Parts Manual: Onan Generator Set For RV

Parts Manual
Onan Generator Set for RV
HDKAH (Spec L P)
HDKAJ (Spec L M)
HDKAK (Spec L P)
English
Original Instructions 4-2019 A029S789 (Issue 18)
Introduction
This parts catalog applies to the standard generator sets listed below. Parts are arranged in groups of related
items and each illustrated part is defined by a reference number corresponding to the same reference number
in the parts list. Parts illustrations are typical. Using the model and specification number from your generator
set nameplate, select parts that apply to your set. Right and left sides are detemined by facing the engine end
(front) of the set.
Generator Set Data Table
Model Wiring
Identification Fuel Diagram Voltage Hertz Phase
6.0HDKAH 1044L Diesel 611 1236 120 60 1
6.0HDKAH 1044M Diesel 611 1236 120 60 1
7.5HDKAJ 1044L Diesel 611 1236 120 60 1
7.5HDKAJ 1045L Diesel 611 1236 120 60 1
7.5HDKAJ 11296L Diesel 611 1236 120 60 1
7.5HDKAJ 11451L Diesel 611 1236 120 60 1
7.5HDKAJ 11454L Diesel 611 1236 120 60 1
7.5HDKAJ 11502L Diesel 611 1236 120 60 1
8.0HDKAK 1046L Diesel 611 1236 120 60 1
8.0HDKAK 11296L Diesel 611 1236 120 60 1
8.0HDKAK 11451L Diesel 611 1236 120 60 1
8.0HDKAK 11454L Diesel 611 1236 120 60 1
* The specification number denotes customer requested options or deviations from a

standard (1A, 1B, etc.) model. The specification letter advances (A, to B, to C, etc.)
with major manufacturing changes.
Copyright 2019 Cummins Inc. 1

This Page Intentionally Left Blank.
2 Copyright 2019 Cummins Inc.

Index
A Cap, Valve, 22
Carrier, 24
Arm, Rocker, 22
Case, Governor Ball, 17
Assy, Cap Panel, 43
Clamp, 30
Assy, Cover Enclosure, 43
Clamp, Hose Bracket, 35 , 36
Assy, Cover Enclosure (Rail), 43
Clamp, Isolator, 41
Assy, Main Bearing Case, 13
Clamp, Loop, 47
Assy, Pump Injection, 16
37
Assy, Wheel Bearing Case, 13
32
Clip, Loop, 47
B Coil, Governor, 24
Baffle, Inlet, 32 Collar, 23
Ball, Injection Pump Gear, 17 Collar, Crankshaft, 11
Ball, Valve Seat, 27 Collet, Valve Spring, 22
Base, Mounting, 42 Components, Injection Nozzle, 20
Bearing, Carrier Ball, 24 Components, Water Pump, 28
Bearing, Crankshaft, 13 Control, Speed, 15
Bearing, Fuel Camshaft, 17 Cooling System 8HDKAK 2010K, 36
Bearing, Water Pump Ball, 28 Core, Battery Harness Ferrite, 50
Belt, Water Pump, 39 Cover, AC, 43
Block, AC Terminal, 49 Cover, Access, 43
Block, Battery Harness Terminal, 50 Cover, Air Cleaner (Intake), 32
Block, Cylinder, 9 Cover, Air Cleaner Element, 32
Block, Exhaust Fiberglass, 41 Cover, Bearing Plate, 13
Bracket, Inverter, 47 Cover, Enclosure, 43
Bracket, Rocker Arm, 22 Cover, Enclosure (Access), 43
Breaker, Circuit, 49 Cover, Fuel Camshaft, 9
Bushing, Crankshaft, 11 Cover, Gearcase Hole, 27
Bushing, Idle Gear, 12 Cover, Governor, 24
Bushing, Piston Pin, 11 Cover, Main Bearing, 13

Cover, Valve, 26
Cover, Water Temperature Thermostat, 25
C Crankshaft, 11
Camshaft, 12
Camshaft, Fuel, 17
Cap, Coolant Drain, 35 , 36
D
Cap, Coolant Fill, 35 , 36 Door, Maintenance, 42
Cap, Coolant Recovery, 37

Cap, Cylinder Block Sealing, 9 E
Cap, Cylinder Head Sealing, 18
Element, Intake Air Cleaner, 32
Cap, Speed Control, 15

Index
Enclosure, 43 Gear, Injection Pump, 17
Enclosure 8HDKAK 2010, 44 Gear, Oil Pump Drive, 9
Engine, Replacement, 9 Gearcase, 27
Exhaust Manifold, 40 Generator, 45 , 46
Exhaust, (Flex Pipe), 41 Governor, 24
Eye, Lifting, 18 Grommet, Engine Harness, 48
Guard, Circuit Breaker, 43 , 44
F Guard, Fan, 42
Guide, Valve, 18
Fan, Generator, 45 , 46
Filter, Fuel, 30
Filter, Oil, 27 H
Fitting, Bulkhead, 29 , 30 Hardware, Meter Mounting, 54 , 55
35 , 36 Harness, AC, 49
Flange, Component Water Pump, 28 Harness, Battery, 50
Flange, Outlet Water Pump, 25 Harness, Engine, 48
Fuel, EFI Filter, 29 Harness, Extension, 51
Fuse, 48 Harness, Pigtail, 51
Harness, Remote Panel (Gauges), 55
G Harness, Remote Panel (Switch/Hourmeter), 53

Harness, Remote Panel (Switch/Voltmeter), 54
Gasket, 23
Harness, Remote Panel (W/Switch), 52
Gasket, Bearing Plate Cover, 13
Head, Cylinder, 18
Gasket, Case Cover, 13
Hinge, Maintenance Door, 42
Gasket, Control Plate, 23
Holder Assy, Nozzle, 21
Gasket, Cylinder Head, 18
Holder, Fuse, 48
Gasket, Exhaust Manifold, 40 , 41
Holder, Main Bearing, 13
Gasket, Gearcase, 27
Holder, Nozzle, 19
Gasket, Gearcase Hole Cover, 27
Hose, Air Bleed, 35 , 36
Gasket, Inlet Manifold, 31
Hose, Coolant Fill Neck, 35 , 36
Gasket, Oil Filter Flange, 27
Hose, Fuel, 30
Gasket, Oil Pan, 38
Hose, Intake, 32
Gasket, Oil Pump, 9
Hose, Oil Fill, 37
Gasket, Speed Control, 15
Hose, Overflow, 35 , 36
Gasket, Water Flange, 25
Hose, Radiator, 35 , 36
Gasket, Water Pump, 28
Hourmeter, 43
Gasket, Water Temperature Thermostat, 25
Hourmeter (Remote Gauge Panel), 55
Gauge, Oil Pressure (Remote Panel), 55
Hourmeter (Remote Switch Panel), 53
Gauge, Water Temperature (Remote Panel), 55
Housing, Air Cleaner, 32
Gear, Camshaft, 12
Housing, Flywheel, 45
Gear, Idle, 12

Index
I Meter, 44
Meter, Voltage (Remote Panel), 54
Impeller, Water Pump, 28
Mount, Inverter, 47
Indicator, Oil Level, 37
Muffler, Exhaust, 41
Insulation, Cover, 43 , 44
Insulation, Enclosure, 44
Insulation, Panel, 43 , 44
N
Insulation, Panel Curb, 43 , 44 Neck, Coolant Fill, 35 , 36
Insulation, Rail, 43 , 44 Nipple, Gearcase Hex Pipe, 27
Insulator, Terminal, 48 Nozzle, Injection, 19
Intake, Air, 32 Nozzle, Injection Component, 21
Inverter, 47 Nut, Speed Control, 23
Isolator, Muffler, 41
Isolator, Vibration, 42
O
27
K 24
Key, Camshaft Feather, 12 37
Key, Crankshaft Feather, 11 38
Key, Cylinder Block Feather, 9 Outlet, Water, 25
Key, Fuel Camshaft Feather, 17
Kit, Air Cleaner, 32
P
Kit, Filter, 29 , 30
Pan, Oil, 38
Kit, Nozzle Holder, 19
Panel Enclosure, 43
Kit, Remote Control Panel (W/Switch), 52
Panel, Air Baffle, 35 , 36
Kit, Remote Panel (Gauges), 55
Panel, Cap, 44
Kit, Remote Panel (Switch/Hourmeter), 53
Panel, Curb, 43 , 44
Kit, Remote Panel (Switch/Voltmeter), 54
Panel, Printed, 54
Panel, Rail, 43
L Panel, Remote (W/Switch), 52
Labels, 56 Panel, Remote Gauge, 55
Latch, Service Panel, 42 Panel, Remote Switch/Hourmeter, 53
Lever, Engine Stop, 23 Panel, Remote Switch/Voltmeter, 54
Lever, Fork, 14 Panel, w /Decal, 55
Lever, Governor, 23 PCB Assy, Filter DC, 50
Lever, Speed Control, 23 Pin, Cylinder Block Hollow, 9
Line, Fuel, 29 , 30 Pin, Cylinder Block Straight, 9
Pin, Gearcase Spring, 27
M Pin, Governor Spring, 14

Pipe, Injection, 19
Manifold, Exhaust, 40
Pipe, Overflow, 19
Manifold, Inlet, 31

Index
Pipe, Water Pump Return, 28 Sender, Water Temperature, 25
Pipe, Water Return, 25 Shaft, Governor, 14
Piston, 11 Shaft, Idle Gear, 12
Plate, Camshaft Retaining, 12 Shaft, Lever, 23
Plate, Fuel Camshaft Retaining, 17 Shaft, Rocker Arm, 22
Plate, Speed Control, 23 Shim, Injection Pump, 16
Plug, Cylinder Head Pipe, 18 Sleeve, Air Intake, 32
Plug, Gearcase Pipe, 27 Sleeve, Governor, 17
Plug, Oil Drain, 38 Spacer, Idle Gear, 12
Pulley, Drive, 39 Spacer, Injection Nozzle, 21
Pulley, Fan, 39 Speed Control, 23
Pump, Fuel, 29 , 30 Spring, Fork Lever Governor, 14
Pump, Injection, 16 Spring, Governor, 24
Pump, Water, 28 Spring, Injection Nozzle, 21
Spring, Rocker Arm, 22
R Spring, Valve, 22
Spring, Valve Seat, 27
Radiator, 35 , 36
Starter Mounting, 45
Resonator, Intake, 32
Stator, Generator, 45
Retainer, Valve Spring, 22
Stick, Oil, 37
Ring, Idle Gear Retaining, 12
Switch, Oil Pressure, 9
Rod, Camshaft Push, 12
Switch, Remote Control Panel Rocker, 52
Rod, Injection Nozzle Push, 21
Switch, Rocker, 43 , 44
Rotor, Generator, 45
Switch, Start/Stop (Remote Gauge Panel), 55
Rotor, Governor, 24
Switch, Start/Stop (Remote Hourmeter Panel), 53
S Switch, Start/Stop (Remote Voltmeter Panel), 54

System, Cooling, 35
Seal, Air Cleaner Spacer, 32
System, Exhaust, 41
Seal, Bearing Plate Cover Oil, 13
System, Fuel, 29 , 30
Seal, Coolant Hose, 35 , 36
Seal, Exhaust, Pipe , 41
Seal, Fuel Pump, 29 , 30 T
Seal, Gearcase Oil, 27 Tank, Coolant Recovery, 37
Seal, Housing, 32 Tank, Cooling, 37
Seal, Injection Nozzle Heat, 19 Tappet, Camshaft, 12
Seal, Maintenance Door, 42 Thermostat, Water Temperature, 25
Seal, Oil Drain, 37 Transformer, 49
Seal, Valve Stem, 22 Trough, Oil Drain, 29 , 30
Seal, Water Pump, 28 Tube, Oil Pickup, 38
Seat, Valve, 27

Index
V
Valve, Exhaust, 22
Valve, Intake, 22


Cylinder Block
3. 14. 3.
26. 4.
25.
24. 9. 8.
2.
1. 12. 11.
14.
2. 10.
15. 16.
3.
3.
3. 6.
13.
4.
5.
2.
20. 21. 5.
19.
5.
18.
5. 23.
6.
17.
12. 6.
7.
22.
REF PART QTY PART REF PART QTY PART

NO. NO. USED DESCRIPTION NO. NO. USED DESCRIPTION
0100 4111 1 Engine, Replacement A040R285 2 (Spec N)

(Spec L M) 13. 185 5488 2 *Pin, Hollow
A044B674 1 Engine, Replacement 14. 185 5489 1 *Cover, Fuel Camshaft
(Begine Spec N) 15. 181 9022 1 Plug
1. 1 Block Assy, Cylinder (Includes 16. 509 0549 1 Washer, W/ Seal
Parts Marked *)(Spec L M) 17. 185 5416 1 Nut
110 4125 1 (Spec L M) 18. A040P916 1 Gear, Oil Pump Drive
A046W974 1 (Spec N) 19. 181 9165 1 Pump, Oil
2. 185 5482 3 *Cap, Sealing 20. 185 5415 1 Key, Feather
3. 185 5483 5 *Cap, Sealing 21. 185 5413 1 Gasket, Oil Pump
4. 185 5484 2 *Cap, Sealing 22. 181 9062 3 Bolt
5. 185 2188 3 *Plug 23. 185 5492 1 Switch, Oil Pressure (S15)
6. 185 2233 1 *Plug 24. 185 5798 1 Cover
7. 185 2234 1 *Plug 25. 185 6919 1 Gasket, Fuel Pump
8. 185 5485 2 *Plug, Expansion 26. 185 2389 2 Bolt
9. 185 5486 2 *Pin, Straight
10. 185 5487 2 *Pin, Straight
11. 185 2094 1 *Pin, Hollow
12. *Pin, Hollow * All parts included in Cylinder Block Assembly.
185 2115 2 (Spec L M)

Crankshaft
2.
4. 9.
12.
10.
3. 1.
11.
4.
6.
5.
8. 18.
7.
19.
14. 16. 17.

22.
20. 19.
15.
13.
21.

Crankshaft

1. Piston 185 5577 1 Standard

112 0332 3 (Spec L M) 185 5578 1 0.20 mm
185 5350 3 (Spec L M) (.25mm) 185 5579 1 0.40 mm
A046X258 3 (Spec N) 16. Bushing, Crankshaft
A046X266 3 (Spec N) (.25mm) 185 5581 2 Standard
2. Ring, Piston 185 5360 2 0.20 mm
185 7076 3 (Spec L M) 185 5361 2 0.40 mm
185 7386 3 (Spec L M) (.25mm) 17. Bushing, Crankshaft
A046X269 3 (Spec N) 185 5580 1 Standard
A046X274 3 (Spec N) (.25mm) 185 5356 1 0.20 mm
3. 185 5568 3 Pin, Piston 185 5357 1 0.40 mm
4. 185 2016 6 Circular Clip, Piston Pin 18. Bushing, Crankshaft
5. Rod, Connecting 185 2022 2 Standard
181 9162 3 (Spec L M) 185 2028 2 0.20 mm
A046X323 3 (Spec N) 185 2029 2 0.40 mm
6. 508 1255 3 Bushing, Piston Pin 19. Bushing, Crankshaft
7. 185 5570 6 Bolt, Connecting Rod 185 2029 2 Standard
8. Bearing, Piston 140 2169 2 0.20 mm
185 5571 3 (Spec L M) 185 2031 2 0.40 mm
104 2174 3 (Spec L M) 20. 185 7407 1 Collar
185 5572 3 (Spec L N) (.20mm) 21. 185 5583 1 Sling, Oil
185 5573 3 (Spec L N) (.40mm) 22. 509
A046X327 3 (Spec N)
9. 181 9179 1 Assy, Crankshaft
10. 181 9176 1 Component, Crankshaft
11. 185 5575 3 Ball
12. 185 2033 1 Sleeve, Crankshaft
13. 185 5576 1 Gear, Crank
14. 185 2353 1 Key, Feather
15. Bushing, Crankshaft

Camshaft
14.
13.
10. 2.
11. 9.
12.
1.
8. 4.
6. 3.
7.
5.

1. 181 9159 6 Tappet 9. 185 5562 1 Gear, Idle (Includes Bushing)

2. 185 5555 6 Rod, Push 10. 185 7385 1 Bushing, Idle Gear
3. Camshaft Assy (Includes Parts 11. 185 5563 1 Spacer
Marked *) 12. 185 5564 1 Ring, Retaining
105 0778 1 (Spec L M) 13. 185 5565 1 Shaft, Idle Gear
A046X244 1 (Spec N) 14. Screw, Hex Washer Head Cap
4. 185 5924 1 *Ball W/ Lock (M6 x 14mm)
5. *Gear, Camshaft A040P211 3 (Spec L M)
A040P910 1 (Spec L M) A046X254 3 (Spec N)
A046X251 1 (Spec N)
6. 185 5560 1 *Key, Feather
7. 185 5561 1 *Plate, Retaining * Parts Included in Camshaft Assy.
8. 185 2380 2 Bolt

Main Bearing Holders
9. 7.
6.
8.
4.
6.
5.
10.
7.
2.
1.
2.
2.
3.
12.
11.
13.
12.
13.

