (1202F) for 2 secs when the set is running | Shutdown | See an authorized Onan dealer |
| 81 | Overprime Shutdown | While running, EGT temp falls below 60C (140F) for 2 minutes - OR - if EGT temperature is not above 60C (140F) after 2 minutes from starting, set will shut down | Shutdown | See an authorized Onan dealer |
| 82 | Exhaust Gas Temp Shutdown/Fault | With the set running and/or startup - control reads 1000C (1832F) for 1 second | Shutdown | See an authorized Onan dealer |
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 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
⚠ If fault shutdown or STOP pressed during voltage set mode, adjustment is not stored
Tools: AC voltmeter, Frequency meter
- Disconnect all alternator loads.
- Connect accurate AC voltmeter and frequency meter.
- Start genset and let voltage/frequency stabilize 5-10 seconds.
- Rapidly press control switch to START 6 times within 1 minute.
- Press START briefly to raise voltage ~0.6 V per press.
- Press START for ~2 seconds to lower voltage ~0.6 V per press.
- Normal operation resumes 20 seconds after last adjustment.
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.
Voltage Adjustment (HGJAD, HGJAE, HGJAF) adjustment
⚠ Hazardous voltage: touching uninsulated live parts can cause severe injury or death
Tools: AC voltmeter, frequency meter
- Disconnect all generator loads and connect accurate AC volt and frequency meters.
- Start genset; let voltage and frequency stabilize 5 to 10 seconds.
- Rapidly press control switch to START 6 times within 1 minute of start.
- Adjust up: press START and release quickly (voltage rises about 0.6 volt).
- Adjust down: press START and release after about 2 seconds (voltage drops about 0.6 volt).
Fuel Pump Flow Test (EFI Gasoline Models) diagnostic
⚠ Gasoline is flammable; do not smoke; keep ignition sources away
Tools: Fuel pressure gauge, Gallon container
- Disconnect fuel return line between genset and tank.
- Collect fuel in a gallon container.
- Prime the genset for exactly one minute.
- Verify flow is approximately 1 quart (0.9 liter) per minute.
- Verify fuel pressure is approximately 45 psi.
- Reconnect the fuel return line.
Fuel Pump Flow Test (EFI) diagnostic
⚠ Gasoline is flammable and explosive
Tools: gallon container, fuel pressure gauge
- Disconnect the fuel return line between genset and supply tank.
- Be prepared to collect fuel in a gallon container.
- Prime the genset for exactly one minute.
- Verify flow is approximately 1 quart (0.9 liter) per minute and pressure about 45 psi.
- Reconnect the fuel return line.
Lock-Off Pressure Test (Low-Pressure LPG Demand Regulator) diagnostic
⚠ Bench test: keep diaphragm in vertical plane to avoid erroneous readings
Tools: Inclined manometer 0-2 in WC, Regulated air source, Soap bubble
- Connect regulator inlet to air pressure regulated to 11 in WC (28 cm).
- Disconnect hose from carburetor at regulator outlet.
- Tee two hoses to the regulator vent hose (3/8 in I.D.).
- Connect one hose to inclined manometer reading 0 to 2 in WC.
- Attach soap bubble to hose barb at regulator outlet.
- Blow lightly into pressurizing hose and read lock-off pressure.
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 |
|---|---|---|---|---|
| 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 kind of fuel does the Cummins/Onan HGJAF run on?
The Cummins/Onan HGJAF runs on gasoline/LPG.
How much oil does the Cummins/Onan HGJAF take?
The Cummins/Onan HGJAF has an engine oil capacity of 1.8 liters (1.9 US quarts), per the manufacturer specification sheet.
How loud is the Cummins/Onan HGJAF?
The Cummins/Onan HGJAF is rated at 75.0 dBA at 3 m, per the manufacturer specification sheet.
What is the dry weight of the Cummins/Onan HGJAF?
The Cummins/Onan HGJAF has a dry weight of 104 kg (229 lb).
What voltage does the Cummins/Onan HGJAF produce?
The Cummins/Onan HGJAF is offered in 120/240 V, 1-phase.
How many cold cranking amps does the Cummins/Onan HGJAF require?
The Cummins/Onan HGJAF uses 12 V each, 450 CCA, per the manufacturer specification sheet.
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 HGJAF troubleshooting guide (31 entries) →
Repair guides
8- Adjusting Governor (Mechanical)
- Cleaning the Spark Arrestor (Series HGJAD)
- Cylinder Head Reassembly and Torque Sequence
- Fuel Pump Flow Test (EFI Gasoline Models)
- Lock-Off Pressure Test (Low-Pressure LPG Demand Regulator)
- Replacing Spark Plugs
- Spark Check
- Testing Low-Pressure LPG Shutoff E4
Step-by-step procedures compiled from the Cummins/Onan service manual for this model.
