Service parts for the HDKCA
Grouped by system, with how many of each the parts manual calls for.
Air intake
1 requiredFuel system
1 requiredOil system
1 requiredBelts
1 requiredCooling system
1 requiredPrices captured from merchant listings; some links are affiliate links. Confirm against your serial number before ordering.
Specifications
Ratings spec sheet not in our library yet — see the documents below.
Maintenance & consumables
| Item | Spec | Capacity | Part # | Interval | |
|---|---|---|---|---|---|
| Air filter | Air filter | 140-3071 | Amazon eBay $13.50 FridayParts $16.50 | ||
| Fuel filter | Fuel filter | 149-2513 | Amazon eBay $36.95 NAPA $31.59 FridayParts $48.61 | ||
| Oil filter | Oil filter | 122-0893 | eBay $49.99 | ||
| Belt | Belt | 143-2095 | Amazon eBay | ||
| Coolant filter | Coolant Filter | 143-2078 | Amazon eBay |
Service intervals
22| Item | Action | Hours | Months | Notes |
|---|---|---|---|---|
| Battery and Battery Connections | Check | 8 hr | Every Day or Every 8 Hours | |
| Engine Coolant Level | Check | 8 hr | Every Day or Every 8 Hours | |
| Engine Oil Level | Check | 8 hr | Every Day or Every 8 Hours | |
| General Inspection | Inspect | 8 hr | Every Day or Every 8 Hours | |
| Engine Air Filter | Replace | 250 hr | Perform more often in dusty conditions | |
| Engine Oil & Oil Filter | Change | 250 hr | First service — Every 250 Hrs; perform at least once a year; perform more often in hot/dusty conditions | |
| Fuel Filter | Replace | 500 hr | Perform at least once a year | |
| Spark Arrestor | Clean | 250 hr | Perform at least once a year | |
| V-Belt Tension | Check | 250 hr | Tighten or replace if deflection exceeds 1/2 in (12 mm) by thumb | |
| Coolant Pressure Cap | Replace | 1500 hr | 24 mo | Perform at least once every two years |
| Engine Air Filter Element | Replace | 500 hr | Perform more often in dusty conditions | |
| Engine Valve Lash | Adjust | 800 hr | Must be performed by trained/experienced personnel | |
| Generator Slip Rings and Brushes | Check | 800 hr | Also more often in dusty conditions | |
| Coolant System | Drain | 1500 hr | 24 mo | Flush coolant system; at least once every five years |
| Fuel Injector Pressure | Check | 1500 hr | EPA requirement; trained personnel only | |
| Fuel injector pressure | Test | 1500 hr | EPA requirement; trained personnel (Table 3-1) | |
| Generator Slip Rings / Brushes | Check | 3000 hr | Perform more often in dusty conditions; trained personnel only | |
| V-Belt & Coolant Hoses | Replace | 1500 hr | Perform at least once every five years; trained personnel only | |
| V-Belts & Coolant Hoses | Replace | 1500 hr | At least once every five years | |
| Generator Bearing | Replace | 3000 hr | Trained personnel only | |
| Battery & Battery Connections | Check | 1 mo | Every month | |
| Engine Oil and Oil Filter | Change | First service — After First 50 Hours (footnotes 1,2,3: perform more often in hot weather/dusty environments; perform at least once a year); also recurs later per schedule table |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Service specifications
60| Type | Item | Value | Unit | Condition |
|---|---|---|---|---|
| Gap | Fan Belt Tension (with alternator) | deflection 8-10 mm (0.3-0.4 inch) | mm | 10 kg (22 pounds) applied midway between alternator and pump pulleys |
| Gap | Fan belt deflection (with battery charging alternator) | 8-10 | mm (0.3-0.4 inch) | Under a force of 10 kg (22 pounds) applied midway between alternator and pump pulleys |
| Gap | Primary Belt Tension (deflection midway between alternator and pump pulleys) | 8-10 mm (0.3-0.4 inch) | mm | with a force of 10 kg (22 pounds) applied |