1. 232 4193 1 Assy, Wheel Bearing Case 8. 101 0872 1 Gasket, Case Cover
2. 185 5515 6 Screw, Hex Head Cap 9. A040P227 8 Screw, Hex Head W/ Lock Cap
3. Bearing, Crankshaft Washer (M6 x 20mm)
185 5580 1 (Spec L M) 10. 185 2559 8 Screw, Hex Head Cap
A046X183 1 (Spec N) 11. 232 4192 1 Assy, Main Bearing Case
A046X193 1 (Spec N) (.20mm) 12. Bearing, Crankshaft
A046X195 1 (Spec N) (.40mm) 185 5581 2 (Spec L M)
4. 185 5438 1 Gasket, Bearing Case A046X199 2 (Spec N)
5. 185 7073 1 Cover Assy, Main Bearing Case A046X204 2 (Spec N) (.20mm)
(Includes Cover and Seal) A046X207 2 (Spec N) (.40mm)
6. 185 5516 1 Cover, Bearing Plate 13. 185 5519 2 Bolt, Bearing Case
7. A040R304 1 Seal, Oil

Fork Lever
1.
4. 2.
7.
10.
9.
6. 8.
11.
12.
4.
6.
3. 5.
9. 8.
10.

1. 181 9169 1 Spring, Start 9. 181 9039 1 *Screw, Hex Head Cap
2. 184 0054 1 Spring, Governor 10. *Washer, Spring Lock
3. Lever Assy, Fork (Includes 185 6999 1 (Spec L M)
Parts Marked *) A046X581 1 (Spec N)
150 2996 1 (Spec L M) 11. A040P972 1 Holder, Fork Lever
A046X574 1 (Spec N) 12. 185 2393 2 Screw, Hex Head Cap
4. 181 9203 1 *Spring (M6 x 35mm)
5. 185 5701 1 *Lever Assy, Outer Fork
(Includes Lever, Shaft and Pin)
6.185 5702 1 *Lever, Outer Fork
7. 185 5703 1 *Shaft * Parts Included in Fork Lever Assy.
8. 185 5696 1 *Pin, Spring

Speed Control
2. 6.
4.
3.
5.
5.
2.
1.
5.
10. 7.
8.
9.
11.

1. 185 5679 1 Assy, Idle Apparatus (Includes 7. 181 9057 1 Screw, Adjusting
Parts Marked *) 8. 185 6931 1 Nut, Hex
2. 185 5680 1 *Bolt, Adjusting (Includes Nuts) 9. 185 2284 1 Gasket
3. 185 2180 1 *Nut, Hex 10. 185 7313 1 Gasket
4. 185 5681 1 *Nut, Cap 11. 185 6931 1 Nut
5. 185 2338 2 *Gasket
6. 185 5682 1 Cap
* Parts Included in Idle Assy.

Injection Pump
10. 9.
11. 1.
4.
8. 9.
7.
12.
13.
6.
7.
2.
3.
5.

185 5425 1 Assy, Pump Injection 6. 185 5625 2 Nut, Cap

(Includes Parts Marked*) 7. Washer, Spring Lock
1. 185 5626 1 Joint, Eye A040P435 4 (Spec L M)
2. Shim, Injection Pump 850 2083 4 (Spec N)
147 0971 1 0.175mm 8. 185 5660 1 *Screw, Hollow
185 6883 1 0.20mm 9. 185 5661 2 *Gasket
185 6739 1 0.25mm 10. 185 5662 1 *Screw
147 0970 1 0.35mm 11. 185 5663 1 *Gasket
3. 185 6845 1 Shim, Injection Pump 12. 185 6888 1 *Plug
4. Screw, Socket Head Cap 13. 185 5820 1 *Gasket
185 5623 2 (Spec L M)
800 6549 2 (Spec N)
5. 185 5624 2 Stud * Parts Included in Fuel Camshaft Assy.

Fuel Camshaft
8.
6.
5. 7.
4. 11.
9.
3. 2. 10.
12.
13.
1.

Camshaft Assy, Fuel (Includes 6. 185 5632 1 +Case, Governor Ball

Parts Marked +) 7. 185 2357 32 +Ball
105 0777 (Spec L M) 8. 185 2163 1 +Circlip, Governor Sleeve
A046X479 (Spec N) 9. 185 5633 8 +Ball
1. 181 9075 1 +Camshaft, Fuel 10. 181 9182 1 Bearing
2. 185 5629 1 +Bearing, Ball 11. 185 5634 1 Circlip
3. +Gear, Injection Pump 12. 185 5635 1 Plate, Retaining
A040P914 1 (Spec L M) 13. 185 2386 2 Screw
A046X490 1 (Spec N)
4. 185 2353 1 +Key, Feather
5. 185 5631 1 +Sleeve, Governor * Parts Included in Fuel Camshaft Assy.

Cylinder Head
6.
10. 9. 1.
7. 4. 2.
4.
3.
9.
1.
8.
2.
11.
5.

1. 185 2414 1 Eye, Lifting 7. 185 5501 3 *Guide, Exhaust Valve

2. Screw 8. 185 2413 2 *Cap, Sealing
185 6762 1 (Spec L M) 9. 185 5502 1 *Plug, Pipe
A046W997 1 (Spec N) 10. 185 5503 14 Bolt, Cylinder Head
3. Head Assy, Cylinder (Includes 11. Gasket, Cylinder Head
Parts Marked *) 185 6120 1 (Spec L M)
110 4128 1 (Spec L M) A046X148 1 (Spec N)
A046X144 1 (Spec N)
4. 185 2411 1 *Cap, Sealing
5. 185 2188 1 *Plug * Parts Included in Cylinder Head Assy.
6. 185 5500 3 *Guide, Intake Valve

Injection Nozzle
11.
11. 14.
10.
14. 12.
10.
13.
8. 14.
7.
6.
9.
9. 4.
15.
1.
2. 4.
15.
3.
4. 5.
15.
3. 5.
5.

A046X501 1 Kit, Nozzle Holder (Includes 9. 185 5612 2 Clamp, Bottom Pipe
Parts Marked *) 10. 185 2345 2 Clamp, Top Pipe
1. Pipe, Overflow 11. 185 2385 2 Screw, Pan Head Machine
181 9202 1 (Spec L M) W/Lock Washer
A046X497 1 (Spec N) 12. Plug, Glow
2. 185 7082 1 Screw, Air Bleeder 185 5421 3 (Spec L M)
3. 185 A046X513 3 (Spec N)
4. *Holder, Nozzle 13. 185 5614 1 Cord, Glow Plug
185 6738 3 (Spec L M) 14. 185 5615 3 Nut, Flange
A046X504 3 (Spec N) 15. A046X510 3 Nut
5. A046X568 3 *Seal, Heat
6. 501 1128 1 Pipe, Injection
7. 501 1130 1 Pipe, Injection * Parts included in Nozzle Holder Kit.
8. 501 1131 1 Pipe, Injection

Injection Nozzle Components
3.
4.
1.
2.
5.
6.
7.
8.
9.
10.
11.
12.

1. 185 5363 3 Washer Assy Includes the 185 5401 3 1.825 mm

Following Adjusting Washers: 185 5402 3 1.850 mm
185 5364 3 0.900 mm 185 5403 3 1.875 mm
185 5365 3 0.925 mm 185 5404 3 1.900 mm
185 5366 3 0.950 mm 185 5405 3 1.925 mm
185 5367 3 0.975 mm 185 5406 3 1.950 mm
185 5368 3 1.000 mm 2. 3 Holder Assy, Nozzle (Includes
185 5369 3 1.025 mm Parts Marked *)
185 5370 3 1.050 mm A040P650 3 (Spec L M)
185 5371 3 1.075 mm A046X501 3 (Spec N)
185 5372 3 1.100 mm 3. *Nut, Hex
185 5373 3 1.125 mm 185 5616 3 (Spec L M)
185 5374 3 1.150 mm A046X510 3 (Spec N)
185 5375 3 1.175 mm 4. *Washer
185 5376 3 1.200 mm 185 5621 3 (Spec L M)
185 5377 3 1.225 mm A046X554 3 (Spec N)
185 5378 3 1.250 mm 5. *Washer, Adjusting
185 5379 3 1.275 mm 185 5364 3 (Spec L M)
185 5380 3 1.300 mm A046X525 3 (Spec N)
185 5381 3 1.325 mm 6. *Spring
185 5382 3 1.350 mm 185 5617 3 (Spec L M)
185 5383 3 1.375 mm A046X534 3 (Spec N)
185 5384 3 1.400 mm 7. *Rod, Push
185 5385 3 1.425 mm 185 5619 3 (Spec L M)
185 5386 3 1.450 mm A046X545 3 (Spec N)
185 5387 3 1.475 mm 8. *Spacer
185 5388 3 1.500 mm 185 56183 3 (Spec L M)
185 5389 3 1.525 mm A046X537 3 (Spec N)
185 5390 3 1.550 mm 9. *Nozzle
185 5391 3 1.575 mm 185 5622 3 (Spec L M)
185 5392 3 1.600 mm A046X561 3 (Spec N)
185 5393 3 1.625 mm 10. *Nut, Nozzle
185 5394 3 1.650 mm 185 6825 3 (Spec L M)
185 5395 3 1.675 mm A046X547 3 (Spec N)
185 5396 3 1.700 mm 11. A046X565 3 Gasket (Spec N)
185 5397 3 1.725 mm 12. A046X568 3 Seal (Heat)
185 5398 3 1.750 mm
185 5399 3 1.775 mm
185 5400 3 1.800 mm * Parts Included in Nozzle Holder Assy.

Rocker Arm
13.
6.
8. 5.
4.
11.
16. 10.
13. 3.
9.
16.
16.
12. 15. 7.
12.
16.
13.
16.
17.
18.
15. 2.
16. 2.
12.
1.
14. 2.
1.
9.
10.
11. 1.

1. 110 3990 3 Valve, Intake 11. 185 2386 2 Screw, Hex Head Cap
2. 110 3991 3 Valve, Exhaust (M6 x 12mm)
3. 185 5539 6 Spring, Valve 12. 181 9251 3 Bracket, Rocker Arm
4. 185 5540 6 Retainer, Valve Spring 13. A040P671 3 Bolt, Flange
5. 185 5541 6 Collet, Valve Spring 14. 185 2351 1 Pin, Spring
6. 185 5793 6 Cap, Valve 15. 185 5550 2 Spring, Rocker Arm
7. 185 5348 6 Seal, Valve Stem 16. 185 5551 6 Arm, Rocker (Includes Nut and
8. 185 5827 1 Shaft, Rocker Arm Screw)
9. 185 7086 6 Washer, Flat 17. 185 5552 6 Screw, Adjusting
10. 185 7395 2 Washer, Flat 18. 185 5553 6 Nut

Speed Control
12.
13.
10.
3.
9.
17. 7. 4.
15.
16. 8.
5.
1.
15.
2.
6.
14.
11.

185 7267 1 Assy, Speed Control Plate 10. 181 9063 2 *Nut, Speed Control
(Includes Parts Marked *) 11. 184 0060 1 *Shaft, Lever
1. 185 6847 1 *Plate, Speed Control 12. 184 0059 1 *Lever, Engine Stop
2. 185 7080 1 Gasket, Control Plate 13. 185 5696 1 *Pin, Spring
3. Screw, Socket Head Cap 14. 184
(M5 x .8 x 80mm) 15. 185 4255 3 *Nut
184 0013 4 (Spec L M) 16. 181 9205 3 *Bolt
A046X492 4 (Spec N) 17. A046X495 2 Screw
4. 185 6759 2 #Washer, Spring
5. 185 2284 2 #Gasket
6. 184 0053 1 *Lever, Governor * Parts Included in Speed Control Plate Assy.
7. 184 0057 1 *Collar
8. 184
# Not used for Spec N.
9. 184 0056 1 *Lever, Speed Control

Governor
1.
3.
3. 2.
4.
4. 5.
6.
8.
7.
9.

1. 150 2641 1 Cover, Governor 5. 150 2643 S0 1 Carrier Assy (Includes Bearing)
2. 150 2724 1 Spring, Governor 6. 510 0184 1 Bearing, Ball
3. 815 0877 4 Screw, Socket Head Cap 7. 518
(M5 x .8 x 80mm) 8. 150 2630 1 Coil, Governor
4. 740 1002 4 Washer, Flat (M5) 9. 150 2639 1 Rotor, Governor

Water Outlet
8.
7.
4.
6.
3. 3. 5.
10.
2.
1.
9.
12. 11.

1. 181 9185 1 Flange, Water Pump (Includes 8. 185 6677 2 Bolt

Water Return Pipe) 9. 181 9059 1 Gasket, Water Flange
2. 185 6445 1 Pipe, Water Return 10. 193 0318 1 Sender, Water Temperature
3. 185 6667 2 Band, Pipe 11. 185 2386 2 Bolt (M6 x 16mm)
4. 185 5722 1 Pipe, Water Return 12. Bolt
5. 185 2238 1 Gasket, Thermostat A040P219 1 (Spec L M)
6. 185 5458 1 Thermostat A046X152 1 (Spec N)
7. 185 5792 1 Cover, Thermostat

Valve Cover
1. 8.
2. 2.
6.
5.
7.
4.
3.
8.
11.
10.
12.
9.

1. 181 9249 1 Tube, Breather 8. 185 2384 4 Screw, Flanger

2. 181 9024 2 Clamp, Hose 9. 181 9253 1 Gasket, Head Cover
3. 134 5396 1 Assy, Cover Cylinder Head 10. 800 6330 4 Bolt
4. 134 5395 1 Cover Cylinder Head 11. 123 2428 1 Plug, Oil Filler
5. 185 6445 1 Pipe, Water Return
6. 181 9238 1 Cover, Breather 185 7426 1 (Spec L M)
7. 181 9241 1 Comp. Valve, Breather A046X165 1 (Spec N)

Gearcase
1.
2. 3.
14.
22. 13.
24. 23.
18.
3.
26.
25. 17.
29.
28. 27.
16.
15. 12. 9.
11.
15. 10.
2.
15.
30.
8. 6.
4.
21. 7.
15.
19. 2. 5.
15.
20. 2. 2.

1. 103 0844 1 Gearcase Assy (Includes Pin (M6 x 1 x 62mm)

and Plugs) 17. 185 2395 1 Bolt (M6 x 60mm)
2. 185 2234 8 Plug, Pipe 18. 185 2379 1 Screw, Hex Head Cap
3. 185 5506 1 Pin, Start Spring (M6 x 70mm)
4. 122 0912 1 Cover 19. 185 5745 2 Bolt
5. 185 5742 1 Bolt 20. 185 5746 1 Screw, Hex Head Cap
6. 185 (M6 x 1 x 87mm)
7. 185 21. 185 5410 1 Seal, Front Oil
8. 185 2124 1 Nipple, Hex Pipe 22. 185 6257 1 Cover
9. 185 5509 1 Spring 23. 181 9211 1 Gasket, Flange
10. 185 5510 1 Seat, Valve 24. 185 2389 3 Bolt (M6 x 18mm)
11. 185 5511 1 Ball 25. 185 5512 1 Cover
12. 185 5727 1 Stud 26. 185 5513 1 Gasket
13. 185 7382 1 Gasket, Gearcase 27. 185 2105 3 Stud
14. Screw, Hex Head Cap 28. Nut, Hex
(M6 x 18mm) 185 4255 3 (Spec L M)
185 2389 1 (Spec L M) 181 9014 3 (Spec N)
A026E389 1 (Spec N) 29. 185 6759 3 *Washer, Spring Lock
15. Screw, Hex Head Cap 30. 122 0833 1 Filter, Oil
185 7069 7 (Spec L M)
A046X152 7 (Spec N)
16. 185 5507 3 Screw, Hex Head Cap * Not used for Spec N.

Water Pump Components
4.
7.
5. 6.
2.
1.
7.
3.
2.
8.
9.

