CUMMINS ONAN HGJA Series Generator SET Workshop Manual

Printed in U.S.A. 2−2005 900−0617D HGJAA, HGJAB, HGJAC HGJAD, HGJAE, HGJAF Redistribution or publication of this document by any means, is strictly prohibited.

Redistribution or publication of this document by any means, is strictly prohibited.

i Table of Contents Contents Page Foreword v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information vi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Types of Standard Repair Times vi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRT Coding System viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Organization ix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cummins/Onan SRT Objectives and Philosophy ix . . . . . . . . . . . . . . . . . . . . . . . . How Standard Repair Times are Developed x . . . . . . . . . . . . . . . . . . . . . . . . . . . . How To Use This Manual xiv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group 00 − Complete Engine 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Administrative Time 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshoot (Genset) 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshoot (Fault Codes) 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine − Remove and Install 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft − Remove and Install 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Block − Rebuild 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set, Mobile − Remove and Install 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . Group 01 − Cylinder Block 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Rings 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod Bearings 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear, Crankshaft 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Assembly 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Seal, Bottom 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Seal, Top 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group 02 − Cylinder Head 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Gasket 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Guides 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group 03 − Rocker Levers 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Breather Valve 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redistribution or publication of this document by any means, is strictly prohibited.

ii Contents Page Group 04 − Cam Follower 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Tappets 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group 05 − Fuel System 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor/Throttle Body 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor Controller 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump, Electric 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group 06 − Injectors 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injectors 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector Fuel Rail 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group 07 − Lubricating Oil System 39 . . . . . . . . . . . . . . . . . . . . . . . . . Oil Base 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump Assembly 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Muffler 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Filter 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating Oil & Filter 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group 08 − Cooling System 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Fan 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group 10 − Intake Air System 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake Manifold 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner Element 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group 11 − Exhaust System 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold Gaskets 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group 13 − Electrical Equipment 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Motor 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plug 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Coil and Spark Plug Wires 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group 14 − Engine or Generator Set Testing 51 . . . . . . . . . . . . . . . . Test Run Generator 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redistribution or publication of this document by any means, is strictly prohibited.

iii Contents Page Group 15 − Electronics 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAP (Manifold Absolute Pressure) Sensor 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAT (Manifold Absolute Temperature) Sensor 54 . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Block Temp Sensor 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group 16 − Mounting Adaptations 55 . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel Isolator 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt Drive Flywheel Pulley 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt Drive Pulley Bearing 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine and Generator Mounting Base 58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group 17 − Miscellaneous 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vibration Isolators 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pump 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group 25 − Generator 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Rotor 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Stator 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slip Rings 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Bearing 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Group 26 − Generator Control 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DC Wiring Harness 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Control Box Assembly 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Wiring Harness 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCB Control Board 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start Solenoid 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Circuit Breaker 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRT Request Form Redistribution or publication of this document by any means, is strictly prohibited.

iv Redistribution or publication of this document by any means, is strictly prohibited.

− v − Foreword The Standard Repair Times (SRT) in this manual represent the time required to perform service repairs on Onan Engine and Generator Sets. These times are representative of an average mechanic in a typical dealer or distributorship using the prescribed hand tools, equipment, and all avail- able service tools and equipment required to perform quality repairs and do all necessary testing. The use of this manual will: • Encourage uniform terminology throughout the Cummins/Onan organization • Standardize Repair Order job description write−ups • Provide shop managers with a guide for establishing flat rate quotations • Serve as a basis for Onan Corporation, Inc. to establish its warranty labor obligations Reporting of errors, omissions, and recommendations for improving this publication is encouraged. Send your suggestions or comments to: Onan Corporation 1400 73rd Avenue NE Minneapolis, MN 55432 Attn: Service Department Redistribution or publication of this document by any means, is strictly prohibited.