| Injection timing | Fuel Injection Timing (BTDC) | 14.25° | ||
| Injection timing | Fuel Injection Timing (BTDC) | 14.5 | degrees | |
| Other | Compression Ratio | 23.0:1 | ||
| Other | Engine preheat time | up to 15 | seconds | Depending on engine temperature |
| Other | Fuel Flow Test minimum flow | not less than 200 ml (0.4 pints) per minute | ml/min | |
| Other | Fuel system priming time (control switch held in Stop) | at least half a minute | minutes/seconds | Shutdown Code No. 57, Overprime, occurs after 3 minutes of holding the switch down |
| Other | Genset mounting screw protrusion into base | at least 1/2 inch (10 mm) but not more than 1 inch (25 mm) | inch (mm) | Measured from bottom surface of base |
| Other | Maximum cranking time | 30 | seconds | Wait at least 2 minutes before trying again |
| Other | Maximum power at/below 500 ft (152 m) elevation | 12,000 W (rated); 11,280 W at 2500 ft (762 m); 10,200 W at 5500 ft (1676 m); above 5500 ft 10,200 W minus 360 W every 1000 ft (305 m) | W | Approximately 3.5 percent power decrease per 1000 ft (305 m) elevation increase |
| Other | Special tool - torque wrench | 0-75 | lbs-ft (0-100 N-m) | |
| Other | Tailpipe extension beyond vehicle perimeter | at least 1 | inch (25.4 mm) | |
| Pressure | Cooling System Pressure Cap | 14 | psi | |
| Pressure | Cooling system pressure | 14 | psi | |
| Pressure | Cylinder Compression Test | 2.55 | mPa (370 psi) minimum | |
| Pressure | Cylinder Compression Test | 2.55 MPa (370 psi) minimum | ||
| Pressure | Cylinder Compression Test | 370 | psi minimum | |
| Pressure | Cylinder Compression Test | 370 psi (2.55 mPa) minimum | psi | |
| Pressure | Exhaust Back Pressure (full load, max) | 51 | mm (2 in) water column | measured within 153 mm (6 in) of muffler outlet flange |
| Pressure | Fuel Injection Timing (BTDC) | 14.25 | degrees | |
| Pressure | Fuel Nozzle Injection Pressure | 13.731 | mPa (1991 psi) | |
| Pressure | Fuel Nozzle Injection Pressure | 13.731 MPa (1991 psi) | ||
| Pressure | Fuel Nozzle Injection Pressure | 1991 | psi | |
| Pressure | Fuel Nozzle Injection Pressure | 1991 psi (13.731 mPa) | psi | |
| Pressure | Fuel pump flow (minimum) | 200 | ml (0.4 pints) per minute | During prime with Start/Stop held at STOP |
| Pressure | Low Oil Pressure Shutdown | 14 | psi (97 kPa) | 3 seconds, switch closed |
| Pressure | Low Oil Pressure shutdown threshold | less than 14 psi for 3 seconds | psi | during normal operation |
| Pressure | Oil Pressure Switch opens | 14 psi (96 kPa) | psi | |
| Pressure | Oil Pressure Switch opens at | 14 psi (96 kPa) | psi | |
| Resistance | Coolant Temperature Sender | 1300 ohms in ice water, 700 ohms at room temperature, 57 ohms in boiling water | ohms | |
| Resistance | Coolant Temperature Sender | approximately 2617 ohms in ice water or 54 ohms in boiling water | ohms | |
| Resistance | Governor Actuator | 2 to 4 | ohms | |
| Resistance | Governor Actuator | 2 to 4 ohms | ohms | |
| Resistance | Governor Actuator (Code 19 test) | 2.8 to 2.9 ohms | ohms | |
| Resistance | Governor Actuator (fault code 19 test) | 2.8 to 2.9 | ohms | |
| Resistance | Insulation Rotor (P3-7) to GROUND | 1 megohm minimum | megohm | |
| Resistance | Insulation T1, T3 & Q1 to GROUND | 1 megohm minimum | megohm | |
| Resistance | Insulation T1-T3, T2-T4, T1-Q1, T3-Q1 | 1 megohm minimum | megohm | |
| Resistance | New Stator Winding Insulation Resistance | at least 5 megohms | megohm | dry windings; polarization index at least 2 |
| Resistance | Q1-Q50 (P3-3 to P3-5) | 2.4-2.9 | ohms | |
