The Cummins/Onan HDKAL/HDKAS is a 1124 L 3-cylinder naturally aspirated engine rated at 1800 rpm. It powers generator sets from Cummins/Onan, including the HDKA. It holds 5.1 L (1.3 gal) of oil and 4.73 L (1.2 gal) of coolant.
Also known as: Cummins Onan HDKAL/HDKAS
Part of the Cummins/Onan HDKAL engine family — 2 variants share parts & fitment.
| Oil capacity | 5.1 L |
|---|---|
| Coolant capacity | 4.73 L |
| Displacement | 1124.0 L |
| Cylinders | 3 |
| Aspiration | Naturally aspirated |
| Rated speed | 1800 rpm |
| Gross power | 0.0 kW |
How to read your Cummins/Onan engine serial & model number →
| Symptom | Cause | Remedy |
|---|---|---|
| NO AC OUTPUT VOLTAGE AT RATED ENGINE RPM | Load circuit breakers closed, circuit open between brush block and voltage regulator, brushes stuck in holder or not making good contact with slip rings, opens or grounds in rotor, stator, incorrect field voltage, broken wires or loose connections on voltage regulator assembly, engine running at correct RPM, adjustment of Voltage Adjust control on the regulator board results in correct output voltage, generator output leads improperly connected | Locate cause of overload and correct as required. Reset breaker, or replace if bad. Check continuity of circuit breakers and replace if necessary. Is circuit open between brush block and voltage regulator? If yes, check for continuity and correct if circuit is open. Are brushes stuck in holder or not making good contact with slip rings? If yes, release brushes if jammed in holder. Clean slip rings if dirty. Test continuity of rotor, stator per Tests [B], [C]. Are there opens or grounds? If yes, replace component if defective. Test field voltage per TEST [A]. Is there correct field voltage? If no, examine brush block connections. Are F1 and F2 leads installed on correct terminals? Perform TEST [D]. Connect brush leads to correct terminals. |
| UNSTABLE OUTPUT VOLTAGE, ENGINE SPEED STABLE | Broken wires or loose connections on voltage regulator assembly, brushes stuck in holder or not making good contact with slip rings, engine running at correct RPM, adjustment of Voltage Adjust control on the regulator board results in correct output voltage, generator output leads improperly connected | Check wiring harness from regulator assembly to end bell per TEST [F]. Check OK? Repair as required. Inspect brushes per procedure in Manual Section 4. Brushes OK? Repair wiring or replace as required. Replace the voltage regulator per procedure [E]. Repair or replace as required. |
| Engine does not crank. | Follow the troubleshooting procedure in Flow Chart A. | |
| Output voltage too high or too low | Remove part of the set load. Remove load at generator terminals. Are generator leads connected and grounded properly? See Test [C]. Is generator stator winding continuous per TEST [C]? Check load for ground faults and correct as necessary. Check for correct grounding of generator and load. Correct as necessary. Replace stator assembly. | |
| Unbalanced generator output voltage | Remove load at generator terminals. Are generator leads connected and grounded properly? See Test [C]. Is generator stator winding continuous per TEST [C]? Check load for ground faults and correct as necessary. Check for correct grounding of generator and load. Correct as necessary. Replace stator assembly. | |
| Dizziness | Get out into the fresh air immediately. If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired. | |
| Muscular Twitching | Get out into the fresh air immediately. If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired. | |
| Vomiting | Get out into the fresh air immediately. If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired. | |
| Weakness and Sleepiness | Get out into the fresh air immediately. If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired. | |
| Inability to Think Coherently | Get out into the fresh air immediately. If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired. |
Fault codes and symptom→remedy steps extracted from this engine’s service/owner documentation; verify against the official manual before servicing.
Compiled from service & troubleshooting documentation across every generator set that uses the Cummins/Onan HDKAL/HDKAS.