1. 132 0492 1 Pump, Water (Includes Parts 7. 132 0493 1 *Impeller

Marked *) 8. 185 5717 1 Bolt
2. 185 5712 1 *Flange, Water Pump 9. 185 2559 4 Bolt
3. 185 5713 1 *Bearing, Ball
4. 185 5716 1 *Pipe, Return
5. 132 0525 1 Gasket, Water Pump * Parts Included in Water Pump.
6. 185 5714 1 *Seal

Fuel System
6.
5.
16.
6.
13. 8. 4.
10.
7.
12. 11.
16.
3. 15. 18. 1.
19 14. 9.
17. 2. 7.

541 1442 1 Kit, Filter (Includes Part (5/8ID 1.07OD)

Marked *) 12. 868 0007 1 Nut, Hex Jam (5/8 18)
1. 149 2790 1 Pump, Fuel 13. 502 0395 1 Connector, Hose
2. 403 3860 1 Seal, Fuel Pump 14. 518 0548 61 1 Clamp, Hose
3. 821 2096 03 2 Screw, Pan Head Mach 15. 147 0860 1 *Fuel, EFI Filter
(Torx M6 x 1.0 x 20mm) 16. 503 1951 13 3 Clamp, Hose
4. 403 3863 02 1 Trough, Oil Drain 17. 501 0944 1 Hose, Fuel
5. 503 2895 1 Hose, Fuel 18. 149 2782 02 1 Bracket
6. 503 1951 09 2 Clamp, Hose 1 Line, Fuel (Includes parts
7. 517 0273 2 Plug, Pipe marked + )
+8. 898 1196 33 1 Sleeving, Convoluted +19. A029M042 1 Hose, Fuel
9. 823 0003 02 1 Screw, Pan Head Torx Thread
Form (M6 x 1.00 x 14mm)
10. 502 1296 02 1 Fitting, Bulkhead
11. 854 0028 1 Washer, IT Locking

Fuel System
Begin Spec M
4.
1.
2.
7.
6. 18.
5.
14. 7.
10.
8.
3.
6. 13.12.11.
17 18. 9. 16. 18. 19.

15.

541 1442 1 Kit, Filter (Includes Part 10. 502 1296 02 1 Fitting, Bulkhead
Marked *) 11. 854 0028 1 Washer, IT Locking
1. 149 2790 1 Pump, Fuel (5/8ID 1.07OD)
2. 403 3860 1 Seal, Fuel Pump 12. 868 0007 1 Nut, Hex Jam (5/8 18)
3. 821 2096 03 2 Screw, Pan Head Mach 13. A029Z860 1 Hose, Elbow
(Torx M6 x 1.0 x 20mm) 14. 332 1554 1 Clamp, Loop
4. 403 3863 02 1 Trough, Oil Drain 15. 518 0548 61 1 Clamp
5. A029L892 1 Hose, Fuel 16. 147 0860 1 *Filter, Fuel
6. 503 1951 09 2 Clamp, Hose 1 Line, Fuel (Includes parts
7. 517 0273 2 Plug, Pipe marked + )
+8. 898 1196 33 1 Sleeving, Convoluted +17. A029M042 1 Hose, Fuel
9. 823 0003 02 1 Screw, Pan Head Torx Thread 18. 503 1951 13 3 *Clamp
Form (M6 x 1.00 x 14mm) 19. A029L914 1 Hose, Fuel

Inlet Manifold
5.
2. 1.
5.
3.
4.

1. 185 7087 1 Manifold Assy, Inlet (Includes 4. Bolt

Manifold and Gasket) 181 9001 2 (Spec L M)
2. 181 9256 1 Pipe, Breather A026E389 2 (Spec N)
3. 185 5832 1 Gasket, Manifold 5. 185 5833 3 Bolt

Air Intake
18. 12.
17.
18. 16.
13.
15. 14.
11.
2.
10.
2.
9.
8. 7.
5. 8. 9. 19.
8.
9.
1.
6.
19. 5.
19.
3.
4.

140 3233 1 Kit, Air Cleaner 9. 823 1002 03 3 Screw, Pan Head Machine
(Includes Parts Marked*) (M6 x 1 x 10mm)
1. 134 5063 1 Baffle Assy, Inlet 10. 800 0603 01 1 Screw, Hex Head Machine
(Includes Insulation) (1/4 20 x 2)
2. 823 0003 02 7 Screw, Pan Head 11. 140 3232 1 *Cover, Air Cleaner
(M6 x 1 x 14mm) 12. 140 4018 1 *Seal, Housing
3. 503 1979 1 Hose, Intake (Dirty) 13. 140 3231 1 *Housing, Air Cleaner
4. 503 1985 1 Hose, Intake (Clean) 14. 870 0540 03 1 Nut, Push On
5. 823 1002 04 2 Screw, Pan Head Machine 15. 140 2536 05 1 Seal, Air Cleaner Spacer
(M6 x 1 x 14mm) 16. 140 2897 1 Element, Air Cleaner
6. 140 4273 1 Resonator, Intake 17. 140 2961 02 1 Cover, Air Cleaner Element
7. 140 2898 1 Sleeve, Air Intake 18. 865 0029 2 Nut, Wing (1/4 20)
8. 332 19. 503 0429 4 Clamp, Hose


Cooling System
11.
12. 11.
5. 10.
25.
9.
4. 25.
1.
6.
11.
22.
23. 24.
4. 3. 7.
8.
2.
13.
7.
7.
14.
21. 7. 15.
17.
12. 16.
26.
18.
19.
7. 20.

Cooling System

1. 130 6936 1 Radiator 15. 821 2035 1 Screw, Lock Flange

2. 404 0179 1 Panel, Air Baffle (M6 x 1 x 25mm)
3. 332 1553 1 Clamp, Loop 16. 130 4392 1 Cap, Drain
4. 815 0753 2 Screw, Hex Head Cap 17. 130 4462 1 Seal, Coolant Hose
(M6 x 14mm Self Tapping) 18. 503 1970 02 1 Clamp, Hose Bracket
5. 130 7902 1 Cap, Coolant Fill 19. 870 2054 1 Nut, Lock Flange (M6 x 1)
6. 130 4321 1 Neck, Fill 20. 503 1921 1 Hose, Lower Engine
7. 503 1137 5 Clamp, Hose 21. 503 1920 1 Hose, Upper Radiator
8. 502 1367 01 1 Connector, Hose 22. 503 1951 35 2 Clamp, Hose
9. 503 1922 1 Hose, Fill Neck 23. 502 1529 1 Connector, Hose
10. 503 1923 1 Hose, Overflow (90
11. 503 1951 12 4 Clamp, Hose 24. 503 1136 1 Clamp, Hose
12. 503 1959 2 Hose, Air Bleed 25. 821 2096 03 2 Screw, Lock Flange
13. 503 1954 1 Hose, Lower Radiator (M6 x 1 x 16mm)
14. 130 26. 503 1951 40 1 Clamp

Cooling System
8HDKAK 2010K
10.10. 9. 4. 11. 23.1. 23.
10.
5. 7.
6.
21. 3. 12.
8. 4.
22.
7.
20.
7.
13.
11. 14.
24.
16.
15.
2.
17.
18.
7. 19.

1. 130 6936 1 Radiator 14. 821 2035 1 Screw, Lock Flange

2. 404 0179 1 Panel, Air Baffle (M6 x 1 x 25mm)
3. 332 1553 1 Clamp, Loop 15. 130 4392 1 Cap, Drain
4. 815 0753 2 Screw, Hex Head Cap 16. 130 4462 1 Seal, Coolant Hose
(M6 x 14mm Self Tapping) 17. 503 1970 02 1 Clamp, Hose Bracket
5. 130 7902 1 Cap, Coolant Fill 18. 870 2054 1 Nut, Lock Flange (M6 x 1)
6. 130 4321 1 Neck, Fill 19. 503 1921 1 Hose, Lower Engine
7. 503 1137 5 Clamp, Hose 20. 503 1920 1 Hose, Upper Radiator
8. 503 1922 1 Hose, Fill Neck 21. 503 1951 35 2 Clamp, Hose
9. 503 1923 1 Hose, Overflow 22. 503 1136 1 Clamp, Hose
10. 503 1951 12 4 Clamp, Hose 23. 821 2096 03 2 Screw, Lock Flange
11. 503 1959 2 Hose, Air Bleed (M6 x 1 x 16mm)
12. 503 1954 1 Hose, Lower Radiator 24. 503 1951 40 1 Clamp
13. 130

Oil Stick and Cooling Tank
1.
2. 4.
3.
8.
7.
5.
9.
6.
10.
11.
8.
12.
1. 130 4450 02 1 Cap, Coolant Recovery 8. 503 1951 46 2 Clamp, Hose

2. 509 9. 332
3. 130 4322 1 Tank, Coolant Recovery 10. 526 2083 1 Washer, Flat (M6)
4. 821 2096 02 3 Screw, Locking Flange 11. 821 2032 1 Screw, Lock Flange
(M6 x 1 x 12mm) (M6 x 1 x 12mm)
5. 123 2051 1 Indicator, Oil Level (Includes 12. 403 3859 1 Seal, Oil Drain
6. 509
7. 123 2120 1 Hose, Oil Fill

Oil Pan
8.
7. 2.
9.
3.
4.
1.
5. 6.

1. 185 6846 1 Pan, Oil 7. 181 9146 1 Tube, Oil Pickup

2. 181 9210 1 Gasket, Oil Pan 8. 185
3. 185 2389 15 Bolt 9. Bolt
4. 181 9005 2 Bolt 185 6956 1 (Spec L M)
5. 185 2398 1 Bolt A046W994 1 (Spec N)
6. 181 9227 1 Plug, Oil Drain

Pulley
1.
2.
5.
3.
4.

1. 185 5707 1 Pulley, Fan 4. 185 7083 1 Pulley, Drive

2. 185 2572 4 Screw, Hex Head Flange 5. 511 0235 1 Belt, Water Pump
3. 185 5709 1 Screw, Hex Head Cap

Exhaust Manifold
2.
1.
4.
5.
3.

1. 181 9226 1 Manifold, Exhaust 4. Stud

2. 154 3294 1 Gasket, Exhaust Manifold A040P644 3 (Spec L M)
3. Bolt A046X600 3 (Spec N)
A040P209 3 (Spec L M) 5. 185 5536 3 Nut
A046X592 3 (Spec N)

Exhaust System
9.
12. 9.
12.
7.
9.
12.
8.
6. 4.
3.
2.
5.
3.
3.
1. 1.
5. 5.
10.

1. 402 0688 02 2 Clamp, Isolator 9. 725 1051 6 Screw, Socket Head Cap
2. 402 0695 02 1 Clamp, Isolator (U Shaped) (M8 x 1.25 x 25mm)
3. 823 0003 02 6 Screw, Pan Head Torx 10. 405 5787 1 Block, Fiberglass
(M6 x 1 x 14mm) 11. 405 5755 1 Seal, Exhaust, Pipe
4. 155 4661 1 Muffler, Exhaust (Not Shown)
5. 402 0687 01 3 Isolator, Muffler 12. 850 2008 6 Washer, Split Lock (M8)
6. 154 2800 1 Gasket, Exhaust Manifold
7. Exhaust, (Flex Pipe)
154 3018 1 (Spec L)
154 3237 1 (Spec M)
8. 185 6853 1 Gasket, Exhaust Manifold

Mounting Base
4.
2.
1.
3.
8. 3.
5. 11.
10. 10.
7.
9.
6.

1. 403 3847 04 1 Base, Mounting 7. 406 0612 2 Latch, Service Panel

2. 402 0680 01 3 Isolator, Vibration 8. 130 4655 1 Guard, Fan
3. 815 0861 3 Screw, Mounting 9. 823 1002 03 2 Screw, Pan Head
4. 823 0003 03 6 Screw, Pan Head Torx (M6 x 1 x 10mm)
(M6 x 1 x 20mm) 10. 815 0753 4 Screw, Hex Head
5. 402 0673 02 1 Hinge, Door (M6 x 1.00 x 14 Self Tap)
6. 405 5818 S0 1 Door Assy, Maintenance 11. 403 3861 4 Seal, Door
(Includes Latch and Seal)

Enclosure HDKAH and HDKAJ
9.
9.
7.
12. 8.
11.
4.
10. 1.,2.,3.
15.
14.
9. 13.
6.
9.
9.
5.
9.

1. 404 0376 03 1 Panel, Enclosure 7. Assy, Cover Enclosure (Rail)

2. 405 9608 1 Insulation Included in Assembly
3. 518 0581 7 Nut, Push On 405 5876 03 1 Panel, Rail
4. 405 9068 Assy, Cap Panel (Includes Cap 405 9605 1 Insulation, Rail
Insulation 405 5875) 518 0581 8 Nut, Push On
405 6037 02 1 Standard 8. 405 5380 05 1 Cover, AC
405 6037 03 1 Standard w/ Hourmeter 9. 800 6497 02 18 Screw, Hex Head Flange
5. Assy, Cover Enclosure (Curb) (M6 x 1 x 16mm)
Included in Assembly 10. 405 5309 03 1 Cover, Access
405 5758 03 1 Panel, Curb 11. Cover, Enclosure (Access)
405 9607 1 Insulation, Panel Curb Included in Assembly
518 0581 7 Nut, Push On 405 5545 02 1 Cover, Access
6. Assy, Cover Enclosure 405 9609 1 Insulation, Cover
Included in Assembly 518 0581 1 Nut, Push On
405 9833 03 1 Cover, Enclosure 12. 821 2096 03 34 Screw, Flange Head
405 9606 1 Insulation, Panel (M6 x 1 x 12mm)
518 0581 5 Nut, Push On 13. 320 1939 02 1 Guard, Circuit Breaker
14. 302 2002 1 Hourmeter (Standard
Enclosure w/ Hourmeter)
15. 308 1038 1 Switch, Rocker

Enclosure
HDKAK
11.
11.
12.
6. 4.
7.
1.
11. 10.
12.
9. 8. 8.
2. 11.
11.
11.
10.
5.
3. 10.
10.

1. 404 0375 1 Panel, Cap 4. Cover, Enclosure

Included in Assembly Included in Assembly
405 5875 1 Cap, Insulated 405 9606 1 Insulation, Panel
405 5874 07 1 Panel, End Cap (Hour Meter) 518 0581 5 Nut, Push On
2. Cover, Enclosure 5. Cover, Enclosure
Included in Assembly Included in Assembly
405 6037 03 1 Panel, Cap (Black with HR 405 9609 1 Insulation, Cover
MTR 518 0581 1 Nut, Push On
405 9607 1 Insulation, Panel Curb 6. 405 5380 05 1 Cover, Access
518 0581 8 Nut, Push On 7. 405 5309 03 1 Insulation, Enclosure
3. Cover, Enclosure 8. 320 1939 02 1 Guard, Circuit Breaker
Included in Assembly 9. 302 2002 1 Meter
405 9605 1 Insulation, Rail 10. 800 6497 02 18 Screw, Hex Flange Head
518 0581 8 Nut, Push On (M6 x 1 x 16mm)
11. 800 6497 01 34 Screw, Hex Flange Head
(M6 x 1 x 12mm)
12. 308 1038 1 Switch, Rocker

Generator Spec A N
14.
10. 13.
8. 9.
5. 6.
3.
4.
11.
1.
12.
7.
3.
2.

1. 205 0302 1 Fan, Generator 9. 526 2100 6 Washer, Flat (M8)

2. 800 2044 3 Screw, Hex Head Cap 10. 815 0781 2 Screw, Hex Washer Head
(M6 x 1 x 70mm) (M8 x 1.25 x 30mm)
3. 526 2080 7 Washer, Flat (M6) 11. 191 2200 1 Starter (See Separate Page for
4. 815 0936 4 Screw, Socket Head Cap Components)
(M6 x 1 x 100mm) 12. 104 1890 1 Housing, Flywheel
5. 220 4484 01 1 Stator 13. 850 2008 1 Washer, Lock (M8)
6. 201 3540 01 1 Rotor Assy (Includes Ring Gear) 14. 870 0557 1 Nut, Hex (M8 x 1.25)
(M8 X 1.25 X 25mm)
Note Rotor and Stator parts for Spec A N are now only available to order as combined generator
part A053K355.

Generator Begin Spec P
3.
4.
1.
2.
5.

1. 205 0302 1 Fan, Generator 4. 815 0936 4 Screw, Socket Head Cap
2. 800 2044 3 Screw, Hex Head Cap (M6 x 1 x 100mm)
(M6 x 1 x 70mm) 5. A053K355 1 Generator
3. 526 2080 7 Washer, Flat (M6)

Inverter Mount
1.
6.
4.
3.
5.
2.
6.
6.
6.
7.