| Resistance | Q1-Q60 (P3-3 to P3-6) | 2.0-2.4 | ohms | |
| Resistance | Rotor (P3-7 to P3-8) | 19.4 | ohms | |
| Resistance | Rotor (P3-7 to P3-8) | 22.5 | ohms | |
| Resistance | Stator Winding Resistance - Main Winding T1-T2 | 0.2 (10 kW) / 0.15 (12.5 kW) | ohms | at 77 F (25 C), +/- 10% |
| Resistance | Stator Winding Resistance - Quad Winding Q1-Q2 | 1.1 (10 kW) / 1.0 (12.5 kW) | ohms | at 77 F (25 C), +/- 10% |
| Resistance | Stator Winding Resistance - Rotor | 22.0 (A053L081, 10 kW) / 25.9 (A053L502, 12.5 kW) | ohms | at 77 F (25 C), +/- 10% |
| Resistance | Voltage Sense Transformer TX1 secondary winding | approximately 586 ohms | ohms | between P1-33 and P1-34 |
| Resistance | Winding Insulation Resistance (in service) | not less than 1 megohm | megohm | winding-to-winding or winding-to-ground |
| Resistance | Winding T1-T2, T3-T4 | 0.178-0.218 | ohms | @ 70° F (21° C) |
| Resistance | Winding T1-T2, T3-T4 | 0.197-0.241 | ohms | @ 70° F (21° C) |
| Speed | High-Idle Speed | 67.3-68.3 Hertz (2019-2049 rpm) | Hz | |
| Speed | High-Idle Speed | 67.3-68.3 Hz (2019-2049 rpm) | Hz | |
| Speed | Mechanical Fault threshold | engine speed fell below 1000 RPM for 0.5 seconds | rpm | |
| Speed | Over Frequency shutdown threshold | more than 70 Hz for 40 ms or more than 66 Hz for 6 seconds | Hz | after starter engaged |
| Speed | Over Frequency threshold | more than 70 Hz for 40 milliseconds or more than 66 Hz for 6 seconds | Hz | |
| Speed | Starter disconnect | 800 | rpm | |
| Speed | Under Frequency shutdown threshold | less than 54 Hz for more than 8 seconds | Hz | during normal operation |
| Speed | Under Frequency threshold | less than 54 Hz for more than 8 seconds | Hz |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Recommended fluids
| Fluid | Grade | Standard | Ambient | Capacity | Notes |
|---|---|---|---|---|---|
| Coolant | 50/50 ethylene glycol antifreeze / distilled water | above -37°C | 6.6 quart | Suitable for temperatures down to -34 F (-37 C) | |
| Coolant | 50/50 mixture of ethylene glycol anti-freeze and water | Fully formulated with rust inhibitors and coolant stabilizers; use fresh water low in minerals and corrosive chemicals (distilled best) | above -37°C | Factory fill suitable for temperatures down to -34 F (-37 C); see Section 14 Specifications for coolant capacity | |
| Coolant | 50/50 mixture of ethylene glycol antifreeze and water | fully formulated with rust inhibitors and coolant stabilizers; distilled water best | above -37°C | 6.2 liter | Suitable for temperatures down to -34 F (-37 C) |
| Coolant | Ethylene glycol antifreeze, 50/50 mixture | above 37°C | 6.2 liters (6.6 qt) | Fully formulated with rust inhibitors and coolant stabilizers, mixed with fresh distilled water | |
| Engine oil | SAE 15W-40 (multi-grade recommended for year-round use) | API CF, CF-4, CG-4, CH-4 or CI-4 | 5.9 quart | CF, CF-4, CG-4, CH-4 or CI-4 required with low/ultra-low sulfur fuel in emissions-regulated areas; CF class recommended for high sulfur fuel in non-regulated areas (change oil/filter twice as often) | |
| Engine oil | SAE 15W-40 multi-grade recommended for year-round use | API performance Class CH-4 or better | 5.9 quarts (5.6 liters) | Choose SAE viscosity grade per Figure 2-1 for ambient temperatures expected until next scheduled oil change | |
| Engine oil | SAE 30 (OnaMax) | API SJ, SH or SG, may be in combination with CH-4, CG-4 or CF-4 | above 0°C | 5.6 liters (5.9 qt) | 0 C (32 F) and higher |
| Engine oil | 15W-40 (OnaMax) | API SJ, SH or SG, may be in combination with CH-4, CG-4 or CF-4 | 12°C to 38°C | -12 to 38 C (10 to 100 F) | |
