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Cummins/Onan Repair Guides

236 step-by-step procedures compiled from Cummins/Onan service manuals.

Removing the Frame (disassembly chart example)

2400, 3500

Installing Piston Rings

2400, 3500

Checking Oil Level Switch Continuity

2400, 3500

Measuring Ignition Coil Resistance

2400, 3500

Rotor Loosening

4CFKM, 4CFKM/4CKMR (50 Hz), 4CFKMR, 4CKM

Generator Disassembly Preparation

P3200i, P4300i, RG2800i, RG2800iS

Water Pump Disassembly

J Series, J-Series, JC - 3CR / 96 T, MAJ

Remove the outer housing panels (Figure 4-2) to

HDZAA

connector shorts to ground.

HDZAA

CONNECTOR

HDZAA

Disconnect the 6-pin connector from the Internal

HDZAA

connections between the engine harness and

HDZAA

Installation Manual).

HDZAA

replace the inverter.

HDZAA

Remove exhaust and test, (spark arrestor

HDZAA

Check the popping pressure and replace as

HDZAA

connector on the internal control panel and

HDZAA

check for air leaks with soapy water at fittings

HDZAA

Check the popping pressure and replace as

HDZAA

connectors. A loose, contaminated, or mis-

DKG, RGA-IN1

replace if bad.

DKG, RGA-IN1

Check lead continuity per

DKG, RGA-IN1

Connect the positive lead to the F1 (+}exciter stator

DKG, RGA-IN1

connect electrical power by removing starting

DKG, RGA-IN1

CONNECTION TO GENERATOR

DKG, RGA-IN1

REPLACEMENT

DKG, RGA-IN1

Disconnect lead wires from diodes CR1, CR2,

DKG, RGA-IN1

Check for grounds between each rotor lead and the

DKG, RGA-IN1

removed and installed. More often than not, this other work is covered by another SRT. If the

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

installed in order to access the engine or generator set.

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

Remove And Install

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

Removed

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

connector to voltage regulator

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

connector to voltage regulator

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

connector to voltage regulator

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

Removed

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

Removed

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

Removed

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

CONNECT

AT U C D ‘400 - 4X / 11 10 C

remove undervoltage sensors, 2 and 3 (if

AT U C D ‘400 - 4X / 11 10 C

remove the panel as described under Changing

AT U C D ‘400 - 4X / 11 10 C

removed, con=

AT U C D ‘400 - 4X / 11 10 C

Install the terminal boards (from new control

AT U C D ‘400 - 4X / 11 10 C

Disconnect the starting batteries.

AT U C D ‘400 - 4X / 11 10 C

connections on the transformer for the nominal

AT U C D ‘400 - 4X / 11 10 C

replace with the 12-volt time delay module 300-

AT U C D ‘400 - 4X / 11 10 C

replace with the 24-volt time delay module 300-

AT U C D ‘400 - 4X / 11 10 C

replace with 322-0126 and 322-0127 lamps

AT U C D ‘400 - 4X / 11 10 C

replace with a 300-0926 2 to 3 wire converter

AT U C D ‘400 - 4X / 11 10 C

INSTALLATION OF KEYING PLUG

AT U C D ‘400 - 4X / 11 10 C

Remove the receptacle and circuit breaker mounting

5.0N8-341E, 5.0N8-341P, 5.0N8-343E, 5.0N8-343P

Remove the 1/4-20 machine bolt from the top-center

5.0N8-341E, 5.0N8-341P, 5.0N8-343E, 5.0N8-343P

CLEANING

5.0N8-341E, 5.0N8-341P, 5.0N8-343E, 5.0N8-343P

connection circuit in Figure 28.

5.0N8-341E, 5.0N8-341P, 5.0N8-343E, 5.0N8-343P

install the sheave assembly in the cover so that the

5.0N8-341E, 5.0N8-341P, 5.0N8-343E, 5.0N8-343P

INSTALLING THE READI-PULL STARTER

5.0N8-341E, 5.0N8-341P, 5.0N8-343E, 5.0N8-343P

INSTALLATION OF READI-PULL STARTER

5.0N8-341E, 5.0N8-341P, 5.0N8-343E, 5.0N8-343P

connects the field winding to the battery to provide

3.6MKY, 4MKY

CONNECTORS P5 & P6

3.6MKY, 4MKY

check that each brush is being held off the slip

3.6MKY, 4MKY

remove.