1. 300 6058 02 1 Inverter 5. 332

2. 815 0896 03 2 Screw, Pan Head Torx 6. 823 0003 05 11 Screw, Pan Head
(8 (M6 x 1 x 14mm)
3. 518 0515 1 Clip, Loop 7. 319 3033 02 1 Bracket, Inverter
4. 823 1002 04 2 Screw, Pan Head Machine 8. 327 1461 1 Board, Control (Not Shown)
(M6 x 1 x 14mm)

Engine Harness
10. 13.
12. 14.
11.
P8
15.,16.
19. 3.
4.
17.
1.
2.
18.
P9
8. 20.
5., 6.
9.
7.
P1, P2

338 3822 1 *Harness, Engine 15. 332 0819 1 Housing, Receptacle Terminal
1. 321 0322 2 Holder, Fuse (1 (Natural) (A1 J7)
2. 321 0321 07 2 Fuse, Blue Blade (F1, F2) (15A) 16. 332 0819 02 1 Housing, Receptacle Terminal
3. 321 (Red) (A1 J5)
4. 321 0307 08 1 Fuse, Natural Blade (F3) (25A) 17. 332 2298 01 1 Housing, Tab Terminal (Black)
5. 323 1582 1 Connector, Plug (12 Pin) (P1) (A1 J8)
6. 323 1582 02 1 Connector, Plug (12 Pin ) (P2) 18. 308 1019 1 Connector, Switch (P9)
7. 323 1583 2 Wedge, Plug (12 Pin) (P1, P2) 19. 508 1105 1 Grommet
8. 323 1492 20 Terminal, Socket (P1, P2) 20. 332 2112 1 Insulator, Terminal
9. 323 1591 4 Seal, Plug (P1, P2)
10. 323 1711 1 Connector, Plug (10 Pin) (P8)
11. 323 1708 9 Seal, Cable (P8)
12. 323 1709 9 Terminal, Socket (P8) * See Also the Mounting Base Page for Hardware Included
13. 323 1712 1 Plug, Cavity (P8) with this Harness.
14. 323 1719 1 Lock, Housing (P8)

AC Harness
2.
1.
4.
3.

Harness, AC Wiring 2. Breaker, Circuit

338 3823 01 1 W/Battery Charger 320 1875 01 1 35A (All Specs Except 11502
W/O Battery Charger and 1044M)
338 3824 01 1 All Specs Except 320 1875 04 1 30A (Spec 11502 Only)
11502 and 1044M 320 2442 02 1 30A (Spec 1044M Only
338 3824 04 1 Spec 1044M Included in Harness
1. 315 0760 1 Transformer 338 3824 04)
3. 332 3531 04 1 Block, AC Terminal
4. 812 0070 Screw, Round Head Machine
(6 32 x 1

Battery Harness
8.
9.
10.
12. 7.
11.
6.
5. 2.
4.
12.
2.
3.
2.
2.
1.
7.
11.
2.

1. 338 3841 1 Harness, Battery (Includes 9. 526

Parts Marked *) 10. 821 2096 03 2 Screw, Lock Flange
2. 332 1554 4 *Clamp, Insulated Loop (M6 x 1 x 20mm)
3. 315 0770 1 *Core, Ferrite (Not Included with 11. 870 2054 3 Nut, Lock Flange (M6 x 1)
4. 862 0015 2 *Nut, Hex (5/16 18) 12. 823 0003 05 3 Screw, Pan Head
5. 856 (M6 x 1 x 14mm)
6. 300 4884 1 *PCB Assy, Filter DC
7. 332 3408 1 *Block, Terminal
8. 871 0025 2 Nut, Hex Brass (5/16 18) * Parts Included in Battery Harness.

Harnesses
9.
10.
12.
11.
13.
14.
17.
16. 15.
2.
3.
4.
8.
6.
1. 7.
5.

1. Harness, Extension (Reaches 10. 323 1719 1 Housing, Lock

From DC Control Harness to 11. 323 1707 8 Pin, Contact
Remote Panel) (Includes Parts 12. 323 1708 8 Seal, Cable
Marked +) 13. 323 1712 2 Plug, Cavity
338 3490 01 1 10 Feet 14. 323 1710 1 Connector, Receptacle (10 Pin)
338 3490 02 1 30 Feet 15. 338 3573 1 Harness, Customer Interface
2. 323 1719 1 +Housing, Lock
3. 323 1708 8 +Seal, Cable Remote Panel to Customer
4. 323 1712 2 +Plug, Cavity Interface) (Includes Sockets
5. 323 1200 AR +Socket, Contact and Cap)
6. 323 1325 1 +Cap, Connector 16. 323 1200 8 Socket, Contact
7. 323 1707 AR +Pin, Contact 17. 323 1325 1 Cap, Connector
8. 323 1710 1 +Connector, Receptacle (10 Pin)
9. 300 4947 1 Harness, Remote Connector
+ Parts Included in Extension Harness.
(Reaches From DC Control Parts Included in Remote Connector Harness.
Harness to Customer
Interface)
(Includes Parts Marked )

Remote Control Panel
1.
3.
6.
5. 2.
4.

300 4942 1 Kit, Remote Panel 4. 338 3812 1 Harness, Remote Panel
1. 308 1062 1 Switch, Rocker (S11) 5. 323 1199 4 Pin, Contact
2. 319 6988 01 1 Panel, Remote (Includes Label) 6. 323 1291 1 Plug (9 Pin)
3. 815 0910 2 Screw, Wood (#6 x 1)

Remote Switch/Hourmeter Panel
2.
3.
1.
4.
5.
7.
6.

300 4943 1 Kit, Switch/Hourmeter Remote 4. 302 2002 1 Hourmeter

Panel 5. 338 3475 1 Harness, Remote Panel
1. 815 0910 2 Screw, Wood Mounting (#6 x 1) (Includes Pins and Plug)
2. 319 6988 02 1 Panel, Printed 6. 323 1199 4 Pin, Contact
3. 308 1062 1 Switch, Rocker 7. 323 1291 1 Plug (9 Pin)

Remote Switch/Voltmeter Panel
6.
1.
2.
4.
3.
5.
8.
7.

300 4944 1 Kit, Remote Switch/Voltmeter 6. Hardware, Meter Mounting

Panel 526
1. 308 1062 1 Switch, Rocker 526 0049 4 Washer, Flat (#10)
2. 319 6989 03 1 Panel, Printed 871 0010 4 Nut, Hex Brass Machine
3. 302 1641 1 Meter, Voltage (#10 32)
4. 815 0910 2 Screw, Wood Mounting (#6 x 1) 850 0030 2 Washer, Lock (#10)
5. 338 3509 1 Harness, Remote Panel 7. 323 1199 4 Pin, Contact
(Includes Pins and Plug) 8. 323 1291 1 Plug (9 Pin)

Remote Gauge Panel
11
3
10
2
1

300 5027 1 Kit, Remote Gauge Panel 8 323 1291 1 Plug (9 Pin)
1 319 6993 1 Panel, w /Decal 9 323 1199 8 Pin, Contact
2 808 0023 4 Screw, Pan Head Sheet Metal 10 302 2002 1 Hourmeter
11 Hardware, Meter Mounting
3 308 1062 1 Switch, Rocker (SPDT) 526
4 302 1641 1 Meter, Voltage 526 0049 16 Washer, Flat (#10)
5 193 0351 1 Gauge, Water Temperature 871 0010 16 Nut, Hex Brass Machine
6 193 0352 1 Gauge, Oil Pressure (#10 32)
7 338 3637 1 Harness, Remote Panel 850 0030 8 Washer, Lock (#10)
(Includes Plug and Pins)

Labels

098 7244 1 Package, Label (Includes Parts 098 6876 01 2 Label, Model Ident
Marked *) (7500 HDKAJ)
098 6877 1 *Label, Coolant Level 098 6876 02 2 Label, Model Ident
098 6878 1 *Label, Fuel Attachment (8000 HDKAK)
098 7127 1 *Label, Warning (Hazardous 098 6876 04 1 Label, Model Ident (6000
Voltage) HDKAH)
098 7128 2 *Label, Warning (Voltage/ 098 8816 1 Label, Certification
Rotating Parts/Operation 098 7125 01 1 Label, Control Panel (35Amp
Service Risk) 2 Pole w/ Hourmeter)
098 7130 1 *Label, Warning (Overheat) 098 7125 05 1 Label, Control Panel (30Amp
098 7131 1 *Label, Warning (Voltage/ 2 Pole w/ Hourmeter)
Rotating Fan)
098 7196 1 *Label, Cool/Oil Fill
098 7197 1 *Label, Patent
098 7199 1 *Label, Service Info
098 7497 02 1 *Label, Warning Install
098 7368 1 Label, GenVerter

Numerical Index
Part No. Page Part No. Page Part No. Page Part No. Page
0100 4111, 9 130 7902, 35 , 36 181 9063, 23 185 2163, 17

098 6876 04, 56 132 0492, 28 181 9075, 17 185 2180, 15
098 6877, 56 132 0493, 28 181 9146, 38 185 2188, 9
098 6878, 56 132 0525, 28 181 9159, 12 185 2233, 9
098 7125 01, 56 134 5063, 32 181 9162, 11 185 2234, 9 , 27
098 7125 05, 56 134 5395, 26 181 9165, 9 185 2238, 25
098 7127, 56 134 5396, 26 181 9169, 14 185 2284, 15 , 19
098 7128, 56 140 2536 05, 32 181 9176, 11 185 2338, 15
098 7130, 56 140 2897, 32 181 9179, 11 185 2345, 19
098 7131, 56 140 2898, 32 181 9182, 17 185 2351, 22
098 7196, 56 140 2961 02, 32 181 9185, 25 185 2353, 11 , 17
098 7197, 56 140 3231, 32 181 9202, 19 185 2357, 17
098 7199, 56 140 3232, 32 181 9203, 14 185 2379, 27
098 7244, 56 140 3233, 32 181 9205, 23 185 2380, 12
098 7368, 56 140 4018, 32 181 9210, 38 185 2384, 26
098 7497 02, 56 140 4273, 32 181 9211, 27 185 2385, 19
098 8816, 56 147 0860, 29 , 30 181 9226, 40 185 2386, 17 , 22 , 25
101 0872, 13 147 0970, 16 181 9227, 38 185 2389, 9 , 27 , 38
103 0844, 27 147 0971, 16 181 9238, 26 185 2393, 14
104 1890, 45 149 2782 02, 29 181 9241, 26 185 2395, 27
104 2174, 11 149 2790, 29 , 30 181 9249, 26 185 2398, 38
105 0777, 17 150 2630, 24 181 9251, 22 185 2411, 18
105 0778, 12 150 2639, 24 181 9253, 26 185 2413, 18
110 3990, 22 150 2641, 23 , 24 181 9256, 31 185 2414, 18
110 3991, 22 150 2643 S0, 23 , 24 184 0013, 23 185 2559, 13 , 28
110 4125, 9 150 2724, 24 184 0017, 23 185 2572, 39
110 4128, 18 150 2996, 14 184 0019, 23 185 4255, 23 , 27
112 0332, 11 154 2800, 41 184 0053, 23 185 5348, 22
122 0833, 27 154 3018, 41 184 0054, 14 185 5350, 11
122 0912, 27 154 3237, 41 184 0056, 23 185 5356, 11
123 2051, 37 154 3294, 40 184 0059, 23 185 5357, 11
123 2120, 37 155 4661, 41 185 2016, 11 185 5360, 11
123 2428, 26 181 9001, 31 185 2022, 11 185 5361, 11
130 4321, 35 , 36 181 9005, 38 185 2028, 11 185 5363, 21
130 4322, 37 181 9014, 27 185 2029, 11 185 5364, 21
130 4391, 35 , 36 181 9022, 9 185 2031, 11 185 5365, 21
130 4392, 35 , 36 181 9024, 26 185 2033, 11 185 5366, 21
130 4450 02, 37 181 9039, 14 185 2094, 9 185 5367, 21
130 4462, 35 , 36 181 9057, 15 185 2105, 27 185 5368, 21
130 4655, 42 181 9059, 25 185 2115, 9 185 5369, 21
130 6936, 35 , 36 181 9062, 9 185 2124, 27 185 5370, 21

Numerical Index
185 5371, 21 185 5425, 16 185 5568, 11 185 5696, 14 , 23

185 5372, 21 185 5438, 13 185 5570, 11 185 5701, 14
185 5373, 21 185 5458, 25 185 5571, 11 185 5702, 14
185 5374, 21 185 5482, 9 185 5572, 11 185 5703, 14
185 5375, 21 185 5483, 9 185 5573, 11 185 5707, 39
185 5376, 21 185 5484, 9 185 5575, 11 185 5709, 39
185 5377, 21 185 5485, 9 185 5576, 11 185 5712, 28
185 5378, 21 185 5486, 9 185 5577, 11 185 5713, 28
185 5379, 21 185 5487, 9 185 5578, 11 185 5714, 28
185 5380, 21 185 5488, 9 185 5579, 11 185 5716, 28
185 5381, 21 185 5489, 9 185 5580, 11 , 13 185 5717, 28
185 5382, 21 185 5492, 9 185 5581, 11 , 13 185 5722, 25
185 5383, 21 185 5500, 18 185 5583, 11 185 5727, 27
185 5384, 21 185 5501, 18 185 5587, 45 185 5742, 27
185 5385, 21 185 5502, 18 185 5612, 19 185 5743, 27
185 5386, 21 185 5503, 18 185 5614, 19 185 5744, 27
185 5387, 21 185 5506, 27 185 5615, 19 185 5745, 27
185 5388, 21 185 5507, 27 185 5616, 21 185 5746, 27
185 5389, 21 185 5509, 27 185 5617, 21 185 5792, 25
185 5390, 21 185 5510, 27 185 5618, 21 185 5793, 22
185 5391, 21 185 5511, 27 185 5619, 21 185 5798, 9
185 5392, 21 185 5512, 27 185 5621, 21 185 5820, 16
185 5393, 21 185 5513, 27 185 5622, 21 185 5827, 22
185 5394, 21 185 5515, 13 185 5623, 16 185 5832, 31
185 5395, 21 185 5516, 13 185 5624, 16 185 5833, 31
185 5396, 21 185 5519, 13 185 5625, 16 185 5924, 12
185 5397, 21 185 5536, 40 185 5626, 16 185 6120, 18
185 5398, 21 185 5539, 22 185 5629, 17 185 6257, 27
185 5399, 21 185 5540, 22 185 5631, 17 185 6445, 25 , 26
185 5400, 21 185 5541, 22 185 5632, 17 185 6667, 25
185 5401, 21 185 5550, 22 185 5633, 17 185 6677, 25
185 5402, 21 185 5551, 22 185 5634, 17 185 6738, 19
185 5403, 21 185 5552, 22 185 5635, 17 185 6739, 16
185 5404, 21 185 5553, 22 185 5660, 16 185 6759, 23 , 27
185 5405, 21 185 5555, 12 185 5661, 16 185 6762, 18
185 5406, 21 185 5560, 12 185 5662, 16 185 6825, 21
185 5410, 27 185 5561, 12 185 5663, 16 185 6845, 16
185 5413, 9 185 5562, 12 185 5679, 15 185 6846, 38
185 5415, 9 185 5563, 12 185 5680, 15 185 6853, 41
185 5416, 9 185 5564, 12 185 5681, 15 185 6883, 16
185 5421, 19 185 5565, 12 185 5682, 15 185 6888, 16