| Engine oil | 10W-30 / 10W-40 | API SJ, SH or SG, may be in combination with CH-4, CG-4 or CF-4 | 18°C to 27°C | -18 to 27 C (0 to 80 F) | |
| Engine oil | 5W-30 | API SJ, SH or SG, may be in combination with CH-4, CG-4 or CF-4 | 28°C to 10°C | -28 to 10 C (-20 to 50 F) | |
| Fuel | Bio-diesel B5-B20 blend | ASTM D7467 (blend); ASTM D6751 or EN14214 (bio-diesel component); ASTM D975 (petroleum diesel component) | Fuel tanks must be aluminum, steel, fluorinated polyethylene, fluorinated polypropylene, or Teflon (PTFE); bio-diesel compatible fuel water separator required; not recommended for emergency standby/low annual hour use | ||
| Fuel | Diesel Grade 1-D or 2-D, S500 or S15 | ASTM D975 or EN 590 | Minimum Cetane Rating 45 (50 below -4F/-20C or above 5000 ft/1500m); B5 Bio-Diesel suitable; sulfur content max 10,000 ppm (1.0% weight) | ||
| Fuel | No. 2 diesel (ASTM 2-D) above freezing; No. 1 diesel (ASTM 1-D) below freezing | Cetane number of at least 45 | B5 biodiesel suitable; B5-B20 blends require ASTM D7467 (bio-diesel component ASTM D6751 or EN14214, petroleum diesel component ASTM D975) and additional OEM conditions | ||
| Fuel | No. 2 diesel fuel (ASTM 2-D) above freezing; No. 1 diesel fuel (ASTM 1-D) below freezing | Cetane number of at least 45 | Bio-diesel B5-B20 approved per ASTM D7467; use within 6 months of manufacture | ||
| Fuel | No. 2 diesel fuel (ASTM 2-D) when outdoor ambient above freezing; No. 1 diesel fuel (ASTM 1-D) when below freezing | Cetane number of at least 45; ULSD meeting ASTM D975 lubricity is suitable; B5 Bio-Diesel meeting industry specifications and quality is suitable | Use clean, fresh fuel; ULSD has 1 to 2 percent less energy content |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Fault codes
24| Code | Name | Meaning | Severity | Action |
|---|---|---|---|---|
| 1 | Engine Over Temperature | Shutdown due to high engine coolant temperature (exceeded 239° F [115° C] for 10 seconds) | Shutdown | Check coolant level, remove blockages, clean radiator, reduce load, check fan belts, check for air leaks, reconnect sender E3, replace thermostat, test sender E3. |
| 12 | Over Voltage | Output voltage jumped to more than 150 VAC [125% of rated] for 75 ms or more than 138 VAC [115% of rated] for 3 seconds | Shutdown | Turn breaker OFF, measure output; if normal problem external; if no voltage test windings and voltage sense transformer; replace control board. |
| 13 | Under Voltage | Output voltage fell to less than 108 VAC [90% of rated] for 5 seconds | Shutdown | Turn off line circuit breaker; run with fewer connected loads |
| 14 | Over Frequency | Frequency jumped to more than 70 Hz for 40 ms or more than 66 Hz for 6 seconds | Shutdown | Reset tripped breaker, check fuel fittings, test governor actuator, check high-idle speed, replace control board |
| 15 | Under Frequency | Frequency fell to less than 54 Hz for more than 8 seconds | Shutdown | Turn breaker OFF and restart, run fewer loads, check fuel fittings and reprime, replace air filter and clean spark-arrest muffler, replace fuel filter, fuel flow test, test/replace governor actuator, check high-idle speed, replace control board, service injectors/pump and engine. |
| 19 | Governor Actuator | Controller sensed an open or shorted governor actuator/harness at startup | Shutdown | See an authorized Onan dealer |
| 2 | Low Oil Pressure | Shutdown due to loss of engine oil pressure (dropped to less than 14 psi for 3 seconds) | Shutdown | Check oil level, drain excess oil, test low oil pressure switch S2, service engine. |