| Item | Action | Hours | Months | Notes |
|---|---|---|---|---|
| Air cleaner dust cap | Check | 50 hr | Clean if required; footnote 3: perform more often in extremely dusty conditions | |
| Air cleaner dust cap | Clean | 8 hr | Clean if required; perform more often in extremely dusty conditions (table footnote 3) | |
| Coolant level | Check | 8 hr | Keep recovery tank level between COLD and HOT | |
| Engine oil | Check | 8 hr | Daily or after 8 hours | |
| Engine oil level | Check | 8 hr | 0 mo | Keep oil level between FULL and ADD |
| Fuel level | Check | 8 hr | Daily or after 8 hours | |
| Generator set | Inspect | 8 hr | Footnote 1: check for oil, fuel, cooling and exhaust system leaks; check exhaust audibly and visually with set running | |
| Genset | Inspect | 8 hr | Check for oil, fuel, coolant and exhaust system leaks | |
| Oil Level | Check | 8 hr | Every Day / 8 Hr per Table 7-1 | |
| Battery charging system | Check | 100 hr | Weekly or after 50 hours | |
| Battery specific gravity | Check | 100 hr | Weekly or after 50 hours | |
| Drive belt tension | Check | 100 hr | Visually check belts for evidence of slippage (table footnote 4) | |
| Genset service (first service interval, all models) | Other | 50 hr | First service — First service interval is 50 hours for all models. | |
| Air Cleaner Dust Boot | Clean | 100 hr | 1 mo | Perform more often in dusty conditions (footnote 5) |
| Air cleaner element | Clean | 100 hr | ||
| Antifreeze | Check | 250 hr | 6 mo | Monthly or after 100 hours |
| Battery | Check | 100 hr | 1 mo | See battery manufacturer's recommendations (footnote 2) |
| Fuel filter water/sediment | Drain | 250 hr | Monthly or after 100 hours | |
| Air Filter Element | Replace | 150 hr | Every 150 hours, more often in dusty conditions | |
| Engine Oil and Filter | Change | 1000 hr | First service — Perform more often in dusty conditions; more often in hot weather; at least once a year | |
| Genset service — GEN TYPE GAS RV (Camp Power) | Other | 150 hr | EC-30 service hour meter interval | |
| Genset service — GEN TYPE GAS/LP (Marquis, Microlite, Micro Quiet) | Other | 150 hr | EC-30 service hour meter interval | |
| Genset service — GEN TYPE QD 5.5 (Quiet Diesel; model HDKBx) | Other | 150 hr | EC-30 service hour meter interval | |
| Genset service — GEN TYPE QD 6/8 (Quiet Diesel; model HDKAx) | Other | 150 hr | EC-30 service hour meter interval | |
| genset service | Other | 250 hr | First service — GEN TYPE QD 7.5/8 (Quiet Diesel, HDKAx) Service IN hours | |
| Anti-freeze | Check | 250 hr | ||
| Crankcase oil and filter | Change | 250 hr | 6 mo | First service — Perform after first 35 hours of operation on new genset; change crankcase oil every 50 operating hours in extremely dusty conditions |
| Fuel filter element | Change | 500 hr | 12 mo | 6 months or after 250 hours |
| Fuel shut-off linkage | Check | 500 hr | 12 mo | 6 months or after 250 hours |
| Fuel tank sediment | Drain | 250 hr | 6 mo | Footnote 5: drain one cup of fuel to remove water and sediment |
| Generator assembly | Clean | 250 hr | 6 mo | Clean the generator set at least every six months |
| Generator set brushes | Check | 250 hr | 6 mo | Brushes inspected for wear and cleaning every six months |
| Genset service — GEN TYPE QD 10/12 (Quiet Diesel; models HDCAx, HDKCx) | Other | 250 hr | EC-30 service hour meter interval | |
| V-Belt Tension | Check | 250 hr | 6 mo | Check for slippage (footnote 3) |
| Water in Fuel | Drain | 250 hr | 6 mo | Drain about one cup to remove water and sediment (footnote 4) |
| Water/sediment from fuel filter | Drain | 250 hr | 6 mo | |
| Air Cleaner Element | Change | 500 hr | 12 mo | Perform more often in dusty conditions (footnote 5) |
| Coolant Anti-freeze Protection | Check | 1000 hr | 1 mo | Perform at least once a year |
| Coolant Anti-freeze Protection | Test | 500 hr | Check Coolant Anti-freeze Protection | |
| Cooling system | Clean | 500 hr | 12 mo | Once a year drain, flush and refill the cooling system with new coolant |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| Type | Item | Value | Unit | Condition |
|---|---|---|---|---|
| Clearance | Bore | 2.64 inch (67 mm) | inch (mm) | |
| Clearance | Clearance to top of genset compartment | 1 | inch (25.4 mm) | minimum, including acoustic insulation |
| Clearance | Compartment opening free area, generator end | 200 | square inches | minimum |
| Clearance | Exhaust system distance from combustible material | 3 | in | |