Numerical Index
185 6919, 9 315 0760, 49 332 3531 04, 49 501 1128, 19

185 6931, 15 315 0770, 50 338 3475, 53 501 1130, 19
185 6956, 38 319 3033 02, 47 338 3490 01, 51 501 1131, 19
185 6999, 14 319 6988 01, 52 338 3490 02, 51 502 0395, 29
185 7069, 27 319 6988 02, 53 338 3509, 54 502 1296 02, 29 , 30
185 7073, 13 319 6989 03, 54 338 3573, 51 502 1367 01, 35
185 7076, 11 319 6993, 55 338 3637, 55 502 1529, 35
185 7080, 23 320 1875 01, 49 338 3812, 52 503 0429, 32
185 7082, 19 320 1875 04, 49 338 3822, 48 503 1136, 35 , 36
185 7083, 39 320 1939 02, 43 , 44 338 3823 01, 49 503 1137, 35 , 36
185 7086, 22 321 0307 08, 48 338 3824 01, 49 503 1920, 35 , 36
185 7087, 31 321 0321 07, 48 338 3824 04, 49 503 1921, 35 , 36
185 7313, 15 321 0322, 48 338 3841, 50 503 1922, 35 , 36
185 7382, 27 321 0349, 48 402 0673 02, 42 503 1923, 35 , 36
185 7385, 12 323 1199, 53 , 54 , 55 402 0680 01, 42 503 1951 09, 29 , 30
185 7386, 11 323 1200, 51 402 0688 02, 41 503 1951 12, 29 , 35 , 36
185 7395, 22 323 1291, 53 , 54 , 55 402 0695 02, 41 503 1951 13, 29 , 30
185 7407, 11 323 1325, 51 403 3847 04, 42 503 1951 35, 35 , 36
185 7421, 38 323 1492, 48 , 52 403 3859, 37 503 1951 40, 35 , 36
185 7426, 26 323 1541, 52 403 3860, 29 , 30 503 1951 46, 37
191 2200, 45 323 1582, 48 403 3861, 42 503 1954, 35 , 36
193 0318, 25 323 1582 02, 48 403 3863 02, 29 , 30 503 1959, 35 , 36
193 0351, 55 323 1583, 48 404 0179, 35 , 36 503 1970 02, 35 , 36
193 0352, 55 323 1591, 48 404 0375, 44 503 1979, 32
201 3540 01, 45 323 1707, 51 404 0376 03, 43 503 1985, 32
205 0302, 45 , 46 323 1708, 48 , 51 405 5309 03, 43 , 44 503 2895, 29
220 4484 01, 45 323 1709, 48 405 5380 05, 43 , 44 508 1105, 48
232 4192, 13 323 1710, 51 405 5545 02, 43 508 1255, 11
232 4193, 13 323 1711, 48 405 5755, 41 509 0329, 37
300 4884, 50 323 1712, 48 , 51 405 5787, 41 509 0380, 11
300 4942, 52 323 1719, 48 , 51 405 5818 S0, 42 509 0549, 9
300 4943, 53 327 1461, 47 405 5876 03, 43 510 0184, 24
300 4944, 54 332 0819, 48 405 6037 02, 43 511 0235, 39
300 4947, 51 332 0819 02, 48 405 6037 03, 43 , 44 517 0273, 29 , 30
300 5027, 55 332 1356, 32 405 9068, 43 518 0515, 47
300 6058 02, 47 332 1553, 35 , 36 , 47 405 9605, 44 518 0548 61, 29 , 30
302 1641, 54 , 55 332 1554, 30 , 50 405 9606, 43 , 44 518 0581, 43 , 44
302 2002, 43 , 44 , 53 , 55 332 2112, 48 405 9607, 43 , 44 518 0672, 23 , 24
308 1019, 48 332 2298 01, 48 405 9609, 43 , 44 526 0049, 54 , 55
308 1038, 43 , 44 332 2898, 37 405 9833 03, 43 526 0054, 50
308 1062, 52 , 53 , 54 , 55 332 3408, 50 406 0612, 42 526 0409, 54 , 55

Numerical Index
526 2080, 45 , 46 870 2054, 35 , 36 , 50 A046X266, 11

526 2083, 37 871 0010, 54 , 55 A046X269, 11
526 2100, 45 871 0025, 50 A046X274, 11
541 1442, 29 , 30 898 1196 33, 29 , 30 A046X323, 11
725 1051, 41 A026E389, 27 , 31 A046X327, 11
740 1002, 24 A029L892, 30 A046X479, 17
800 0603 01, 32 A029L914, 30 A046X490, 17
800 2044, 45 , 46 A029M042, 29 , 30 A046X492, 23
800 2058, 45 A029Z860, 30 A046X495, 23
800 6330, 26 A040P209, 40 A046X497, 19
800 6497 01, 44 A040P211, 12 A046X501, 19 , 21
800 6497 02, 43 , 44 A040P219, 25 A046X504, 19
800 6549, 16 A040P227, 13 A046X510, 19 , 21
808 0023, 55 A040P435, 16 A046X513, 19
812 0070, 49 A040P644, 40 A046X525, 21
815 0753, 35 , 36 , 42 A040P650, 21 A046X534, 21
815 0781, 45 A040P671, 22 A046X545, 21
815 0861, 42 A040P910, 12 A046X547, 21
815 0877, 24 A040P914, 17 A046X554, 21
815 0896 03, 47 A040P916, 9 A046X561, 21
815 0910, 52 , 53 , 54 A040P972, 14 A046X565, 21
815 0936, 45 , 46 A040R285, 9 A046X568, 19 , 21
821 2032, 37 A040R304, 13 A046X574, 14
821 2035, 35 , 36 A044B674, 9 A046X581, 14
821 2096 02, 37 A046W974, 9 A046X592, 40
821 2096 03, 29 , 30 , 35 , A046W994, 38 A046X600, 40
36 , 43 , 50
A046W997, 18 A053K355, 46
823 0003 02, 29 , 30 , 32 ,
41 A046X144, 18
A046X148, 18
823 0003 03, 42
823 0003 05, 47 , 50 A046X152, 25 , 27
823 1002 03, 32 , 42 A046X165, 26
823 1002 04, 32 , 47 A046X183, 13

A046X193, 13
850 0030, 54 , 55
850 2008, 41 , 45 A046X195, 13
850 2083, 16 A046X199, 13
856 0008, 50 A046X204, 13

A046X207, 13
862 0015, 50
865 0029, 32 A046X244, 12
868 0007, 29 , 30 A046X251, 12
870 0540 03, 32 A046X254, 12
870 0557, 45 A046X258, 11

power.cummins.com
Copyright 2019 Cummins Inc. All rights reserved.
Other company, product, or service names may be trademarks or service marks of others.
Specifications are subject to change without notice.
Operator Manual
RV Generator Set
HDKAH (Spec A−M)

HDKAJ (Spec A−M)
HDKAK (Spec A−M)
HDKAT (Spec A−M)
HDKAU (Spec A−M)
HDKAV (Spec A−M)
English − Original Instructions 5−2010 981−0161 (Issue 7)

California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
diesel warnings
Table of Contents
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Typical Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Starting Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operator’s Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Remote Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Conducting the Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Starting the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Stopping the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Restarting the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Loading the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Resetting Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connecting to Utility Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operating in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating in Hot Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating at High Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating in Dusty Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Breaking in a New Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exercising the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Storing the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Conducting General Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Changing Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maintaining the Battery and Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacing the Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cleaning the Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Changing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INFORMATION FOR CALIFORNIA GENSET USERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
HOW TO OBTAIN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
i
Safety Precautions
Thoroughly read the OPERATOR’S MANUAL • Do not operate the genset when the vehicle is
before operating the genset. Safe operation and in a confined space, such as a garage.
top performance can only be obtained when • Disable the automatic genset starting feature of
equipment is operated and maintained properly. an inverter-charger or other automatic starting
device before storing the vehicle or parking it in
The following symbols in this manual alert you to po- a garage or other confined space.
tential hazards to the operator, service person and
equipment. • The exhaust system must be installed in accor-
dance with the genset Installation Manual.
alerts you to an immediate hazard • Engine cooling air must not be used for heating
that will result in severe personal injury or working or living spaces or compartments.
death.
GENERATOR VOLTAGE IS DEADLY
WARNING alerts you to a hazard or unsafe • Disable the automatic genset starting fea-
practice that can result in severe personal injury ture(AGS) of an inverter−charger or other auto-
or death. matic starting device before servicing the gen-
set to avoid electric shock from an unexpected
CAUTION alerts you to a hazard or unsafe start.
practice that can result in personal injury or • Generator electrical output connections must
equipment damage. be made by a trained and experienced electri-
cian in accordance with applicable codes.
When equipped with an integral or add−on Auto−
matic Generator Starting System (AGS) control,ex- • The genset must not be connected to the public
haust carbon monoxide (CO), electric shock, and- utility or any other source of electrical power.
moving parts hazards are possible due to unex− Back-feed could lead to electrocution of utility
pected starting. Turn off AGS whenever performing- personnel and damage to equipment. An ap-
maintenance or service, when the vehicle is stored- proved switching device must be used to pre-
between uses, is awaiting service, or is parked in vent interconnections.
agarage or other confined area. • Use caution when working on live electrical
equipment. Remove jewelry, make sure cloth-
Electricity, fuel, exhaust, moving parts and batteries ing and shoes are dry, stand on a dry wooden
present hazards which can result in severe personal platform or rubber insulating mat and use tools
injury or death. with insulated handles.
ENGINE EXHAUST IS DEADLY DIESEL FUEL IS COMBUSTIBLE

• Inspect for exhaust leaks at every startup and • Do not smoke or turn electrical switches ON or
after every eight hours of running. OFF where fuel fumes are present or in areas
sharing ventilation with fuel tanks or equip-
• Learn the symptoms of carbon monoxide poi- ment. Keep flames, sparks, pilot lights, arc-pro-
soning in the Operator’s Manual. ducing equipment and all other sources of igni-
• Never sleep in the vehicle while the genset is tion well away.
running unless the vehicle is equipped with a • Fuel lines must be secured, free of leaks and
working carbon monoxide detector. separated or shielded from electrical wiring.
1
MOVING PARTS CAN CAUSE SEVERE • Let the engine cool down before removing the
PERSONAL INJURY OR DEATH coolant pressure cap or opening the coolant
drain. Hot coolant under pressure can spray
• Disable the automatic genset starting fea- out and cause severe burns.
ture(AGS) of an inverter−charger or other auto-
matic starting device before servicing the gen- • Keep the genset and its compartment clean.
set to avoid unexpected starting. Excess oil and oily rags can catch fire. Dirt and
• Do not wear loose clothing or jewelry near mov- gear stowed in the compartment can restrict
ing parts such as PTO shafts, fans, belts and cooling air.
pulleys. • Make sure all fasteners are secure and torqued
• Keep hands away from moving parts. properly.
• Do not work on the genset when mentally or
BATTERY GAS IS EXPLOSIVE
physically fatigued or after consuming alcohol
• Wear safety glasses. or drugs.
• Do not smoke. • You must be trained and experienced to make
• To reduce arcing when disconnecting or recon- adjustments while the genset is running—hot,
necting battery cables, always disconnect the moving or electrically live parts can cause se-
negative (−) battery cable first and reconnect it vere personal injury or death.
last.
• Used engine oil has been identified by some
FLAMMABLE VAPOR CAN CAUSE A U. S. state and federal agencies as causing
cancer or reproductive toxicity. Do not ingest,
DIESEL ENGINE TO OVERSPEED
inhale, or contact used oil or its vapors.
Flammable vapor can cause a diesel engine to • Ethylene glycol, used as engine antifreeze, is
overspeed and become difficult to stop, resulting in toxic to humans and animals. Clean up spills
possible fire, explosion, severe personal injury and and dispose of used engine coolant in accor-
death. Do not operate a diesel-powered genset dance with local environmental regulations.
where a flammable vapor environment can be
created by fuel spill, leak, etc. The owners and op- • Keep multi-class ABC fire extinguishers handy.
erators of the genset are solely responsible for oper- Class A fires involve ordinary combustible ma-
ating the genset safely. terials such as wood and cloth; Class B fires,
combustible and flammable liquid fuels and
GENERAL PRECAUTIONS gaseous fuels; Class C fires, live electrical
• Keep children away from the genset. equipment. (ref. NFPA No. 10)
• Do not use evaporative starting fluids. They are • Genset installation and operation must comply
highly explosive. with all applicable local, state and federal codes
and regulations.
• To prevent accidental or remote starting while
working on the genset, disconnect the nega- • Keep guards in place over fans, belts, pulleys,
tive (−) battery cable at the battery. and other moving parts.
Mobile-8
2
Introduction
ABOUT THIS MANUAL
This manual covers the operation and maintenance

80HDKAK11454J
of the generator set (genset) models on the front
F990 123456
cover. Study this manual carefully and observe all of
its instructions and precautions. Keep this manual
and the genset Installation Manual with the other ve-
hicle manuals.
Operation, Periodic Maintenance and Trouble- SKB719U6D2RA 719 cc

shooting provide the instructions necessary for op-
erating the genset and maintaining it at top perfor-
mance. The owner is responsible for performing
maintenance in accordance with the PERIODIC
MAINTENANCE SCHEDULE (Page 12). This
manual also includes genset specifications, infor-
mation on how to obtain service and information for
California users.
WARNING This genset is not a life support sys-

tem. It can stop without warning. Children, per-
sons with physical or mental limitations, and
pets could suffer personal injury or death. A per-
sonal attendant, redundant power or an alarm
system must be used if genset operation is criti-
cal.
MODEL IDENTIFICATION
RECORD NUMBERS HERE
When contacting an Onan dealer for parts, service MODEL NUMBER:
or product information, be ready to provide the mod-
el and serial numbers on the genset nameplate. Fig-
SERIAL NUMBER:
ure 1 illustrates the nameplate and its location. The
numbers in the gray boxes are typical model and se-
rial numbers. Every character in these numbers is
significant. (The last character of the model number
is the specification letter, which is important for ob-
FIGURE 1. TYPICAL NAMEPLATE
taining the right parts.) Record the model and serial
numbers in the boxes in Figure 1 so that they are
easy to find when you need them.
3
TYPICAL GENSET features of a typical genset are shown in Figure 2.
See the PERIODIC MAINTENANCE SCHEDULE
The operator’s console, the components requiring
(Page 12).
attention during periodic maintenance and other
AC TERMINAL LIFTING EYE

BOX COVER ACCESS COVER
OPERATOR’S
CONSOLE
ACCESS DOOR FOR OIL DRAIN FUEL

OIL AND FUEL FILTERS PLUG CONNECTIONS
COOLING BATTERY
AIR INLET CONNECTIONS
GRILLE
EXHAUST TAILPIPE
ACCESS TO COOLANT WARM AIR DISCHARGE FLANGE
AIR FILTER DRAIN CAP OPENING (NOT VISIBLE)
FIGURE 2. TYPICAL GENSET
4
FUEL RECOMMENDATIONS SAE (Society of Automotive Engineers) viscosity
grade. Referring to Chart 1, choose the viscosity
WARNING Diesel fuel is combustible and can grade appropriate for the outdoor ambient tempera-
cause severe personal injury or death. Do not tures expected until the next scheduled oil change.
smoke near diesel fuel tanks or equipment.
Keep flames, sparks, pilot lights, electrical arcs, STARTING BATTERIES
switches and arc-producing equipment and all
other sources of ignition well away. Keep a type These gensets have a 12 volt, direct current (DC)
ABC fire extinguisher in the vehicle. starting and control system. See Specifications
(Page 30) for minimum battery requirements (cold
Use clean, fresh No. 2 diesel fuel (ASTM 2-D) when cranking amperes) for genset starting.
the outdoor ambient temperature is above freezing,
and No. 1 diesel fuel (ASTM 1-D) when below freez- Regular, monthly maintenance of batteries may be
ing. The fuel should have a Cetane number of at required. See MAINTAINING THE BATTERY AND
least 45 for reliable starting. BATTERY CONNECTIONS (Page 16) and any in-
structions available from the vehicle manufacturer
ENGINE OIL RECOMMENDATIONS or battery manufacturer. Either the vehicle or the
genset will be equipped with a battery charger.
Use API (American Petroleum Institute) perfor-
mance Class CH-4, CG-4 or CF-4 engine oil, which Reliable genset starting and starter service life de-
may be in combination with performance Class SJ, pend upon adequate battery system capacity and
SH or SG (for example: CH-4/SJ). Also look for the proper maintenance.
CHART 1. OIL VISCOSITY VS. TEMPERATURE
Anticipated Ambient Temperature
5
OPERATOR’S CONSOLE REMOTE CONTROL PANEL
The operator’s console (Figure 3) has the following The vehicle may be equipped with a remote control
features: panel having a Control Switch and Preheat/Diag-
nostics Light. In addition, it may have an hour me-
Control Switch − This switch is used to start and ter and the following engine gauges:
stop the genset, prime the engine fuel system and
restore the fault code (blinking status light). Oil Pressure Gauge − The oil pressure gauge indi-
cates the presence of engine oil pressure.
Status Light − This is an LED (light emitting diode)
in the control switch which blinks rapidly during pre-
Water Temperature Gauge − The water tempera-
heat and cranking. (Preheat is the period of time
ture gauge indicates engine coolant temperature.
prior to engine cranking when the glow plugs pre-
heat the combustion chambers. The time is auto-
Voltmeter − The voltmeter indicates battery volt-
matically varied by the genset controller on the ba-
age.
sis of engine temperature.) After the genset starts
up, this light stays on continuously, indicating that
the genset is running and that the starter has dis-
connected. Also, if the genset shuts down, this light ACCESS COOLANT OIL FILL CAP
blinks in a coded fashion to indicate the nature of the PLATE RECOVERY TANK AND DIP STICK
shutdown (see Troubleshooting, Page 21). FILL CAP (BLUE) (YELLOW)
Line Circuit Breaker(s) − The line circuit break-

er(s) protect the AC power leads connected to the
genset.
Engine Oil Fill Cap/Dipstick − The oil dipstick is at-

tached to the fill cap and is marked ADD and FULL.
Coolant Recovery Tank Fill Cap − The recovery

tank provides for coolant expansion. Replenish the
normal loss of coolant by filling here.
Coolant Pressure Cap − The coolant pressure cap

is accessible by removing the access plate on the
control console. It provides for a pressurized engine
cooling system. Fill coolant here when refilling the
system.
Fuses F1, F2 and F3 − These fuses are accessible

by removing the access plate on the control con- CONTROL
sole. They protect the control circuits of the genset. SWITCH AND HOUR METER LINE CIRCUIT
STATUS LIGHT (OPTIONAL) BREAKER
Hour Meter (Optional)− The hour meter records
the total running time of the genset. It cannot be re-
set. FIGURE 3. OPERATOR’S CONSOLE
6
Operation
WARNING EXHAUST GAS IS DEADLY!