| 22 | Governor Actuator Overload | Governor actuator maintained at full duty cycle (maximum PWM) for 60 consecutive seconds | Shutdown | Reduce loads, check fuel fittings, replace air and fuel filters, fuel flow test, test actuator, check high-idle speed |
| 24 | Faulty Engine Temperature Sender | Controller sensed an open temperature sender/harness after 10 minutes of normal operation | Warning | See an authorized Onan dealer |
| 27 | Voltage Sense | The Controller lost VAC sensing during normal voltage regulation when the field was functioning and frequency was at least 40 Hz | Shutdown | See an authorized Onan dealer |
| 29 | High Battery Voltage | Voltage across battery system is greater than 19 Volts | Warning | Check battery connections (parallel 12 V not series 24 V), select lower booster charge rate, verify ground at P1-27 |
| 3 | Service Check | See second-level fault code (flashed via STOP/PRIME) | Warning | Press Stop once to read second-level fault code and refer to Table 12-1. |
| 32 | Starting Fault | The Controller could not detect cranking speed (quadrature zero crossings) for 12 seconds | Shutdown | Run vehicle engine while starting, service battery, change oil viscosity, check relay K2 wiring, service starter motor |
| 35 | EE Checksum Fault | Microprocessor EEPROM error occurred during self test | Shutdown | See an authorized Onan dealer |
| 36 | Mechanical Fault | The Controller declared this fault because engine speed fell below 1000 RPM for 0.5 seconds, though not by Controller action | Shutdown | Check fuel level, prime fuel system; check air filter element; check for mechanical damage |
| 37 | Invalid Set Configuration Fault | Continuous 'Stop' input connected to Ground or MAT sensor input not Open; logic checked at every Start or Prime attempt | Warning | Check for any open wire connections for continuous Stop and MAT sensor and repair |
| 38 | Over Current (Field Overload) | Low power factor loads | Shutdown | Reduce low power factor appliances, have air conditioners checked, test generator field and stator windings |
| 4 | Over Crank | First-level fault — cranking time exceeded 35 seconds | Shutdown | Check fuel level, prime fuel system; check air filter element; replace engine oil with proper viscosity; check fuel fittings; replace fuel filter |
| 41 | Generator Rotor Short | While flashing the field the Controller sensed the rotor circuit was shorted to ground | Shutdown | See an authorized Onan dealer |
| 42 | ROM Fault | Microprocessor ROM error occurred during self test | Shutdown | See an authorized Onan dealer |
| 43 | RAM Fault | Microprocessor RAM error occurred during self test | Shutdown | See an authorized Onan dealer |
| 45 | Speed Sense Lost | Controller lost speed sense for 0.25 seconds after start disconnect | Shutdown | See an authorized Onan dealer |
| 48 | Loss of Field Sense | The field sense circuit on the Controller circuit board failed during normal voltage regulation | Shutdown | See an authorized Onan dealer |
| 57 | Overprime | The local or remote control switch was held in the Prime position for more than 3 minutes | Warning | Stop holding the control switch in the Stop position |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Procedures
12Adjusting Voltage adjustment
⚠ Touching uninsulated live parts can result in severe personal injury or death
Tools: Accurate AC voltmeter
- Disconnect all loads and connect accurate meters to measure AC output voltage.
- Start the generator set and let voltage and frequency stabilize for 5 to 10 seconds.
- Rapidly press START 6 times; the status lamp blinks once a second.