| Clearance | Fan belt deflection | 0.4 (10 mm) | inch | 22 pounds (10 kg) finger pressure at middle of belt |
| Clearance | Genset to bulkhead/other equipment (pusher/suction fan) | 6 | inches (152 mm) | minimum |
| Clearance | Minimum clearance between genset and compartment insulation | 1 | in | |
| Clearance | Minimum clearance exhaust system to combustible material | 3 | in | |
| Clearance | Minimum space between engine exhaust components and compartment insulation | 3 | in | |
| Clearance | Muffler/tailpipe to combustible material | 3 | inches (76 mm) | minimum, unless insulated or shielded |
| Clearance | Stroke | 2.68 inch (68 mm) | inch (mm) | |
| Clearance | V-belt deflection | 0.4 | inch (10 mm) | 20 pounds (10 kg) applied at middle of pulley span |
| Clearance | V-belt deflection at 20 pounds (10 kg) applied to middle of pulley span | 0.4 inch (10 mm) | inch | at 20 lbs (10 kg) |
| Current | Battery charging DC alternator output | 30 | amp | |
| Current | Starter motor draw at 12 VDC | 100 | A | |
| Gap | Fan belt deflection | 0.4 | inch (10 mm) | 22 pounds (10 kg) finger pressure at middle of belt |
| Gap | Fan belt deflection at middle of belt | 0.4 | inch (10 mm) | finger pressure of 22 pounds (10 kg) |
| Other | AUTO GEN disabled if safety input not verified | 30 | days | |
| Other | Actuator speed control lever stop screw (beginning Spec B) | Turn in until just makes contact, then one more full turn (rotor not in place); set locknut | Adjust whenever a different actuator base assembly is installed | |
| Other | Altitude power derate | approximately 3 percent per 1000-foot (305 m) increase in elevation | percent | |
| Other | Battery cable size, total cable length 0 to 10 feet (0 to 3 m) | 2 | AWG | temperatures down to –20°F (–29°C) |
| Other | Battery cable size, total cable length 11 to 15 feet (3 to 4.5 m) | 0 | AWG | temperatures down to –20°F (–29°C) |
| Other | Battery cable size, total cable length 16 to 20 feet (4.5 to 6 m) | 000 | AWG | temperatures down to –20°F (–29°C) |
| Other | Battery compartment ventilation opening | 1.7 | in2 | minimum at top and bottom |
| Other | Battery compartment ventilation opening | 11 | cm2 | minimum at top and bottom |
| Other | Battery electrolyte specific gravity (fully charged) | 1.260 | at approximately 80°F (27°C) | |
| Other | Battery electrolyte specific gravity, charge if below | 1.215 | specific gravity | |
| Other | Battery electrolyte specific gravity, fully charged | 1.260 | specific gravity | at 80 F (27 C) |
| Other | Battery rating | 425 | CCA | |
| Other | Battery rating | 625 | CCA | below 32°F (0°C) |
| Other | Battery recharge threshold (charge if specific gravity less than) | 1.215 | specific gravity | |
| Other | Battery specific gravity charge threshold | 1.215 | charge battery if specific gravity is less than this | |
| Other | Bore | 2.64 | inch (67 mm) | |
| Other | Bore | 2.99 (76) for HDKAL/HDKAQ; 2.83 (72) for HDKAR/HDKAS | in (mm) | |
| Other | Bore | 72 | mm | |
| Other | Bore | 76 | mm | |
| Other | Brush wear limit (wire inserted into brush holder) | 1 | inch (25 mm) | replace brush and spring if wire enters holder this far or more |
| Other | Circuit breaker rating | 35 | A | 2 pole, 60 Hz |
| Other | Clamping screw (beginning Spec B high-idle adjustment) | Run back in by hand until snug, back it out 1-1/2 turns, set lock nut | turns | After setting high-idle speed |
| Other | Compartment depth | 25 | in | |
| Other | Compartment height | 25 | in | |
| Other | Compartment width | 38.4 | in | |
| Other | Compression Ratio | 23 : 1 | ||
| Other | Compression ratio | 23 to 1 | ||
| Other | Compression ratio | 23:1 | ||
| Other | Continuous operation at up to 80 percent of maximum power | 6000 | watts | 80% of maximum power |
| Other | Cooling air requirement - Generator Inlet | 100 | in2 | |
| Other | Cooling air requirement - Radiator | 200 | in2 | |
| Other | Cooling system capacity | 4.2 quart (4 l) | quart (l) | includes coolant recovery tank |
| Other | Cooling system capacity | 4.73 | L | |
| Other | Cranking time that triggers fault | 35 | seconds | cranking time exceeded fault (4 blinks) |
| Other | Cranking time that trips fault code 4 | 35 | seconds | |
| Other | Cyclic horizontal forces | ±500 | lbs | ±1 g-force |
| Other | Cyclic vertical forces | ±1500 | lbs | ±3 g-force |
| Other | Dimensions L x W x D | 80.98 x 130.12 x 30.48 | mm (3.188 x 5.125 x 1.20 inches) | |