3.6MKY, 4MKY

installation.

3.6MKY, 4MKY

Install the rotor through bolt and washer. Verify

3.6MKY, 4MKY

Remove the fan (Steps 1 through 9, p. 7-3). In-

3.6MKY, 4MKY

Remove the fan (Steps 1 through 9, p. 7-3). In-

3.6MKY, 4MKY

CONNECTOR

3.6MKY, 4MKY

Inspection

3.6MKY, 4MKY

clean the fan hub assembly. Replace the fan

3.6MKY, 4MKY

clean the engine cooling fins.

3.6MKY, 4MKY

remove the outer housing (see Section 5. Pre-

3.6MKY, 4MKY

Installation

RBAA

Installation is the reverse of removal.

RBAA

connecting the leads from the main rotor (generator

RBAA

connect power, and then switch it ON.

RBAA

Generator Rotor Removal

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

Brush Replacement

HDKAG

Testing for Grounded Rotor

HDKAG

Carburetor Adjustment Under Load

General procedure

Engine Speed Adjustment

General procedure

Flame Arrestor Service (Marine Models)

L600, L654

Exhaust Manifold Removal

NHM

Spark Plug Installation and Tightening

NHM

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

DKG, RGA-IN1

Service Procedure

DKG, RGA-IN1

Service Procedure

DKG, RGA-IN1

Service Procedure

DKG, RGA-IN1

Service Procedure

DKG, RGA-IN1

Service Procedure

DKG, RGA-IN1

Service Procedure

DKG, RGA-IN1

Service Procedure

DKG, RGA-IN1

Service Procedure

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

Service Procedure

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

Service Procedure

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

Service Procedure

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

Service Procedure

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

Service Procedure

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

Service Procedure

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

5.0N8-341E, 5.0N8-341P, 5.0N8-343E, 5.0N8-343P

Service Procedure

5.0N8-341E, 5.0N8-341P, 5.0N8-343E, 5.0N8-343P

Service Procedure

5.0N8-341E, 5.0N8-341P, 5.0N8-343E, 5.0N8-343P

Service Procedure

5.0N8-341E, 5.0N8-341P, 5.0N8-343E, 5.0N8-343P

Service Procedure

5.0N8-341E, 5.0N8-341P, 5.0N8-343E, 5.0N8-343P

Service Procedure

5.0N8-341E, 5.0N8-341P, 5.0N8-343E, 5.0N8-343P

Service Procedure

3.6MKY, 4MKY

Service Procedure

3.6MKY, 4MKY

Service Procedure

3.6MKY, 4MKY

Service Procedure

3.6MKY, 4MKY

Service Procedure

3.6MKY, 4MKY

Service Procedure

3.6MKY, 4MKY

Service Procedure

3.6MKY, 4MKY

Service Procedure

RBAA

Service Procedure

RBAA

Service Procedure

RBAA

Service Procedure

RBAA

Service Procedure

RBAA

Service Procedure

RBAA

Service Procedure

RBAA

Service Procedure

RBAA

Service Procedure

RBAA

Service Procedure

RBAA

Service Procedure

RBAA

Generator Rotor Removal

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

Generator Bearing Inspection and Maintenance

MDKUB/MDKWB, MDKWB

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

HDZAA

Service Procedure

DKG, RGA-IN1

Service Procedure

DKG, RGA-IN1

Service Procedure

DKG, RGA-IN1

Service Procedure

DKG, RGA-IN1

Service Procedure

DKG, RGA-IN1

Service Procedure

DKG, RGA-IN1

Service Procedure

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

Service Procedure

00-901, 00-0AA, 00-0AB, 00-0AD, 00-0AG, 00-0AH, 00-0AN, 00-0AZ, 00-0CM, 00-010, 00-014, 00-022, 00-041, 00-046, 00-047, 00-048, 00-1AB, 00-1AC, 00-201, 00-3AB