- Press START and release quickly to increase voltage about 0.6 volt.
- Press START about 1 second to decrease voltage about 0.6 volt.
- Normal operation resumes in 20 seconds; last adjustment saved by controller.
Belt Tension When Equipped With Battery Charging Alternator adjustment
- Remove top genset housing panel.
- Adjust tension so deflection is 8-10 mm (0.3-0.4 inch) midway between alternator and pump pulleys when 10 kg (22 pounds) force is applied.
Belt Tension When Not Equipped With Battery Charging Alternator adjustment
- Run new belt over both pulleys and pull pump pulley up to its hub and push it on.
- Secure pulley with 4 bolts and tighten according to specifications.
HIGH-IDLE SPEED reset adjustment
⚠ Adjusting screws near rotating belts and pulleys; be careful not to get hands near pulleys and belts.
Tools: 12 volt battery
- Remove governor actuator to allow full fuel rack, leave connected to avoid Fault No. 19.
- Disconnect fuel pump and power directly with 12 volt battery.
- Disconnect all loads and start genset.
- Adjust stop screws to obtain 67.3-68.3 Hertz (2019-2049 rpm).
- Seal adjusting threads with paint.
- Re-install all removed or disconnected components.
Resetting High-Idle Speed adjustment
⚠ Adjusting screws are near rotating belts and pulleys that can cause severe personal injury
- Remove governor actuator but leave it connected; plug the opening.
- Disconnect the fuel pump and power it directly with a 12-volt battery.
- Disconnect all loads from the generator set and start it.
- Adjust the stop screws to obtain 67.3-68.3 Hertz (2019-2049 rpm).
- Seal the adjusting threads with paint.
- Reinstall all components that were removed or disconnected.
Fuel Flow Test diagnostic
⚠ Fuel pump is not serviceable
Tools: Graduated container
- Disconnect the fuel return hose and point the end into a graduated 1 liter container.
- Hold the Start/Stop switch in STOP for the duration of the test.
- Flow should not be less than 200 ml (0.4 pints) per minute.
- If low, replace the fuel filter; check for restrictions; then replace the fuel pump.
Hot Air Recirculation Test diagnostic
⚠ Exhaust gas is deadly
Tools: thermocouples (24 AWG or lighter)
- Complete a representative installation
- Conduct test in well-ventilated space protected from cross drafts
- Connect large constant load (at least 3/4 full load if load bank available)
- Measure temperatures with thermocouples not heavier than 0.21 mm2 (24 AWG)
- Measure generator set intake air temperature 25.4 mm (1 in) from radiator face
- Measure ambient air temperature within 1.2 m (4 ft) of generator set, shielded from sun/discharge air
- Close all compartment doors, run generator set at least 90 minutes, record temperatures at 15 minute intervals
AC Power Output Connections - Wiring Methods installation
⚠ Improper wiring can cause fire or electric shock
- Have a qualified electrician supervise and inspect all AC wiring installation
- Secure only one lead at each AC output terminal (terminals suitable up to No. 6 AWG)
- Install vibration-proof switches and controls
- Use rain-tight conduit, conduit connectors and junction boxes for exterior wiring
- Provide GFCIs for all convenience power receptacles
- Route AC wiring, remote control wiring, and fuel lines separately
- Seal all conduit openings into vehicle interior with silicone rubber or equivalent sealant
- Connect grounding terminal TB2-4 per applicable codes
Installing the Generator installation
- Ensure chamfered edge of drive disc faces flywheel.
- Thread ends of through bolts with shorter thread lengths into adaptor casting.
- Ensure O-ring is in place in bearing bore of end bell; grease bore lightly.
- Before securing air inlet adaptor, ensure brush block is in place and wire holding brushes is removed.