| Other | Displacement | 1001 | cm3 | |
| Other | Displacement | 44 | inch3 (719 cc) | |
| Other | Displacement | 44 inch3 (719 cc) | inch3 (cc) | |
| Other | Displacement | 898 | cm3 | |
| Other | EC-AGS+ gateway dimensions | 120 x 108 x 38 | mm |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| Fluid | Grade | Standard | Ambient | Capacity | Notes |
|---|---|---|---|---|---|
| Coolant | 50/50 ethylene glycol antifreeze and water | 4.2 quarts (4 liters) | Provides protection to -34°F (-37°C). Use distilled water if available. Replace every 2 years. | ||
| Coolant | 50/50 mixture ethylene glycol anti-freeze and water | Contains rust and corrosion inhibitor; no stop-leak additive | above -37°C | 4.0 l | 4.2 quart (4 l) capacity; suitable down to -34 F (-37 C) |
| Coolant | 50/50 mixture of ethylene glycol anti-freeze and water | Reliable brand with rust and corrosion inhibitor; must not contain stop-leak additive | above -37°C | 50/50 provides freeze protection to -34 F (-37 C); use distilled or soft water | |
| Coolant | 50/50 mixture of ethylene glycol anti-freeze and water as shipped; use ethylene or propylene glycol anti-freeze solution containing rust and corrosion inhibitor | Anti-freeze must not contain a stop-leak additive; water must be clean, low in minerals and free of corrosive chemicals; use distilled water if available | above -37°C | 4.0 l | Factory fill suitable down to -34 deg F (-37 deg C); cooling system capacity 4.2 quart (4 l) includes coolant recovery tank; replace coolant every two years |
| Coolant | 50/50 mixture of ethylene glycol anti-freeze and water; ethylene or propylene glycol solution containing rust and corrosion inhibitor | No stop-leak additive; use clean, low-mineral water, distilled if available | above -37°C | 4.0 l | Suitable for temperatures down to -34° F (-37° C); cooling system capacity 4.2 quart (4 l) including coolant recovery tank; replace coolant every two years |
| Coolant | 50/50 mixture of ethylene glycol antifreeze and water | above -37°C | 4.0 l | Suitable for temperatures down to –37 °C (–34 °F); antifreeze should be fully formulated with rust inhibitors and coolant stabilizers, mixed with fresh (distilled) water | |
| Coolant | 50/50 mixture of water and ethylene glycol | above -37°C | Best quality ethylene or propylene glycol antifreeze fully formulated with rust inhibitors and coolant stabilizers, but not stop-leak additives. Use fresh water low in minerals; distilled water is best. Shipped 50/50 mixture good for -34 F (-37 C). | ||
| Coolant | 50/50 mixture of water and ethylene glycol (or propylene glycol) antifreeze | Fully formulated with rust inhibitors and coolant stabilizers but not with stop-leak additives; use fresh water low in minerals, distilled best | above -37°C | 4.73 L | Shipped with recommended 50/50 mixture, good for -34 F (-37 C); cooling system capacity 1.25 gal (4.73 L) |
| Coolant | Ethylene or propylene glycol anti-freeze, 50/50 mixture | above -34°C | 4.2 quart | Must contain rust and corrosion inhibitor; no stop-leak additives | |
| Coolant | Ethylene glycol antifreeze, fully formulated with rust inhibitors and coolant stabilizers | above 37°C | 4.0 l (4.2 qt) incl. recovery tank | 50/50 mixture recommended for all climates | |
| Engine oil | CH-4, CG-4, or CF-4 | API performance class | 3.0 quarts (2.6 liters) | May be combined with SJ, SH, or SG. Select viscosity grade per Chart 1 based on ambient temperature. | |
| Engine oil | SAE 15W-40 multi-grade recommended for year-round use | API Class CF-4 or CF or better | 4.7 L | Pre-start checks state engine oil capacity 4.7 liters (5 quarts); Specifications state lubricating oil capacity with oil filter 6.0 liters (6.34 quarts). Choose viscosity grade per ambient temperature before next oil change. | |
| Engine oil | SAE 15W-40 multi-grade recommended for year-round use (choose viscosity grade per ambient temperature chart, Figure 2) | API Class CG-4, CF-4, CF or better | 4.1 L | Lube oil capacity 4.34 qt (4.1 L) including filter | |
| Engine oil | SAE viscosity grade chosen from Chart 1 (Oil Viscosity vs. Temperature) for ambient temperatures expected until next oil change | API performance Class CH-4, CG-4 or CF-4, may be in combination with SJ, SH or SG (e.g. CH-4/SJ) | 2.6 l | 3 quart (2.6 l) with filter | |
| Engine oil | SAE viscosity grade per Chart 1 (Oil Viscosity vs. Temperature) | API CH-4, CG-4 or CF-4 (may combine with SJ, SH or SG) | 2.6 l | 3 quarts (2.6 l) capacity with filter | |