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

AT U C D ‘400 - 4X / 11 10 C

Service Procedure

5.0N8-341E, 5.0N8-341P, 5.0N8-343E, 5.0N8-343P

Service Procedure

5.0N8-341E, 5.0N8-341P, 5.0N8-343E, 5.0N8-343P

Service Procedure

5.0N8-341E, 5.0N8-341P, 5.0N8-343E, 5.0N8-343P

Service Procedure

3.6MKY, 4MKY

Service Procedure

3.6MKY, 4MKY

Service Procedure

3.6MKY, 4MKY

Service Procedure

3.6MKY, 4MKY

Service Procedure

3.6MKY, 4MKY

Service Procedure

3.6MKY, 4MKY

Service Procedure

RBAA

Service Procedure

RBAA

Service Procedure

RBAA

Service Procedure

RBAA

Brush Replacement

HDKAG

Rotor Insulation Testing

HDKAG

Engine Speed Adjustment

General procedure

Generator Rotor Removal

10/15RMOY, 15/17.5ROY, 15RMY, 22.5-47.5ROZ

AC SCHEMATIC - ELECTRONIC REG

MDL3, MDL4, MDL6

ASSEMBLE DRIVE DISK

MDL3, MDL4, MDL6

ELECTRICAL SCHEMATIC

MDL3, MDL4, MDL6

TESTING ROTATING RECTIFIERS

MDL3, MDL4, MDL6

TESTING GENERATOR STATOR

MDL3, MDL4, MDL6

WIRING HARNESS CHECK

MDL3, MDL4, MDL6

NOZZLE INSTALLATION

20W-20

NOZZLE REPAIR

20W-20

BUTTON WITH CODE LETTER

20W-20

PREPARATION FOR PUMP

20W-20

R O T A T E F A C E G E A R U N T I L

20W-20

TIMING BUTTON THICKNESS

20W-20

BLEEDING FUEL SYSTEM

20W-20

ENGINE DISASSEMBLY

4CCK, 5CCK

TESTING AND ADJUSTING PLANTS

4CCK, 5CCK

ADJUSTMENTS

4CCK, 5CCK

USE INSIDE MOUNTING

4CCK, 5CCK

LOOSEN THE SCREWS

4CCK, 5CCK

STARTING SYSTEM

NH-MS/1, NH-S/1

INSPECTION OF PARTS

NH-MS/1, NH-S/1

INSTALLING THE READI-PULL STARTER

NH-MS/1, NH-S/1

STARTER ROPE

NH-MS/1, NH-S/1

COOLING SYSTEM

TGHAA

ENGINE-GENERATOR

TGHAA

LUBRICATION SYSTEM

TGHAA

CUTOUT SWITCH

TGHAA

GOVERNOR ROD AND ACTUATOR

TGHAA

Water Pump Disassembly

MJA, MJB, MJC

Water Pump Assembly

MJA, MJB, MJC

Centrifugal Pump Disassembly

MJA, MJB, MJC

Centrifugal Pump Assembly

MJA, MJB, MJC

Generator Disassembly

MDKAD/MDKAE/MDKAF

Generator Reassembly

MDKAD/MDKAE/MDKAF

Engine Disassembly

4.0BF-1R/9500

Engine Assembly

4.0BF-1R/9500

Tappet Adjustment (Valve Clearance)

4.0BF-1R/9500

Flywheel Removal

4.0BF-1R/9500

Remove Blower Wheel

N52M, NHA, NHAV, NHB

Tappet Adjustment

General procedure

Starter Motor Armature Removal and Disassembly

NHP-NHPV

Disconnections Before Removal

2018

Disconnections Before Removal

2018

Disconnecting the Generator Set

QG7000i DF Generator Set for RV, RV Generator Set

Removing the Generator Set

QG7000i DF Generator Set for RV, RV Generator Set