Remote Control Connections installation
- Remove AC terminal access cover and remove one control wiring knockout
- Pull out remote control connector plug, fit bushing into knockout slot, secure access cover
- Snap connector plug and harness receptacle together
- If no plug, use solder-type butt connectors and heat-shrink tubing with 18 AWG copper conductors
- Route control leads separately from AC power leads
- Seal opening where leads enter vehicle interior with silicone rubber or equivalent
Starting Battery Connections installation
⚠ Accidental starting can cause severe personal injury or death
⚠ Arcing can ignite explosive battery hydrogen gas
- Size battery cables per Battery Cable Sizes table
- Coat all battery cable connections with battery terminal oxidation inhibitor
- Terminate battery cables with ring terminals sized for 5/16 inch screws
- Secure insulating boot on positive (+) terminal, tie to cable with tie-wrap
- Torque positive (+) cable terminal to 9-12 Nm (7-9 ft-lbs)
- Torque negative (-) cable terminal to 9-12 Nm (7-9 ft-lbs)
- Connect battery cables to battery, positive (+) cable first, only after installation review checklist is complete
Tailpipe Installation installation
⚠ Exhaust gas is deadly
⚠ Do not use flexible pipe for tailpipe
⚠ Hot tailpipe can cause severe burns
- Use 18-gauge 1-3/8 inch I.D. aluminized steel tubing or equivalent for tailpipe
- Secure tailpipe/adapter flange to muffler flange with gasket and 2 stainless steel M8 x 1.25 bolts
- Use U-bolt muffler clamps to connect tailpipe sections, slot overlapping pipe
- Use automotive-type tailpipe hangers every 600-900 mm (2-3 ft), attached to steel framework
- Extend tailpipe minimum 25 mm (1 in) beyond perimeter of vehicle; do not terminate underneath vehicle
- Do not route within 76 mm (3 in) of combustible material unless insulated/shielded
- Do not terminate closer than 153 mm (6 in) to any opening into vehicle interior
- Do not interconnect generator set and vehicle engine exhaust systems
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Voltage reconnection
| Voltage | Phase | Connection | Leads | Notes |
|---|---|---|---|---|
| Pin A | Battery Ground | 10-pin remote control connector | ||
| Pin B | Status Light | 10-pin remote control connector | ||
| Pin C | Start/Preheat | 10-pin remote control connector | ||
| Pin D | Not Used | 10-pin remote control connector | ||
| Pin E | Stop/Prime | 10-pin remote control connector | ||
| Pin F | Hour Meter | 10-pin remote control connector | ||
| Pin G | Not Used | 10-pin remote control connector | ||
| Pin H | Not Used | 10-pin remote control connector | ||
| Pin J | Service Tool | 10-pin remote control connector | ||
| Pin K | Service Tool | 10-pin remote control connector |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Common questions
Which oil filter part number does the Cummins/Onan HDKCA take?
The Cummins/Onan HDKCA uses oil filter part number 122-0893.
What fuel filter fits the Cummins/Onan HDKCA?
The Cummins/Onan HDKCA uses fuel filter part number 149-2513.
What air filter does the Cummins/Onan HDKCA use?
The Cummins/Onan HDKCA uses air filter part number 140-3071.
Troubleshooting
6Fault codes
| Code | Meaning |
|---|---|
| Code 1 | Engine Over Temperature |
| Code 2 | Low Oil Pressure |
| Code 3 | Service Check |
| Code 4 | Over Crank |
| Code 12 | Over Voltage |
| Code 13 | Under Voltage |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing. Full Cummins/Onan HDKCA troubleshooting guide (15 entries) →
Repair guides
16- AC Power Output Connections - Wiring Methods
- Brushes and Slip Rings - Checking and Replacing
- Cleaning the Spark Arrester
- Draining and Refilling Cooling System
- Fuel Flow Test
- HIGH-IDLE SPEED reset
- Installing the Generator
- Manual Starting
- Removal of Engine-Generator-Muffler Assembly
- Removing the Generator
- Removing the Muffler
- Resetting High-Idle Speed
- Starting Battery Connections
- To remove the muffler
- To remove the radiator
- To Replace Fan Coupling
Step-by-step procedures compiled from the Cummins/Onan service manual for this model.