| Engine oil | SAE viscosity grade per Chart 4-1 (oil viscosity vs. temperature) | API performance Class CH-4, CG-4 or CF-4D, may be combined with SJ, SH or SG (e.g. CH-4/SJ) | 2.6 l | Oil capacity with filter 3 quart (2.6 l) | |
| Engine oil | SAE viscosity grade per engine lubrication section | API classification per engine lubrication section | Refer to Engine Workshop Manual for oil recommendation | ||
| Engine oil | SAE viscosity grade selected per anticipated ambient temperature (Chart 1, Oil Viscosity vs. Temperature) | API performance Class CH-4, CG-4 or CF-4, may be in combination with performance Class SJ, SH or SG (e.g. CH-4/SJ) | 3.0 quart (2.6 l) | Oil capacity with filter; change oil if not appropriate for ambient temperatures during break-in | |
| Engine oil | SAE viscosity per anticipated ambient temperature (Table 1, Oil Viscosity vs. Temperature) | API classification CC and later | 4.26 liters (4.5 quarts) | Do not use synthetic oil or non-detergent oil. Do not mix different brands of oil. (Specifications section lists lube oil capacity 4.5 qt (4.25 L) including filter.) | |
| Engine oil | Performance Class CH-4, CG-4 or CF-4 | -40°C to 40°C | 3.0 quart | Select SAE grade based on ambient temperature; see oil viscosity chart | |
| Engine oil | API Class CH-4, CG-4, or CF-4 | SAE viscosity grade based on ambient temperature | above -34°C | 2.6 l | See Chart 1 for viscosity selection by temperature |
| Engine oil | 5W-30 | API CF, CF-4, CG-4, CH-4, or CI-4 | -28°C to 10°C | ||
| Engine oil | 10W-30 10W-40 | API CF, CF-4, CG-4, CH-4, or CI-4 | -18°C to 27°C | ||
| Engine oil | 15W-40 (OnaMax) | API CF, CF-4, CG-4, CH-4, or CI-4 | -12°C to 38°C | Multigrade oils such as SAE 15W-40 are recommended for year round use | |
| Engine oil | SAE 30 | API CF, CF-4, CG-4, CH-4, or CI-4 | above 0°C | 0 °C (32 °F) and higher | |
| Engine oil | 10W-30 / 10W-40 | API CF/CF-4/CG-4/CH-4/CI-4 | 18°C to 27°C | 2.6 l (3 qt) | |
| Fuel | ASTM D975 (petroleum diesel); ASTM D7467 (B5-B20 blend); ASTM D6751 or EN14214 (bio-diesel component) | B5 bio-diesel suitable. Up to B20 requires: HDKAL at Spec G or higher, vehicle engine B20-capable, OEM-installed B20-compatible fuel line and water separator. Blend properties change below 23 F (-5 C). Purge with pure ASTM D975 diesel for min 30 minutes before storage >90 days. | |||
| Fuel | 1-D Diesel | ASTM D975 | below 0°C | Use when ambient temperatures are below 32°F (0°C) and during long periods of light engine load | |
| Fuel | 2-D Diesel | ASTM D975 | Minimum Cetane number 45; best economy and performance under most conditions | ||
| Fuel | ASTM 1-D (No. 1 Diesel) | minimum Cetane number 45 | below 0°C | Use when ambient temperatures are below 32°F (0°C) and during long periods of light engine load. |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| Code | Name | Meaning | Severity | Action |
|---|---|---|---|---|
| 1 | High engine coolant temperature | One blink indicates shutdown due to high engine coolant temperature. | Shutdown | Touch Stop to check the second-level fault code; it will be either No. 33 or No. 34. |
| 1, 2, 3, 4 | First level faults | First-level faults; avoid interpreting as second-level codes 11, 22, 33, or 44 | Shutdown | Pay close attention to the pause sequence |
| 11 | Overload Fault | Second-level shutdown code No. 11 (blink once, pause, blink once). Not assigned a first-level fault (avoid confusion with first-level Code 1). | Shutdown | Turn off the genset line circuit breaker; if the genset no longer shuts down, check for and repair a short in vehicle appliances, wiring or shorted battery charger transformer; check whether vehicle engine and genset share the same starting battery and increase battery capacity or install a separate battery. |
| 12 | Over Voltage | The control is unable to maintain rated voltage. | Shutdown | If the vehicle engine and genset share a starting battery, increase battery capacity or install a separate battery and charging system for the genset. |
| 13 | Under Voltage | The control is unable to maintain rated voltage. | Shutdown | Reduce load (especially air conditioners and battery chargers). |
| 14 | Over Frequency | The engine governor is unable to maintain rated frequency. | Shutdown | Reduce the number of connected appliances, especially when air conditioners and battery chargers are running. |