Exhaust gases contain carbon monoxide, an odorless, colorless gas. Carbon monoxide is poisonous
and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning include:
• Dizziness • Throbbing in Temples • Nausea
• Muscular Twitching • Headache • Vomiting
• Weakness and Sleepiness • Inability to Think Clearly
IF YOU OR ANYONE ELSE EXPERIENCES ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH
AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the genset and do not op-
erate it until it has been inspected and repaired.
Never sleep in the vehicle with the genset running unless the vehicle is equipped with a working car-
bon monoxide detector. Primary protection against poisoning due to inhaling carbon monoxide, how-
ever, consists of proper installation of the exhaust system and inspections every day (every eight
hours of operation) for visible and audible exhaust system leaks.
CONDUCTING THE PRE-START CHECKS 1. Push and hold the switch at START until the
genset starts. The status indicator light on the
Before the first start of the day and after every eight switch flashes during preheat and cranking. It
hours of operation, inspect the genset as instructed will come on solid when the starter disconnects,
under CONDUCTING GENERAL INSPECTIONS indicating that the genset is running. (Depend-
(Page 13). Keep a log of maintenance and the hours ing on how cold it is, preheat can take up to 15
run and perform any maintenance that may be due. seconds, extending the time that the light
See Returning the Genset to Service (Page 11) if blinks.)
the vehicle has been in storage.
CAUTION Excessive cranking can over-
Before each start: heat and damage the starter motor. Do not
crank for more than 20 seconds at a time.
1. Make sure all vehicle CO detectors are work- Wait at least 2 minutes before trying again.
ing.
2. See Troubleshooting (Page 21) if the genset
2. Check for signs of fuel and exhaust leaks and does not start after three tries.
for damage to the exhaust system.
3. For top performance and engine life, especially
3. Turn off the air conditioner and other large ap- in colder weather, let the engine warm up for
pliances. two minutes before connecting appliances.
PRIMING THE FUEL SYSTEM 4. Monitor the engine gauges if the remote panel
is so equipped. Normal readings during opera-
The fuel system should be primed after replacing tion are as follows:
the fuel filter or running the genset out of fuel. To Oil Pressure: Approximate center of scale
prime the fuel system hold the control switch down
in its Stop position for at least 1 minute. Temperature: 160°-220° F (71°-104° C)
DC Voltage: 14-15 volts.
STARTING THE GENSET
5. Check for fuel, exhaust and coolant leaks. Stop
Start the genset from the genset control panel or re- the genset immediately if there is a fuel, ex-
mote control panel inside the vehicle. haust or coolant leak and have it repaired.
7
STOPPING THE GENSET TABLE 1. TYPICAL APPLIANCE LOADS
Appliance Load (watts)
Turn off the air conditioner and other large ap-
Air Conditioner 1400-2000
pliances and let the genset run for two minutes to
cool down. Then press the switch to STOP to stop Battery Charger Up to 2000
the genset. DC Converter 300-1200
Refrigerator 600-1000
RESTARTING THE GENSET Microwave Oven 1000-1500
See Troubleshooting (Page 21) if the genset shuts Electric Frying Pan or Wok 1000-1500
down abnormally. Electric Stove Element 350-1000
Electric Water Heater 1000-1500
LOADING THE GENSET Electric Iron 500-1200
Electric Hair Dryer 800-1500
The genset can power AC motors, air conditioners,
AC/DC converters, battery chargers and other ap- Coffee Percolator 550-750
pliances. How much appliance load* can be pow- Television 200-600
ered depends upon the genset power rating. The Radio 50-200
genset will shut down or its circuit breakers will trip if Electric Drill 250-750
the sum of the loads exceeds genset power. (If the Electric Broom 200-500
genset shuts down, the status light will probably dis-
Electric Blanket 50-200
play Fault Code No. 11, 13, 22 or 38. See Trouble-
shooting, Page 21.)
To avoid overloading the genset and causing shut- TABLE 2. POWER VS. ALTITUDE
downs, compare the sum of the loads of the ap- Elevation
Max Genset Max Genset
pliances that are likely to be used at the same time to above Mean
Power* Power*
the power rating of the genset. Use Table 1 or the Sea Level
ratings on the appliances themselves (if so marked) up to 500 ft 7500 watts 8000 watts
to obtain the individual appliance loads. It may be (152 m) (rated) (rated)
necessary to run fewer appliances at the same 2500 ft
7050 watts 7520 watts
time—the sum of the loads must not be greater (762 m)
than genset rating. 5500 ft
6375watts 6800watts
(1676 m)
The genset may shut down due to overload when a 6375watts minus 6800watts minus
large motor or air conditioner is started or cycles off above
225 watts ev- 240 watts ev-
5500 ft
and then on again, even though the sum of the loads (1676 m)
ery1000 ft ery1000 ft
is less than genset rating. The reason for this is that (305 m) (305 m)
a motor’s startup load is much larger than its running * This table does not take into account the effect cir-
load. It may be necessary to run fewer ap- cuit breakers may have in limiting maximum power.
pliances when large motors and air condition-
ers are cycling on and off.
Commercial Genset Applications
Maximum power decreases as altitude increases
because air density decreases. For every 1000-foot Maximum genset power (nameplate rating) is
(305 m) increase in elevation you can expect power 7500 watts in an ambient of 85° F (29° C), but only
to decrease approximately 3 percent. Table 2 6000 watts in an ambient of 120° F (50° C)—the
shows the results of typical calculations. It may be maximum operating temperature. Also, continuous
necessary to run fewer appliances at higher alti- operation at up to 80 percent of maximum power
tudes. (6000 watts) is acceptable.
* Appliance load and genset power are measured in terms of watts (W) or kilowatts (kW), where 1 kilowatt (kW) = 1000 watts (W).
8
RESETTING CIRCUIT BREAKERS
If a circuit breaker in the main power distribution
panel of the vehicle or on the genset (Figure 4) trips,
either a circuit shorted or too many appliances were
running. Note that the genset will continue to run af-
ter a circuit breaker trips.
If a circuit breaker trips, disconnect or turn off as
many loads as possible and reset the circuit break-
er. (Push the circuit breaker to OFF to reset it and
then to ON to reconnect the circuit.) If the circuit
breaker trips right away, either the electrical dis-
tribution system has a short or the circuit breaker is
faulty. Call a qualified electrician.
If the circuit breaker does not trip, reconnect the ap-
pliances, one by one, up to a total load that does not
overload the genset or cause the circuit breaker to
trip. If a circuit breaker trips right away when an ap-
pliance is connected, the appliance probably has a LINE CIRCUIT
BREAKER
short.
Electrical appliances and tools must be used and FIGURE 4. LINE CIRCUIT BREAKER
maintained properly and be properly grounded to
cause the line circuit breakers to trip when short cir-
cuits occur.
WARNING Short circuits in electrical ap-
pliances and tools can cause fire and electrical
shock leading to severe personal injury or
death. Read and follow the equipment and tool
manufacturer’s instructions and warnings re-
garding use, maintenance and proper ground-
ing.
CONNECTING TO UTILITY POWER
When the vehicle has provisions for connecting to
utility power, such as a cord for plugging into a pow-
er outlet receptacle, it must also have an approved
device to keep the genset and utility from being in-
terconnected. See the genset Installation Manual
for more information.
WARNING Interconnecting the genset and the
public utility (or any other power source) can
lead to the electrocution of personnel working
on the utility lines, damage to equipment and
fire. An approved switching device must be
used to prevent interconnections.
9
OPERATING IN COLD WEATHER 3. Change engine oil more often. See PERIODIC
MAINTENANCE SCHEDULE (Page 12).
Make sure the engine oil viscosity is appropriate for
4. Keep containers of engine oil that have been
the cold weather temperatures. See ENGINE OIL
opened tightly closed to keep out dust.
RECOMMENDATIONS (Page 5). Be sure to
change the oil if a sudden drop in temperature oc- BREAKING IN A NEW ENGINE
curs.
Proper engine break-in on a new genset or on one
OPERATING IN HOT WEATHER with a rebuilt engine is essential for top engine per-
formance and acceptable oil consumption. Run the
Pay particular attention to the following items when genset at approximately 1/2 rated power for the first
operating the genset in hot weather: 2 hours and then at 3/4 rated power for 2 more
1. Make sure nothing blocks airflow to and from hours. See LOADING THE GENSET (Page 8).
the genset.
Proper engine oil and oil level are especially critical
2. Make sure engine oil viscosity is appropriate for during break-in because of the higher engine tem-
the ambient temperatures. See ENGINE OIL
peratures that can be expected. Change the oil if not
RECOMMENDATIONS (Page 5).
appropriate for the ambient temperatures during
3. Keep the genset clean. break-in. See ENGINE OIL RECOMMENDATIONS
4. Perform maintenance due. See PERIODIC (Page 5). Check oil level twice a day or every
MAINTENANCE SCHEDULE (Page 12). 4 hours during the first 24 hours of operation and
change the oil and oil filter after the first 50 hours of
OPERATING AT HIGH ALTITUDE operation.
For the effect of altitude on maximum power, see EXERCISING THE GENSET
LOADING THE GENSET (Page 8).
Exercise the genset at least 2 hours each month if
OPERATING IN DUSTY ENVIRONMENTS use is infrequent. Run the genset at approximately
1/2 rated power. See LOADING THE GENSET
Pay particular attention to the following items when (Page 8). A single two hour exercise period is bet-
operating the genset in dusty environments: ter than several shorter periods.
1. Do not let dirt and debris accumulate inside the Exercising a genset drives off moisture, re-lubri-
genset compartment. Keep the genset clean. cates the engine, replaces stale fuel and removes
2. Perform air cleaner maintenance more often. oxides from electrical contacts. The result is better
See PERIODIC MAINTENANCE SCHEDULE starting, more reliable operation and longer engine
(Page 12). life.
10
STORING THE GENSET 5. Close the fuel supply valve (if so equipped).
Proper storage is essential for preserving top gen- Returning the Genset to Service
set performance and reliability when the genset
1. Check the oil tag on the genset and change the
cannot be exercised regularly and will be idle for
oil if the viscosity indicated is not appropriate for
more than 120 days.
the temperatures expected. See ENGINE OIL
Storing the Genset RECOMMENDATIONS (Page 5).
1. Push the genset line circuit breaker OFF 2. Reconnect the starting battery (negative [−]
(Page 9). cable last). See MAINTAINING THE BATTERY
AND BATTERY CONNECTIONS (Page 16).
2. Change the engine oil and attach a tag indicat-
ing oil viscosity. See ENGINE OIL REC- 3. Remove the plug from the exhaust tailpipe.
OMMENDATIONS (Page 5). 4. Change the air filter element if it is dirty
3. Disconnect the battery cables (negative [−] (Page 16).
cable first) from the starting battery and store 5. Open the fuel supply valve (if so equipped).
the battery according to the battery manufac-
turer’s recommendations. See MAINTAINING 6. Inspect the genset. See CONDUCTING GEN-
THE BATTERY AND BATTERY CONNEC- ERAL INSPECTIONS (Page 13).
TIONS (Page 16). 7. Push the genset line circuit breaker ON
4. Plug the exhaust tail pipe to keep out dirt, mois- (Page 9) when the genset is ready to power
ture, bugs, etc. appliances.
11
Periodic Maintenance
Periodic maintenance is essential for top perfor- help you keep genset maintenance regular and pro-
mance and long genset life. Use Table 3 as a guide vide a basis for supporting warranty claims.
for normal periodic maintenance. In hot and dusty Maintenance, replacement or repair of emission
environments some maintenance procedures control devices and systems may be performed by
should be performed more frequently, as indicated any engine repair establishment or individual. How-
by the footnotes in the table. Keeping a log of main- ever, warranty work must be completed by an au-
tenance performed and hours run (Page 34) will thorized Onan dealer.
TABLE 3. PERIODIC MAINTENANCE SCHEDULE

MAINTENANCE FREQUENCY
P
MAINTENANCE PROCEDURE Every Every Every
Every After First Every a
150 500 1000
Day 50 Hours Month g
Hours Hours Hours
e
General Inspection X 13
Check Engine Oil Level X 14
Check Engine Coolant Level X 19
Clean and Check Battery X3 16
Change Engine Oil and Filter X1 X2, 3, 4 15
Clean Spark Arrestor X4 17
Replace Engine Air Filter X2, 4 16
Replace Fuel Filter X 18
Check Coolant Anti-freeze Protection X 19
Flush Coolant System X5 19
Replace Coolant Pressure Cap X5 19
Replace Engine V-belt X6,7 −
Clean Crankcase Breather X6,7 −
Replace Coolant Hoses and Thermostat X6, 7 −
1 − As a part of engine break-in, change the engine oil after the first 50 hours of operation.
2 − Perform more often when operating in dusty conditions.
3 − Perform more often when operating in hot weather.
4 − Perform at least once a year.
5 − Perform at least once every two years.
6 − Perform at least once every five years.
7 − Must be performed by a qualified mechanic (authorized Onan dealer).
12
CONDUCTING GENERAL INSPECTIONS Do not operate power ventilators or exhaust fans
while the vehicle is standing with the genset run-
Inspect the genset before the first start of the day ning. The ventilator or fan can draw exhaust gases
and after every eight hours of operation. into the vehicle.
Oil Level Fuel System
Check engine oil level (Page 14). Check for leaks at hose, tube and pipe fittings in the
fuel supply system while the genset is running and
Engine Coolant System
while it is stopped. Check flexible fuel hose sections
CAUTION Operating the genset when coolant for cuts, cracks, and abrasions. Make sure the fuel
level is low can cause serious engine damage. line is not rubbing against other parts. Replace worn
or damaged fuel line parts before leaks occur.
Check the coolant level and look for coolant leaks
around the bottom of the genset and on the ground WARNING Diesel fuel leaks can lead to fire. Do
below. Minor leaks that can be replenished by daily not operate the genset if operation causes fuel
additions of coolant to the recovery tank should be to leak.
repaired by a qualified service technician as soon as
possible. Larger leaks are cause for shutting down Battery Connections
the genset until it can be repaired.
Check the battery terminals for clean, tight connec-
Exhaust System tions. Loose or corroded connections have high
electrical resistance which makes starting harder.
WARNING EXHAUST GAS IS DEADLY! Do not See MAINTAINING THE BATTERY AND BATTERY
operate the genset if there is an exhaust leak or
CONNECTIONS (Page 16).
any danger of exhaust gases entering or being
drawn into the vehicle. WARNING Arcing at battery terminals or in
Look and listen for exhaust system leaks while the light switches or other equipment, and flames or
genset is running. Shut down the genset if a leak is sparks, can ignite battery gas causing severe
found and have it repaired before operating the gen- personal injury.
set again.
Ventilate battery area before working on or near
Look for openings or holes between the genset battery—Wear safety glasses—Do not smoke—
compartment and vehicle cab or living space if the Switch trouble light ON or OFF away from bat-
genset engine sounds louder than usual. Have all tery—Stop genset and disconnect charger be-
such openings or holes closed off or sealed to pre- fore disconnecting battery cables—Disconnect
vent exhaust gases from entering the vehicle. negative (−) cable first and reconnect last.
Replace dented, bent or severely rusted sections of Mechanical

the tailpipe and make sure the tailpipe extends at
least 1 inch (25.4 mm) beyond the perimeter of the Look for mechanical damage. Start the genset and
vehicle. look and listen for any unusual noises and vibra-
tions.
WARNING Do not park the vehicle in high grass
or brush. Contact with the exhaust system can Check the genset mounting bolts to make sure they
cause a fire. are secure.
Park the vehicle so that the genset exhaust gases Check to see that the genset air inlet and outlet
can disperse away from the vehicle. Barriers such openings are not clogged with debris or blocked.
as walls, snow banks, high grass and brush and oth-
er vehicles can cause exhaust gases to accumulate Check the engine gauges from time to time while the
in and around the vehicle. genset is running (if so equipped).
13
CHECKING ENGINE OIL LEVEL
WARNING State and federal agencies have de-

termined that contact with used engine oil can
cause cancer or reproductive toxicity. Try to
avoid skin contact and breathing of vapors. Use
rubber gloves and wash exposed skin.
Park the vehicle on level ground and shut off the

genset before checking the engine oil level.
1. Unscrew the oil fill cap, pull out the dipstick and
wipe off the oil (Figure 5). Reinsert the dipstick,
screw the cap back on, remove the dipstick
again and check the oil level on the dip stick.
2. Add or drain oil as necessary. See ENGINE OIL

RECOMMENDATIONS (Page 5). Keep the
oil level between the FULL and ADD marks.
CAUTION Too much oil can cause high oil

consumption. Too little oil can cause severe
engine damage. Keep the oil level between
the FULL and ADD marks.
3. Reinsert the dipstick and screw the oil fill cap

back on securely. FIGURE 5. CHECKING ENGINE OIL LEVEL
14
CHANGING ENGINE OIL AND OIL FILTER old gasket if it does not come off with the filter
canister.
WARNING State and federal agencies have de- 6. Make sure the new gasket is in place on the
termined that contact with used engine oil can new filter canister and apply a thin film of oil to
cause cancer or reproductive toxicity. Avoid the gasket. (The replacement filter canister has
skin contact and breathing of vapors. Use rub- a larger diameter than the original filter cannis-
ber gloves and wash exposed skin. ter, but will fit.)
7. Spin on the new filter canister by hand until the
Refer to Table 3 for scheduled engine oil change. gasket just touches the mounting pad and then
Change oil more often in hot and dusty environ- turn it an additional 1/2 to 3/4 turn. Do not over-
ments. tighten. Close the access door, making sure it
latches securely.
1. Run the engine until warm, stop it and remove
the oil fill cap and dipstick (Figure 5). 8. Refill with 3 quarts (2.6 l) of oil. See ENGINE
OIL RECOMMENDATIONS (Page 5). Check
2. Place a pan underneath the genset and un- the oil level and add or drain oil as necessary.
screw the oil drain plug (Figure 6). Let all oil
drain from the engine. CAUTION Too much oil can cause high oil
consumption. Too little oil can cause severe
3. Reinstall the oil drain plug and tighten it secure- engine damage. Keep the oil level between
ly to prevent oil leakage. the FULL and ADD marks.
4. Squeeze the access door latches together and 9. Reinsert the dipstick and screw the oil fill cap
let the door swing down (Figure 6). back on securely.
5. Spin off the oil filter canister. Thoroughly wipe 10. Dispose of the used oil and oil filter in accor-
off the filter mounting surface and remove the dance with local environmental regulations.
ACCESS DOOR OIL FILTER
OIL DRAIN PLUG
FIGURE 6. OIL DRAIN PLUG AND OIL FILTER
15
MAINTAINING THE BATTERY AND 2. Remove battery cables with a battery terminal
BATTERY CONNECTIONS puller.
3. Make sure which terminal is positive (+) and
WARNING Arcing at battery terminals or in
which is negative (−) before making battery
light switches or other equipment, and flames or
connections, always removing the negative (−)
sparks, can ignite battery gas causing severe
cable first and reconnecting it last to reduce
personal injury.
arcing.
Ventilate battery area before working on or near
battery—Wear safety glasses—Do not smoke— REPLACING THE AIR FILTER ELEMENT
Switch trouble light ON or OFF away from bat-
tery—Stop genset and disconnect charger be- Refer to Table 3 for scheduled air filter element re-
fore disconnecting battery cables—Disconnect placement. In dusty environments the filter element
negative (−) cable first and reconnect last. should be inspected and changed more frequently.
To change the filter element (Figure 7), remove the
Refer to Table 3 for scheduled battery maintenance, outer and inner cover and reassemble with a new air
and follow the battery manufacturer’s instructions. filter element. Turn the inner cover wingnut three to
Have the battery charging system serviced if DC four clicks past seating. Make sure the outer cover is
system voltage is consistently low or high. Always: seated before tightening its wingnut. Check for
1. Keep the battery case and terminals clean and noise when the genset is running, and retighten
dry and the terminals tight. if necessary.
OUTER COVER INNER COVER FILTER ELEMENT SPACER SEAL HOUSING
FIGURE 7. REPLACING THE AIR FILTER ELEMENT
16
CLEANING THE SPARK ARRESTOR fler, accessible through the air outlet opening in the
bottom of the genset. Clean out the spark arrestor
Refer to Table 3 for scheduled cleaning of the spark muffler as follows:
arrestor muffler (which meets U.S. Forest Service
requirements). Cleaning is required for maximum 1. Remove the cleanout plug from the muffler
genset performance. (Figure 8).
2. Restart the genset and load it nearly to full pow-
WARNING A hot muffler can cause severe er. See LOADING THE GENSET (Page 8).
burns. Let the muffler cool down before remov- Let the genset run for about five minutes to ex-
ing or installing the cleanout plug. pel the soot in the muffler.
The muffler is mounted inside the genset housing. 3. Stop the genset, allow the muffler to cool down
The cleanout plug is located on the side of the muf- and then reinstall the plug.
CLEANOUT PLUG
FIGURE 8. SPARK ARRESTOR CLEANOUT PLUG
17
REPLACING THE FUEL FILTER Removing the Fuel Filter: To remove the filter, dis-
connect the two fittings at the filter and remove the
mounting nut. Apply a wrench on the filter fitting as
Refer to Table 3 for scheduled replacement of the
well as on the flare nut so as not to stress the fitting.
fuel filter (Figure 9). A dirty fuel filter may be the
Flare nut wrenches should be used on the flare nuts
cause if the engine fails to start. The fuel filter is ac-
so as not to round the corners on the nuts. Dispose
cessible through the maintenance access door in
of the fuel filter according to local regulations.
the skid-base. Squeeze the latches together to
open the door. Installing the Fuel Filter: Rotate the filter half a
turn around its mounting stud if the fittings interfere
CAUTION Wipe dirt off the fuel hose connec- with the bracket. It only fits properly one way.
tions at the fuel filter before disconnecting the
hoses so as to keep dirt out of the fuel system. Connect the fuel fittings before tightening the filter
mounting nut. Take care not to crossthread the fuel
fittings. Thread them in by hand and tighten one flat
WARNING Diesel fuel is combustible and can past seating.
cause severe personal injury or death. Do not
smoke. Keep flames, sparks, pilot lights, electri- Close the access door and prime the fuel system by
cal arcs, switches and arc-producing equip- holding the control switch down in its Stop position
ment and all other sources of ignition well away. for at least 1 minute. Priming is necessary to dis-
Keep a type ABC fire extinguisher handy. place the air in the new filter with fuel.
FUEL FUEL HOSE

FILTER TO ENGINE
FILTER
MOUNTING
NUT
TUBING FROM
FUEL PUMP
FIGURE 9. FUEL FILTER
18
CHANGING COOLANT down and turning it until it can be withdrawn. Then
get a suitable container and drain the coolant by re-
Refer to Table 3 for scheduled maintenance. The moving the system drain cap (Figure 10).
engine cooling system is filled with a 50/50 mixture
of ethylene glycol anti-freeze and water when the WARNING Ethylene glycol antifreeze is con-
genset leaves the factory, which is suitable for tem- sidered toxic. Dispose of it according to local
peratures down to -34° F (-37° C). regulations for hazardous substances.
Replace the coolant every two years. Use ethylene It is recommended that the system be cleaned and
or propylene glycol anti-freeze solution that con- flushed before refilling. Radiator cleaning chemicals
tains a rust and corrosion inhibitor. The anti-freeze are available at local auto parts stores. Follow the
should not contain a stop-leak additive. instructions for cleaning and flushing that come with
the cleaning solution.
The water used for engine coolant should be clean,
low in minerals, and free of corrosive chemicals. Refilling the Cooling System
Use distilled water if available. The cooling system
Fill the recovery tank with coolant mixture to the
has a 4.2 quart (4 l) capacity.
COLD mark.
Pressure Cap Secure the system drain cap. Fill the cooling system
Replace the pressure cap (Figure 10) every two with coolant mixture through the pressure cap/fill
years because its seals can deteriorate and begin to opening. Pull the hose connected to the pressure
leak. Proper cooling system pressure is essential cap assembly out as far as it will go. When coolant
for optimal engine cooling and minimal coolant loss. fills up to the fill opening, start and operate the gen-
set for a few minutes and shut it down. (It is recom-
Draining the Cooling System mended that the air conditioners or other large loads
be turned on so that the genset will operate under
WARNING Hot coolant spray can cause severe
load, causing the engine to run faster and expel
burns. Let the engine cool before releasing the
trapped air.) Add more coolant if necessary and se-
pressure cap or removing the drain cap.
cure the pressure cap.
Allow the engine to cool before removing the pres-
Coolant Level Check
sure cap. Then relieve any remaining pressure by
turning the pressure cap slowly, without pushing Check coolant level in the recovery tank (Figure 10)
down on it, until it catches. When the pressure has before the first startup of each day and fill to the
been relieved, remove the pressure cap by pushing COLD mark if necessary.
19
PRESSURE CAP AND
SYSTEM FILL OPENING
COOLANT RECOVERY
TANK FILL CAP (BLUE)
COOLING SYSTEM
DRAIN CAP
FIGURE 10. ENGINE COOLING SYSTEM FILL AND DRAIN CAPS
20
Troubleshooting
WARNING Hot engine parts can cause severe • Two blinks indicates shutdown due to a loss of
burns. Always allow the engine time to cool be- engine oil pressure
fore performing any maintenance or service.
• Three blinks indicates shutdown due to some
TABLE 4. TROUBLESHOOTING lists the Fault other abnormal condition.
Codes in numerical order along with step-by-step
Second-Level Fault Codes: For a 1-blink or 3-blink
instructions for corrective action. If you fail to re-
first-level fault code, one touch to Stop brings up a
solve the problem after taking the corrective actions
second-level fault code. This code consists of 1, 2, 3
suggested, contact an authorized Onan dealer. See
or 4 blinks, a brief pause, and then 1 to 9 blinks. The
How to Obtain Service (Page 33).
first set of blinks represents the tens digit and the
First note the following: second set of blinks the units digit of the fault code
number. For example, Fault Code No. 23 would ap-
• Maintaining engine oil level, keeping battery pear as:
connections clean and tight, watching the fuel
gauge, not overloading the genset, etc. will blink-blink—pause—blink-blink-blink—...
prevent most shutdowns.
NOTE: Fault Code Nos. 1, 2 and 3 are first-level faults.
• When the genset and vehicle engine share a Avoid interpreting them as second-level Fault Codes
common fuel tank the fuel dip tubes are usual- 11, 22 and 33. The pauses between repetitions of the
ly arranged so that the genset will run out of fault code are longer than the pauses between the
fuel first. Marking the genset empty point on tens and units digits of the the code. For example,
the fuel gauge will make it easier to tell when Fault Code 33 would appear as:
to stop the genset before running it out of fuel.
blink-blink-blink—pause—blink-blink-blink
First-Level Fault Codes: The genset controller —longer pause—
provides extensive diagnostics by causing the sta- blink-blink-blink—pause—blink-blink-blink—...
tus indicator light on the Control Switch to blink in a
Restoring Fault Code Blinking: The fault code
coded fashion. Following a fault shutdown, the indi-
stops blinking after five minutes. Press Stop three
cator light will repeatedly blink 1, 2 or 3 blinks at a
times within five seconds to restore blinking. Note
time.
that the last fault logged will blink, even after the
• One blink indicates shut down due to high tem- condition that caused the shutdown has been cor-
perature rected.
21
TABLE 4. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and
machinery hazards should perform genset service. See Safety Precautions.
GENSET WON’T STOP RUNNING—STATUS INDICATOR LIGHT ON

(Faulty Stop Switch or grounded wiring)
WARNING Removing genset panels or disconnecting fuel lines to stop a genset that won’t stop
can lead to severe personal injury or death from electrocution, contact with moving parts or fire.
Try the genset Stop Switch if the remote Stop Switch does not work, and vice versa. Otherwise, let
the genset run out of fuel.
GENSET WON’T STOP RUNNING—STATUS INDICATOR LIGHT OFF

(Binding governor mechanism, misadjusted speed stop)
WARNING Removing genset panels or disconnecting fuel lines to stop a genset that won’t stop
can lead to severe personal injury or death from electrocution, contact with moving parts or fire.
Let the genset run out of fuel.
STATUS INDICATOR LIGHT STAYS ON

(Reversed battery connections)
Corrective Action: Reconnect the battery correctly (Page 16).
ENGINE CRANKS WHEN BATTERY CONNECTED

(Faulty Start Switch or grounded wiring)
Corrective Action: See an authorized Onan dealer.
ENGINE WON’T CRANK—FUEL PUMP WON’T STOP

(Faulty Stop Switch or grounded wiring)
STATUS INDICATOR LIGHT DEAD

(Faulty connections, no battery voltage)
Corrective Action:
1. Try the genset Start Switch if the remote Start Switch does not work, and vice versa.
2. Replace Fuse F1 (B+) if blown (Page 6).
3. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery, vehicle
frame and genset (Page 16).
4. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
22
TABLE 4. TROUBLESHOOTING (CONT.)
STARTING BATTERIES RUN DOWN

(Marginal battery, battery connections, or charging system; or parasitic loads)
Corrective Action:
ENGINE CRANKS BUT DOES NOT START

(Fuel delivery, glow plugs or engine are marginal)
Corrective Action:
1. Check fuel level. (Note: The genset fuel pickup is probably higher than the vehicle engine pickup.)
2. Prime the engine fuel system by holding the control switch down in its Stop position for at least 1 min-
ute.
3. Check the engine air filter and remove any blockage (Page 16).
4. Replace Fuse F3 (glow plugs) if blown (Page 6).
STARTER ENGAGES-DISENGAGES
(Cranking voltage dips below 6 volts—low battery charge, poor connections, long cables)
Corrective Action:
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.
4. Increase battery cable size or run parallel cables.
NO POWER—GENSET RUNNING, RUN LIGHT ON

(Line circuit breaker OFF or tripped or faulty wiring)
Corrective Action: Reset or turn “On” the line circuit breaker on the genset operator’s console.
GENSET HUNTS UNDER FULL LOAD

(Fuel delivery marginal, governor misadjusted)
Corrective Action: Prime the engine fuel system by holding the control switch down in its Stop posi-
tion for at least 1 minute.
23
HIGH TEMPERATURE—FAULT CODE NO. 1

(Engine coolant or inverter heat sink temperature exceeded design limit)
Corrective Action: Check the second-level fault code by touching Stop. The second-level fault will be
either No. 33 or No. 34.
LOW OIL PRESSURE—FAULT CODE NO. 2

(Low oil pressure cutoff switch did not open)
Corrective Action:
1. Check engine oil level and add oil as necessary (Page 14).
2. Drain excess oil (above dipstick Full mark).
SERVICE CHECK FAULT—CODE NO. 3

(A second-level fault occurred)
Corrective Action: Check the second-level fault code by touching Stop. The second-level fault will be
one of the following in this table.
OVERLOAD—CODE NO. 8
(Models HDKAH & HDKAV only: Load exceeded110 percent of genset rating for 2 minutes)
Corrective Action: Reduce load and restart
OVERCURRENT FAULT—CODE NO. 11

(AC output short)
Corrective Action:
1. Turn off the genset line circuit breaker. If the genset no longer shuts down, the genset is probably
okay—check for and repair a short circuit in the vehicle appliances, wiring or shorted battery charger
transformer.
2. Check whether the vehicle engine and genset share the same starting battery. If so, and this fault
occurs when cranking the vehicle engine, low battery voltage may be causing this shutdown. In-
crease battery capacity or install a separate battery and battery charging system for the genset.
24
INVERTER OVERVOLTAGE FAULT—CODE NO. 12

(Controller not able to regulate to rated voltage)
Corrective Action: Check whether the vehicle engine and genset share the same starting battery. If
so, and this fault occurs when cranking the vehicle engine, low battery voltage may be causing this
shutdown. Increase battery capacity or install a separate battery and battery charging system for the
genset.
INVERTER UNDERVOLTAGE FAULT—CODE NO. 13