Parts
31| Part # | Description | Qty | System | |
|---|---|---|---|---|
| 0122-0386 | Oil Filter | 1 | Oil filter | eBay |
| 0122-0893 | Filter, Oil | 1 | Oil filter | eBay |
| 0140-3071 | Filter, Air | 1 | Air filter | eBay FridayParts $16.50 |
| 0140-3116 | Element, Air Cleaner | 1 | Air filter | Amazon eBay $9.95 |
| 0140-3351 | Element, Air Cleaner | 1 | Air filter | eBay |
| 0147-0860 | Fuel Filter, EFI | 1 | Fuel filter | Amazon eBay $16.99 NAPA $4.68 |
| 0149-2513 | Filter, Fuel | 1 | Fuel filter | eBay $24.00 |
| 0149-2629 | Fuel Filter, Gasoline | 2 | Fuel filter | eBay |
| 0149-2637 | Fuel Filter, LPG | 1 | Fuel filter | eBay |
| 0149-2661 | Fuel Filter | 1 | Fuel filter | Amazon eBay $21.95 |
| 0167-1638 | Spark Plug | 1 | Spark plug | Amazon eBay $11.95 |
| 0167-1652 | Spark Plug | 1 | Spark plug | Amazon eBay |
| 0185-7444 | Filter, Oil | 1 | Oil filter | eBay |
| 0187-1000 | Filter, Oil | 1 | Oil filter | eBay |
| 122-0893 | Oil filter | Oil filter | eBay $49.99 | |
| 140-3071 | Air filter | 1 | Air filter | Amazon eBay $13.50 FridayParts $16.50 |
| 143-1769 | Air Filter Element | 1 | Air filter | Amazon |
| 143-2058 | Oil Filter | 1 | Oil filter | Amazon eBay |
| 143-2069 | Fuel Filter | 1 | Fuel filter | Amazon eBay |
| 143-2078 | Coolant Filter | 1 | Coolant filter | Amazon eBay |
| 143-2095 | Belt | 1 | Belt | Amazon eBay |
| 143-2108 | Spark Plug | 1 | Spark plug | Amazon eBay |
| 149-2513 | Filter, Fuel | 1 | Fuel filter | Amazon eBay $36.95 NAPA $31.59 FridayParts $48.61 |
| 185-5990 | Glow Plug (12 Volt) | 1 | Glow plug | Amazon eBay $55.74 |
| 500-4040 | OUTLINE DRAWING | Outline drawing | Amazon eBay | |
| 630-2676 | CONTROL SCHEMATIC | Control schematic | Amazon eBay | |
| A030Y328 | Filter, Air | 1 | Air filter | Amazon eBay $30.43 |
| 0212-1285 | Block, Brush | 1 | Service part / kit | eBay |
| 0212-1285-S0 | Block, Brush | 1 | Service part / kit | eBay |
| 0212-1303 | Block, Brush | 1 | Service part / kit | eBay $75.00 |
| A043H188 | Brush Block | 1 | Service part / kit | Amazon eBay |
Service, wear & replacement parts referenced for this model and its engine — confirm the exact part for your serial number. See the full parts catalog to search and cross-reference.
Fuel consumption
| Rating | Load | L/h | gal/h |
|---|---|---|---|
| Full-load | 4.54 | 1.2 | |
| Full_load | 100% | 3.0 | 0.78 |
| Half-load | 1.82 | 0.48 | |
| Half_load | 50% | 2.0 | 0.54 |
| No-load | 0.41 | 0.11 | |
| No_load | 1.2 | 0.33 |
Available documents
Operator's manual (Cummins/Onan)Operator's manual — 981-0173 Onan HDKCA HDKCB Mobile Diesel Genset Operators manual (01-2009) (Cummins/Onan)Parts manual — HDKCA, HDKCB Parts Manual (Cummins/Onan)Service manual (Cummins/Onan)Service manual — 0981-0640 (Cummins/Onan)Service manual — 981-0540B Onan HDKCx (HDKCA to HDKCD) Mobile Diesel Genset Service manual (10-2006) (Cummins/Onan)Service manual — A043D713 (Cummins/Onan)Service manual — a043m526-i13-hdkcx-service-manual (Cummins/Onan)
This page was generated from the 8 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.