| 15 | Underfrequency Fault | The engine governor is unable to maintain rated frequency. | Shutdown | Reduce the number of connected appliances; have air conditioners and other appliances checked for proper operation (a locked compressor rotor can cause very low power factor). |
| 17 | Fuel Pump Fault | Controller sensed open circuit; bypassable fault prior to Spec F, discontinued beginning Spec F | Shutdown | Try priming by holding control switch at Stop; reconnect fuel pump leads; test pump on 12 V battery; check P1-2/E2-1 and E2-2/ground continuity. |
| 18 | Glow Plug Circuit Protection Fault | Controller sensed short circuit; bypassable fault prior to Spec F, discontinued beginning Spec F | Shutdown | Reconnect HR-1 to glow plug bus bar; check HR-1 and A1-J8 for ground short; replace engine harness or control assembly. |
| 19 | Governor Actuator Fault | The control sensed an open or shorted circuit. | Shutdown | See an authorized Onan dealer. |
| 2 | Low Oil Pressure (first-level fault) | Two blinks indicate shutdown due to a loss of engine oil pressure; oil pressure switch actuates below 9 psi (62 kPa) | Shutdown | Check oil level; check switch and wiring; replace switch or service engine if pressure <14 psi (98 kPa). |
| 21 | Starter Solenoid Circuit Protection Fault | Controller sensed short circuit; discontinued beginning Spec F | Shutdown | Reconnect K-1 to starter solenoid; test solenoid and starter; reconnect A1-J6; check continuity to ground; replace controller assembly. |
| 22 | Not assigned | The duration of operation is near full-duty cycle beyond design limit. | Warning | Step 01 (0.5 hr): check load, air intake restriction, exhaust restriction, air leak in fuel system, stator for opens/shorts. Step 02 (1.0 hr): check fuel flow test, governor for binding, high idle adjustment, injectors, injection pump timing, compression (SRT 00-0BL) |
| 23 | Low Oil Pressure Cutoff Switch Fault | Switch still open during start - not a running fault | Shutdown | See an authorized Onan dealer. |
| 24 | Throttle Control Fault | Engine throttle control malfunction | Shutdown | See an authorized Onan dealer. |
| 25 | Engine Sensor Fault | Governor unable to regulate to target speed. | Shutdown | See an authorized Onan dealer. |
| 26 | Engine Below Speed Target Fault | Governor unable to regulate to target speed. | Shutdown | Step 01 (0.5 hr): check loads, air in fuel system, air intake restriction, exhaust restriction. Step 02 (1.0 hr): check binding in the governor, high idle speed, injectors, injection timing, compression (SRT 00-0BQ) |
| 27 | Voltage Sense | The control is unable to sense output voltage. | Shutdown | Test with load bank to isolate load; check PMA-to-control connections; measure PMA lead voltages (T1-T2, T2-T3, T3-T1 - should exceed 20 Vrms); troubleshoot rotor/stator; replace control assembly. |
| 28 | DC Sense Lost Fault | Controller unable to sense DC bus voltage | Shutdown | Open the circuit breaker; if the fault does not persist, check for and disconnect excessive loads from the genset before starting. |
| 29 | High Battery Voltage Fault | Voltage across the battery system is greater than 19 Volts. | Warning | Check battery connections; measure DC voltage; check battery charger; verify ground at P1-7. |
| 3 | Service fault (second-level code follows) | Three blinks indicate a service fault; press Stop once to blink the two-digit second-level shutdown code (tens digit, pause, units digit) | Warning | Touch Stop to check the second-level fault code; it will be one of the codes in the troubleshooting table. |
| 31 | Overspeed Fault | Engine speed greater than 3600 rpm. | Shutdown | See an authorized Onan dealer. |
| 32 | Low Cranking Speed Fault | Cranking speed less than 180 rpm for more than 2 seconds; crank and generator frequency less than 3 Hz for greater than 2 seconds | Shutdown | Step 01 (0.3 hr): check fuse, harness connections to starter, battery connections at set and battery, battery voltage at set. Step 02 (0.7 hr): check starter operation, harness connection for opens/shorts, stator resistance for opens/shorts, rotor magnets for failure (SRT 00-0BS) |
| 33 | Not assigned | Second-level code 33 has not been assigned a fault | Shutdown | Step 01 (0.5 hr): verify FC is actually a secondary code; verify coolant level and fill if needed; verify engine coolant temperature; air inlet/outlet opening for blockage; excessive coach loads; coolant pump belt for wear; cooling fan for damage; housing air leaks. Step 02 (0.5 hr): check temperature sensor lead for opens/shorts; radiator blockage and clean. Step 03 (2.0 hr): clean and flush coolant system; replace coolant thermostat (SRT 00-0CS) |