(Controller not able to regulate to rated voltage)
Corrective Action: Check whether the vehicle engine and genset share the same starting battery. If
so, and this fault occurs when cranking the vehicle engine, low battery voltage may be causing this
shutdown. Increase battery capacity or install a separate battery and battery charging system for the
genset.
INVERTER OVERFREQUENCY FAULT—CODE NO. 14

(Controller not able to regulate to rated frequency)
Corrective Action: Reduce the number of connected appliances, especially when air conditioners and
battery chargers are running.
INVERTER UNDERFREQUENCY FAULT—CODE NO. 15

(Controller not able to regulate to rated frequency)
Corrective Action:
1. Reduce the number of connected appliances, especially when air conditioners and battery chargers
are running.
2. Have air conditioners and other appliances checked for proper operation. (A locked compressor ro-
tor can cause very low power factor.)
GOVERNOR ACTUATOR FAULT—CODE NO. 19

(Controller sensed open or short circuit)
GOVERNOR ACTUATOR OVERLOAD FAULT—CODE NO. 22

(Duration of operation at or near full-duty cycle beyond design limit)
Corrective Action: Reduce the number of connected appliances, especially when air conditioners and
battery chargers are running.
25
LOW OIL PRESSURE CUTOFF SWITCH FAULT—CODE NO. 23

(Controller sensed switch still open during start—not a running fault)
COOLANT TEMPERATURE SENDER FAULT—CODE NO. 24

(Controller did not sense temperature change during first 5 minutes of operation)
ENGINE ABOVE SPEED TARGET FAULT—CODE NO. 25

(Governor unable to regulate to target speed)
ENGINE BELOW SPEED TARGET FAULT—CODE NO. 26

(Governor unable to regulate to target speed)
Corrective Action:
1. Reduce the number of connected appliances, especially when air conditioners and battery chargers
are running.
ute.
PMA SENSE LOST FAULT—CODE NO. 27

(Controller unable to sense PMA frequency)
DC SENSE LOST FAULT—CODE NO. 28

(Controller unable to sense DC bus voltage)
Corrective Action: Open the circuit breaker. If the fault does not persist, check for and disconnect ex-
cessive loads from the genset before starting.
26
HIGH BATTERY VOLTAGE FAULT—CODE NO. 29

(Voltage across battery system greater than 17.5 volts)
Corrective Action:
1. 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).
2. Select a lower battery booster charge rate.
OVERSPEED FAULT—CODE NO. 31

(Engine speed greater than 3600 rpm)
LOW CRANKING SPEED FAULT—CODE NO. 32

(Cranking speed less than 180 rpm for more than 2 seconds)
Corrective Action:
1. Replace Fuse F2 (starter solenoid) if blown (Page 6).
2. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery and at
the genset (Page 16).
4. Replace the engine oil with oil of proper viscosity for the ambient temperature (Page 15). (High oil
viscosity can slow cranking speed.)
HIGH ENGINE COOLANT TEMPERATURE FAULT—CODE NO. 33

(Engine coolant temperature exceeded design limit)
Corrective Action:
1. Check the engine coolant level and add coolant and repair leaks as necessary (Page 19).
2. Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset.
3. Reduce the number of appliances connected at the same time. (Note that high altitude and high am-
bient temperature decrease engine cooling capacity.)
4. Clean and flush the cooling system to remove coolant passage fouling.
5. If the genset overheats only underway, see the coach manufacture regarding air baffles or other
means to direct cooling air into the genset.
27
HIGH INVERTER TEMPERATURE FAULT—CODE NO. 34

(Inverter heat sink temperature exceeded design limit*)
Corrective Action:
1. Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset.
2. Reduce the number of appliances connected at the same time. (Note that high altitude and high am-
bient temperature decrease cooling capacity.)
CONTROL CARD FAILURE FAULT—CODE NO. 35

(Microprocessor EEPROM error during self-test)
ENGINE STOPPED FAULT—CODE NO. 36

(Engine stopped without command by controller)
Corrective Action:
1. Check fuel level. (Note: The genset fuel pickup is probably higher than the vehicle engine pickup.)
ute.
3. Check the engine air filter and remove any blockage (Page 16).
4. Check for mechanical damage.
INVALID GENSET CONFIGURATION FAULT—CODE NO. 37

(Genset configuration is preprogrammed at the factory)
OVERCURRENT FAULT—CODE NO. 38

(Too many loads connected)
Corrective Action: Reduce the number of appliances running at the same time, especially those with
high motor starting loads such as air conditioners. Start up with no load and let the genset run for five
minutes to cool down the inverter.
PROCESSOR FAULT—CODE NO. 42

(Microprocessor ROM error during self-test)
28
PROCESSOR FAULT—CODE NO. 43

((Microprocessor RAM error during self-test)
INVERTER POWER SUPPLY FAULT—CODE NO. 46

(Low battery voltage or power supply device failure)
Corrective Action:
1. Avoid running the genset while cranking the vehicle engine in installations where the genset batteries
are used to supplement the vehicle engine batteries.
4. Install or service a battery charging system in the vehicle if the genset is not so equipped.
29
Specifications
HDKAH HDKAJ HDKAK
GENSET CONTROLLER: Integrated Microprocessor Based Engine and Generator Controller
GENERATOR: Brushless, Exciterless, Bearingless, Permanent Magnet Alternator
AC OUTPUT RATINGS:
Power (@1.0 power factor) 6000 W 7500 W 8000 W
Voltage 120 volts 120 volts 120 volts
Frequency 60 Hz 60 Hz 60 Hz
Number of Phases 1 1 1
Current 50.0 ampere 62.5 ampere 66.7 ampere
Line Circuit Breaker(s) 2-pole, 30 amp 2-pole, 30 or 35 amp 2-pole, 30 or 35 amp
ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection, 4-Stroke Cycle Diesel
Bore 2.64 inch (67 mm)
Stroke 2.68 inch (68 mm)
Displacement 44 inch3 (719 cc)
Compression Ratio 23 : 1
Oil Capacity (with filter)* 3 quart (2.6 l)
Cooling System Capacity** 4.2 quart (4 l)
Intake and Exhaust Valve Lash (Cold) 0.0065 inch (0.165 mm)
OPERATING SPEED RANGE: 1600 to 2900 RPM 1600 to 3200 RPM 1600 to 3300 RPM
FUEL CONSUMPTION:
No-load .13 gph (.49 l/h) .13 gph (.49 l/h) .13 gph (.49 l/h)
Half-load (4000 W) .49 gph (1.85 l/h) .49 gph (1.85 l/h) .49 gph (1.85 l/h)
Full-load .80 gph (3.03 l/h) .96 gph (3.63 l/h) 1.02 gph (3.86 l/h)
DC SYSTEM:
Nominal Battery Voltage 12 volts
450 CCA*** down to 0° F (−17° C)
Minimum Battery Capacity
650 CCA*** down to −20° F (−29° C)
Maximum Regulated-Voltage Battery
Charging Current (Optional)
10 ampere
Fuse F1 (control circuit) 10 ampere mini-bayonet
Fuse F2 (starter solenoid circuit) 10 ampere mini-bayonet
Fuse F3 (glow plug circuit) 25 ampere
WEIGHT AND SIZE:
Weight (wet) 420 lbs (191 kg)
Length x Width x Height 36.3 x 23.6 x 22.3 inch (922 x 599 x 566 mm)
* See oil filling instructions.
** Includes coolant recovery tank.
*** Cold Cranking Amps @ 0° F (−17° C)
30
HDKAV HDKAT HDKAU
GENSET CONTROLLER: Integrated Microprocessor Based Engine and Generator Controller
GENERATOR: Brushless, Exciterless, Bearingless, Permanent Magnet Alternator
AC OUTPUT RATINGS:
Power (@1.0 power factor) 6000 W 7500 W 8000 W
Voltage 120 volts 120 volts 120 volts
Frequency 60 Hz 60 Hz 60 Hz
Number of Phases 1 1 1
Current 50.0 ampere 62.5 ampere 66.7 ampere
Line Circuit Breaker(s) 2-pole, 30 amp 2-pole, 30 or 35 amp 2-pole, 30 or 35 amp
ENGINE: 3-Cylinder In-Line, Water-Cooled, Indirect-Injection, 4-Stroke Cycle Diesel
Bore 2.64 inch (67 mm)
Stroke 2.68 inch (68 mm)
Displacement 44 inch3 (719 cc)
Compression Ratio 23 : 1
Oil Capacity (with filter)* 3 quart (2.6 l)
Cooling System Capacity** 4.2 quart (4 l)
Intake and Exhaust Valve Lash (Cold) 0.0065 inch (0.165 mm)
OPERATING SPEED RANGE: 1600 to 2900 RPM 1600 to 3200 RPM 1600 to 3300 RPM
FUEL CONSUMPTION:
No-load .13 gph (.49 l/h) .13 gph (.49 l/h) .13 gph (.49 l/h)
Half-load (4000 W) .49 gph (1.85 l/h) .49 gph (1.85 l/h) .49 gph (1.85 l/h)
Full-load .80 gph (3.03 l/h) .96 gph (3.63 l/h) 1.02 gph (3.86 l/h)
DC SYSTEM:
Nominal Battery Voltage 12 volts
450 CCA*** down to 0° F (−17° C)
Minimum Battery Capacity
650 CCA*** down to −20° F (−29° C)
Maximum Regulated-Voltage Battery
Charging Current (Optional)
10 ampere
Fuse F1 (control circuit) 10 ampere mini-bayonet
Fuse F2 (starter solenoid circuit) 10 ampere mini-bayonet
Fuse F3 (glow plug circuit) 25 ampere
WEIGHT AND SIZE:
Weight (wet) 420 lbs (191 kg)
Length x Width x Height 36.3 x 23.6 x 22.3 inch (922 x 599 x 566 mm)
* See oil filling instructions.
** Includes coolant recovery tank.
*** Cold Cranking Amps @ 0° F (−17° C)
31
Information for California Genset Users
These gensets meet the requirements of Californi- You should carefully review Operator (Owner),
a’s Exhaust Emissions Standards as stated on the Installation and other manuals and information you
nameplate (Page 3). receive with your genset. If you are unsure that the
installation, use, maintenance or service of your
As a California user of these gensets, please be genset is authorized, you should seek assistance
aware that unauthorized modifications or replace- from an approved Onan dealer.
ment of fuel, exhaust, air intake, or speed control
system components that affect engine emissions California genset users may use Table 5 as an aid in
are prohibited. Unauthorized modification, removal locating information related to the California Air Re-
or replacement of the genset label is prohibited. sources Board requirements for emissions control.
TABLE 5. EMISSIONS CONTROL INFORMATION
The California emissions control warranty statement is located in

Genset Warranty Information the same packet of information as this manual when the genset is
shipped from the factory.
Engine Valve Clearance (Lash) See Specifications (Page 30).
The engine is certified to operate on diesel fuel. See FUEL REC-
Engine Fuel Requirements
OMMENDATIONS (Page 5).
Engine Lubricating Oil Requirements See ENGINE OIL RECOMMENDATIONS (Page 5).
High Idle Speed. This is a service procedure requiring trained
Engine Adjustments
personnel and proper tools. See the Service Manual.
The engine emission control system consists of engine design
Engine Emission Control System
and precision manufacture. (IFI)
32
How to Obtain Service
When you need parts or service for your genset con- rectory of authorized RV servicing dealers: RV
tact the nearest authorized dealer or distributor. Sales and Service Directory F-919.
Onan has factory-trained representatives to handle
your needs for genset parts and service. To locate To get service, contact the authorized dealer or dis-
the nearest authorized distributor: tributor nearest you, explain the problem and make
an appointment. If you have difficulty in arranging
1. Check the North American Sales and Service for service or resolving a problem, please contact
Directory (F-118) and the International Sales the dealer coordinator or service manager at the
and Service Directory (IN-1013) supplied with nearest Onan dealer for assistance.
your Onan genset. These directories list autho-
rized distributors who will assist you in locating Before calling for service, have the following infor-
the nearest authorized dealer. mation available:
2. Consult the Yellow Pages. Typically, our distrib- 1. The complete genset model number and serial
utors are listed under: number. See Model Identification (Page 4).
GENERATORS − ELECTRIC, 2. The date of purchase
ENGINES − GASOLINE OR DIESEL, or
3. The nature of the problem. See Troubleshoot-
RECREATIONAL VEHICLES − EQUIPMENT,
ing (Page 21).
PARTS AND SERVICE.
3. Call 1-800-888-ONAN for the name and tele- WARNING Improper service or replacement of
phone number of the nearest Onan dealer in parts can result in severe personal injury, death,
the United States or Canada. (This automated and/or equipment damage. Service personnel
service utilizes touch-tone phones only). By must be qualified to perform electrical and/or
calling this number you can also request a di- mechanical service.
33
Maintenance Record
Record all periodic and unscheduled maintenance and service. See Periodic Maintenance (Page 12).
HOUR
DATE METER MAINTENANCE OR SERVICE PERFORMED
READING
Record the name, address, and phone number of your authorized Onan service center.
34
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email www.cumminsonan.com/contact
www.cumminsonan.com
CumminsR, OnanR, the “C” logo, and “Performance you rely on.”
are trademarks of Cummins Inc.
E2010 Cummins Power Generation, Inc. All rights reserved.

Parts Manual: Onan Generator Set For RV

Uploaded by

Copyright:

Available Formats

Parts Manual: Onan Generator Set For RV

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Parts Manual: Onan Generator Set For RV

Uploaded by

Copyright:

Available Formats

Parts Manual

Onan Generator Set for RV

Generator Set Data Table

* The specification number denotes customer requested options or deviations from a

Copyright 2019 Cummins Inc. 1

2 Copyright 2019 Cummins Inc.

Baffle, Inlet, 32 Collar, 23

Ball, Injection Pump Gear, 17 Collar, Crankshaft, 11

Ball, Valve Seat, 27 Collet, Valve Spring, 22

Base, Mounting, 42 Components, Injection Nozzle, 20

Bearing, Carrier Ball, 24 Components, Water Pump, 28

Bearing, Crankshaft, 13 Control, Speed, 15

Bearing, Fuel Camshaft, 17 Cooling System 8HDKAK 2010K, 36

Bearing, Water Pump Ball, 28 Core, Battery Harness Ferrite, 50

Belt, Water Pump, 39 Cover, AC, 43

Block, AC Terminal, 49 Cover, Access, 43

Block, Battery Harness Terminal, 50 Cover, Air Cleaner (Intake), 32

Block, Cylinder, 9 Cover, Air Cleaner Element, 32

Block, Exhaust Fiberglass, 41 Cover, Bearing Plate, 13

Bracket, Inverter, 47 Cover, Enclosure, 43

Bracket, Rocker Arm, 22 Cover, Enclosure (Access), 43

Breaker, Circuit, 49 Cover, Fuel Camshaft, 9

Bushing, Crankshaft, 11 Cover, Gearcase Hole, 27

Bushing, Idle Gear, 12 Cover, Governor, 24

Bushing, Piston Pin, 11 Cover, Main Bearing, 13

Cap, Coolant Recovery, 37

Copyright 2019 Cummins Inc. 3

G Harness, Remote Panel (Switch/Hourmeter), 53

4 Copyright 2019 Cummins Inc.

M Pin, Governor Spring, 14

Copyright 2019 Cummins Inc. 5

S Switch, Start/Stop (Remote Voltmeter Panel), 54

6 Copyright 2019 Cummins Inc.

Copyright 2019 Cummins Inc. 7

8 Copyright 2019 Cummins Inc.

REF PART QTY PART REF PART QTY PART

0100 4111 1 Engine, Replacement A040R285 2 (Spec N)

Copyright 2019 Cummins Inc. 9

14. 16. 17.

10 Copyright 2019 Cummins Inc.

REF PART QTY PART REF PART QTY PART

1. Piston 185 5577 1 Standard

Copyright 2019 Cummins Inc. 11

REF PART QTY PART REF PART QTY PART

1. 181 9159 6 Tappet 9. 185 5562 1 Gear, Idle (Includes Bushing)

12 Copyright 2019 Cummins Inc.

REF PART QTY PART REF PART QTY PART

Copyright 2019 Cummins Inc. 13

REF PART QTY PART REF PART QTY PART

14 Copyright 2019 Cummins Inc.

REF PART QTY PART REF PART QTY PART

Copyright 2019 Cummins Inc. 15

REF PART QTY PART REF PART QTY PART

185 5425 1 Assy, Pump Injection 6. 185 5625 2 Nut, Cap

16 Copyright 2019 Cummins Inc.

REF PART QTY PART REF PART QTY PART

Camshaft Assy, Fuel (Includes 6. 185 5632 1 +Case, Governor Ball

Copyright 2019 Cummins Inc. 17

REF PART QTY PART REF PART QTY PART