Parts
22model family| Part # | Description | Qty | System | |
|---|---|---|---|---|
| 0541-1287 | Harness Kit for InPower Diagnostic Service Tool | 1 | Hose | Amazon eBay |
| 0541-1374 | InPower Harness Kit (Spec J and later) | 1 | Hose | Amazon eBay |
| 0541-1389 | Harness Kit for InPower Diagnostic Service Tool | 1 | Hose | Amazon eBay |
| 121-0122-02 | Hydraulic Pump – MCD Part; pump mounted on top of HGJA* gensets with PTO option. 1.6 GPM @ 2000 psi on 5.5 KW / 1.8 GPM @ 2000 psi on 7 Kw. Order 2 ea 815-0954-03 bolts to hold pump to engine. | Pump | Amazon eBay | |
| 149-2573 | Racor Fuel Filter/Water Separator Kit (includes fuel/water separator and all necessary hardware, Instruction Sheet #G-297) | Fuel filter | eBay | |
| 17208238 | 3.1L, 196.5g working capacity | 1 | Carbon canister | Amazon eBay |
| 193-0244-99 | Oil Pressure Sender (Part Only) | Sensor | Amazon eBay $86.15 | |
| 193-0318 | Sender, Water Temperature | 1 | Sensor | Amazon eBay $73.95 |
| 541-0530 | Auxiliary Fuel Pump Kit | Pump | Amazon eBay | |
| 541-0531 | Remote Air Cleaner Kit | Air filter | Amazon eBay | |
| 541-0564 | Fuel Pump Kit (pump with straight in and out 1/8-27 NPSF fittings, wire connectors; Instruction Sheet #G-435) | Pump | eBay | |
| 541-0608-01 | Remote Oil Filter Kit (includes filter adapter, hoses, remote filter mount with bracket and hardware; Instruction Sheet #G-485) | Oil filter | Amazon eBay | |
| 541-1002 | EFI Fuel Pump Kit for truck chassis (EFI fuel pump w/rubber isolators and universal mounting bracket, 6 feet of 1/4-inch ID suction hose, 15-foot wiring harness, clamps and hardware; Instruction Sheet G-591) | Pump | Amazon eBay | |
| 983-0102 | 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. | Battery | Amazon eBay | |
| 0148-1343 | vent filter | 1 | Service part / kit | Amazon eBay |
| 0420-0603 | Bypass Control Board Tester | 1 | Service part / kit | Amazon eBay $599.99 |
| 0541-1143 | Bypass Control Board Tester Adapter Kit | 1 | Service part / kit | Amazon eBay |
| 130-2781 | Coolant Overflow Recovery Kit – One quart capacity. Fits with standard vented cap. Allows recovery of coolant in high ambient operation. (Instruction Sheet #A-304.) | Service part / kit | eBay | |
| 17208252 | 3.3L, 233.8g working capacity | 1 | Service part / kit | buy |
| 333-0593 | Engine Block Heater Kit – 400W, 120VAC (Instruction Sheet #G-288). Will NOT work on the CMQD genset. | Service part / kit | eBay | |
| 416-0796 | Battery – 12V; SAE 31, 660 cold cranking amps at 0° F, 62 pounds, wet | Service part / kit | eBay | |
| 416-0823 | Battery – 12V; SAE 30H, 620 cold cranking amps at 0° F, 42 pounds, dry | Service part / kit | Amazon |
Compiled from this model's family documentation — may include parts for closely-related variants. 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 |
|---|---|---|---|
| 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 — 983-0102 Onan HGJA Series (spec A-E) Mobile Genset Operators manual (07-2011) (Cummins/Onan)Reference (Cummins/Onan)Reference — 983-0601 Onan HGJAD (spec A-E) HGJAE (spec A-E) HGJAF (spec A-D) Mobile Genset Installation Manual (11-2014) (Cummins/Onan)Owner's manual — 983-0601B Onan HGJAD HGJAE HGJAF Mobile Genset Installation Manual (07-2005) (Cummins/Onan)Parts manual — Cummins Onan Commercial Mobile Accessories 1 (Cummins/Onan)Parts manual — HGJAD, HGJAE, HGJAF Parts Manual (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 — HGJAA, HGJAB, HGJAC, HGJAD, HGJAE, HGJAF Service Manual (Cummins/Onan)
This page was generated from the 10 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.