| 34 | High Inverter Temperature Fault | Inverter heat sink temperature exceeded design limit. | Shutdown | Remove objects blocking the air inlet or outlet openings; reduce the number of appliances connected at the same time. |
| 35 | Control Card Fault | Microprocessor EPROM error during self-test. | Shutdown | Verify problem and report to factory (SRT 00-0CA, 0.2 hours) |
| 36 | Unknown Shutdown Fault | The engine stopped without receiving a command from the control. | Shutdown | Step 01 (0.3 hr): check fuel level in coach tanks, prime genset fuel system, air filter blockage, mechanical damage. Step 02 (0.5 hr): check auxiliary fuel pump, conduct fuel flow test, P1 and P2 connectors and wiring (SRT 00-0BW) |
| 37 | Invalid Genset Configuration Fault | The generator set control is not configured properly for the generator set | Shutdown | Verify problem and report to factory (SRT 00-CHA, 0.2 hours) |
| 38 | Overload Fault | Too many loads connected. | Shutdown | Step 01 (0.2 hr): reduce coach loads, cool inverter. Step 02 (1.0 hr): check if set has engine performance issue, fuel supply for sucking air, fuel flow test, governor operates smoothly, high idle speed, current transformer for shorts/opens (SRT 00-0BX) |
| 39 | Low Battery Voltage Fault | Prior to Spec F only | Warning | Inspect connections; check fuel/air leaks; avoid cranking propulsion engine; check battery voltage; replace/recharge battery. |
| 4 | Overcrank | Set cranked for 35 seconds without starting (speed >1200 RPM) (Begin Spec K) | Shutdown | Troubleshoot as an out-of-fuel condition (see FC36); check fuel flow and return, actuator operation, wiring. |
| 4 blinks | Cranking time exceeded 35 seconds | Status indicator light repeatedly blinks four times | Shutdown | Check fuel supply and priming before re-cranking |
| 41 | Generator Rotor | Control unable to sense field or output voltage | Shutdown | Contact local dealer or distributor. |
| 42 | Processor Fault | Microprocessor ROM error during self-test; beginning Spec F and replacement controller assemblies | Shutdown | Verify fault code (SRT 00-0CB, 0.2 hours) |
| 43 | Processor Fault | Microprocessor RAM error during self-test; beginning Spec F and replacement controller assemblies | Shutdown | Verify fault code (SRT 00-0CC, 0.2 hours) |
| 44 | Not assigned | Second-level code 44 has not been assigned a fault | ||
| 45 | Speed Sense | The control is unable to sense quadrature frequency. | Shutdown | Contact local dealer or distributor. |
| 46 | Inverter Power Supply Fault | Low battery voltage or power supply device failure; beginning Spec F and replacement controller assemblies | Shutdown | Verify fault code, voltage at set during cranking, voltage at starter during cranking, battery connections at set and battery, battery condition, set charging system if equipped (SRT 00-0BZ, 0.5 hours) |
| 48 | Generator Field Sense | The control is unable to sense field voltage. | Shutdown | Contact local dealer or distributor. |
| 57 | Over Prime | Priming exceeded 3 minutes. | Shutdown | Check for and remove any object holding either control switch in the STOP/PRIME position. |
| 8 | Overload (Models HDKAH & HDKAV only) | Starter or cranking circuit malfunction | Shutdown | Reduce load and restart. |
| restore | Restoring fault code blinking | Fault code stops blinking after five minutes | Info | Press Stop three times within three seconds to restore fault code blinking |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
⚠ Accidental starting can cause severe personal injury or death. Disconnect the negative (-) cable(s) at the battery(ies).
⚠ Do not operate the generator set without the belt guard in place.
⚠ Stop the set and disable by disconnecting battery cables before service.
⚠ Do not let engine speed exceed 3600 RPM.
Tools: tachometer
⚠ GEN TYPE sets the service interval for service messages and critical automatic starting parameters.
⚠ QUIET ON mode prohibits the genset from automatically starting between the start and end of Quiet Time.
⚠ If it has not been setup (SafeType NONE), automatic operation will not be allowed.
⚠ ENTER to unlock prevents unauthorized changes to the hour-meter.
⚠ Touching uninsulated live parts can cause severe injury or death.