− vi − GENERAL INFORMATION Standard Repair Times (SRT) are lists of work tasks (procedures) and the time required to perform those tasks. The procedures list the work tasks required to be sure an engine or generator set is ready to return to service at the lowest possible cost to the customer. A Standard Repair Time is equitable when the repair described in the procedure can be performed in a period of time less than or equal to the standard by a journeyman mechanic after he/she has performed that repair on the same model, in the same application at least once. Those SRT that a particular mechanic performs more frequently will often require less time than the standard. Conversely, those SRT that a particular mechanic does not frequently perform may require more time than the standard. Several of the procedures may be required to accurately depict all the work actually performed to return a particular engine or generator set to service because the repair of a particular engine or generator set is often unique in light of the complaint, failure model, progressive damage, condition of the parts and customer desires. To allow for differences in the time required to perform a repair because of inter- ference by the application, a Service Accessibility Code Scheme has been created. Types of Standard Repair Times There are three types of SRT. Most often at least one of each type is necessary to accurately depict the repair. The three types are: • Administrative • Troubleshooting • Repair Administrative SRT Administrative SRT are intended to provide time to move the vehicle engine or generator set to and from the work area, fill out the repair order, record SRT used, etc. It is intended that an administrative SRT be used only once for each repair order. There are two administrative SRT found in this manual in Group 00 − Complete Engine. One of the administrative SRT is to be used when the repair takes place in a shop operated by the repairing location. The other administrative SRT is to be used when the repair takes place away from the shop operated by the repairing location (road repairs). The time for the road repair administrative SRT is greater to allow for loading and unloading tools, equipment, parts, etc. from the service truck. Troubleshooting SRT Troubleshooting SRT are found only in Group 00 − Complete Engine. These SRT are intended to be used when diagnosing and analyzing engine, generator set or component failures. Trouble- shooting SRT are broken down in to logical numbered steps. The time for each step is cumulative with successive steps, including the time for the appropriate preceding step(s). Some troubleshooting SRT contain time to remove and install components to perform the check(s) listed. Most do not. If a troubleshooting SRT does NOT include required component removal and installation, it is intended that the SRT for the removal and installation of that component be in addition to the troubleshooting SRT. Refer to the following example: Redistribution or publication of this document by any means, is strictly prohibited.

− vii − Procedure Procedure SRT Number Description Hours 00−055 Troubleshoot − Lubricating Oil Consumption Excessive Includes: −01 − Check: 0.4 − Oil consumption report − For external oil leaks − For overfilled oil pan − Oil specifications − For fuel contamination − Oil change interval − For engine oil in torque converter −02 − Perform checks in Step 01 1.0 − Check: − Oil temperature − Air compressor oil consumption − Turbocharger seal − Crankcase blowby In the above example, the time required to perform the checks in Step 01 is 0.4 hour. If the problem is not located while performing the checks in Step 01, an additional 0.6 hour is allowed to perform the checks in Step 02 for a total of 1.0 hour. The total troubleshooting time appropriate is the time indicated in the column directly in line with the final step required to locate the problem. The step required to locate the problem may or may not be the last step shown in the troubleshooting SRT. Each step contains information as to which steps are included. Repair SRT Repair SRT make up the majority of this manual. These are the SRT that cover the actual repair work. The time shown on the same line as the SRT code and title is the total time for that SRT. Standard Repair Combined Times Standard Repair Combined Times (SRCT) provide for the combining of the three types of SRT un- der one code so that, if appropriate, the user can identify the work performed with fewer SRT codes. Redistribution or publication of this document by any means, is strictly prohibited.

− viii − SRT CODING SYSTEM Each SRT has a unique code so that SRT data can be computerized. The numbering system used is common to all the SRT manuals for all Onan engines and generator sets. The portion of the system shown in the manual contains three segments: • Group Number • Procedure Number • Step Number Group Numbers Group numbers (the first two digits in the SRT code) are used to identify major engine components. The sample list below explains the group numbers used in SRT charts. Procedure Numbers The procedure number consists of three digits. The first digit provides guidance as to the category of the repair. The second and third digits, shown as XX in the following list, are sequential numbers or alpha letters within the category. Group Number Contents of Group Specific Re- pair Number Description of Category 00 Complete Engine or Genset 01 Cylinder Block 0XX Troubleshooting 02 Cylinder Head ONLY in Group 00 03 Rocker Levers 1XX Remove and Install 04 Cam Followers/Tappets 2XX Rebuild 05 Fuel System 3XX Replace 06 Injectors and Fuel Lines 4XX Clean and Visually Check or Inspect for Reuse 07 Lubricating Oil System 08 Cooling System 5XX Machine/Ream/Dowel 09 Drive Units Sleeve 10 Intake Air System Modify/Cut/Lap 11 Exhaust System 6XX Adjust/Calibrate 12 Air (Compressed) System 13 Electrical Equipment 7XX Test 14 Engine or Generator Set Testing 15 Instruments and Controls 16 Mounting Adaptations Redistribution or publication of this document by any means, is strictly prohibited.

CUMMINS ONAN HGJA Series Generator SET Workshop Manual

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