Tools: voltmeter
⚠ Do not change the 50/60 Hz setting on the regulator.
⚠ The V/Hz Break Point pot is factory set and sealed; do not adjust.
Tools: flat-blade screwdriver, voltmeter
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| Voltage | Phase | Connection | Leads | Notes |
|---|---|---|---|---|
| AC Present + positive | #14 | Positive input for shore AC present sensing; do not connect 120VAC or 240VAC line voltage. | ||
| AC Present - ground | #13 | Supplied by UL Listed 120VAC to 12-16VAC transformer, or the 12VDC ground side of a UL Listed 120VAC to 12VDC plug-in power supply. | ||
| Battery ground (negative) | #1 | Supplies the ground or negative side of the circuit for the EC-30; must be supplied from the genset. | ||
| Genset status light | #6 | Diagnostic output that flashes the red light in the START/STOP switch to indicate a genset fault; decoded to a text fault message. | ||
| Start/preheat | #3 | Supplies the start/preheat signal to the genset; controlled by the STOP/START switch and, in automatic mode, by the EC-30. | ||
| Stop output | #2 | Active low or grounded output to the genset; controlled by the STOP/START switch and, in automatic mode, by the EC-30. | ||
| Switched B+ from genset | #5 | Switched to battery positive voltage when the genset is running; provides genset hour meter and running indication. | ||
| single | Quadrature power connection Q60 - 60 Hz, Q50 - 50 Hz units | Q1, Q50, Q60 | Note 2: Quadrature power connection Q60-60 Hz, Q50-50 Hz units. Note 3: AVR reference voltage. Note 1: From J2-15 for field flashing. | |
| 100 | 1 | Reconnection chart | ||
| 100 | 1 | reconnection chart | ||
| 100 | single | reconnection chart | L0 | |
| 100 | single-phase | 50 Hz; see reconnection chart | ||
| 100 | single-phase | L0, L1 | T4, T3, L2, L1, Q50, Q60, T2, T1, S2, 2, S1, Q1 | |
| 100/200 | 1 | Reconnection chart | Wiring diagram 612-6637 reconnection chart | |
| 100/200 | 1 | reconnection chart | ||
| 100/200 | single | As shown | T1, T2, T3, T4; L0(N), L1 | 100/200 volts only; stator resistance values differ (T1-T2, T3-T4: 0.150 ohm; Q1-Q60: 2.3 ohms) |
| 100/200 | single | reconnection chart | L0, L1 | |
| 100/200 | single-phase | 50 Hz; see reconnection chart | ||
| 100/200 | single-phase | L0(N), L1 | Q50, Q60, T2, T1, S2, 2, S1, Q1 | 50 Hz |
| 110 | 1 | reconnection chart | T4, T3; L1 | |
| 110 | single-phase | L0, L1 | T4, T2, T3, T1, L0 | |
| 110/190 | 3 | 50 HZ CODE Z | T1-T12 | |
| 110/220 | 1 | As shown | T1, T2, T3, T4 | See reconnection chart for other voltages |
| 110/220 | 1 | reconnection chart | T4, T3, T2, T1; L2, L1, L0(N) | |
| 110/220 | 3 | 50 HZ CODE M,P,Z | T1-T12 | |
| 110/220 | single | As shown (60 Hz) | T1, T2, T3, T4; L0(N), L1, L2 | 60 Hz |
| 110/220 | single | See reconnection chart (50 Hz) | T1, T2, T3, T4; L0, L1 | 50 Hz |
| 110/220 | single | as shown | T4, T3, T2, T1, L0, L1 | See reconnection chart for other voltages |
| 110/220 | single-phase | As shown (L0(N), L1, L2) | T1, T2, T3, T4, Q60, Q1 | 60 Hz |
| 110/220 | single-phase | as shown |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| Part # | Description | Category |
|---|---|---|
| FS1842 | AC CONDUIT CONNECTORS | hose |
| ES1992 | FUEL AND ELECTRICAL LINE ENTRANCE HOLES | other_service |
| EXS1186 | EXTEND TAIL PIPE 1” PAST OUTSIDE EDGE OF VEHICLE | other_service |
Parts cataloged across all variants of this engine family — verify the exact part fits your specific variant and serial number before ordering.
The Cummins/Onan HDKAL/HDKAS engine has an oil capacity of 5.1 liters.
The Cummins/Onan HDKAL/HDKAS has a displacement of 1124.0 liters with 3 cylinders.
The Cummins/Onan HDKAL/HDKAS powers 1 generator set(s), including Cummins/Onan HDKA.
A commonly reported issue on generators using the Cummins/Onan HDKAL/HDKAS is: Weakness and Sleepiness. Fix: IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired..