Cummins/Onan — Generator Set Removal

For these Cummins/Onan models: HDKAH, HDKAK.

Applies to: Cummins Onan Hdkah, Cummins Onan Hdkak

Procedure

1. Remove all mounting bolts.
2. Slide the generator set out of the compartment onto the forklift.
3. Slowly lower the generator set before moving it to the service area.
4. Preparing for Service
5. Use a forklift to support the generator set. Raise the lift so it contacts the bottom of the generator set
6. Loosen the bolts between the generator set base pan and side mounting panels (loosen bolts about
7. Loosen the bolts securing the side panels to the rear panel (note slotted holes) or braces and pull
8. Retighten side panels to back panel bolts.
9. Remove the mounting bolts securing the side and rear panels to the generator set.
10. Slowly lower the generator set until it clears all obstructions and can be safely moved out from under
11. Preparing for Service
12. Preparing for Service
13. Remove the tall screws around the parameter of each panel.
14. Pull the panel away.
15. Remove the top panel.
16. Remove the screws around the perimeter of the back panel.
17. Remove the 2 screws securing the back panel to the radiator frame.
18. Loosen the screws along the bottom edge of the left end panel, tilt the left end panel out so the back
19. Remove the top panel.
20. Remove the screws around the perimeter of the right end panel.
21. Remove the right end panel.
22. Remove the front, top and back panels.
23. Remove the AC terminal block mounting screws.
24. Remove the line circuit breaker mounting screws from the control panel.
25. Disconnect the engine harness from the control panel switch and hour meter (if provided).
26. Remove the screws along the bottom edge of the left panel and tilt panel out.
27. Disconnect the leads to the control switch and the hour meter (if provided), cutting wire ties securing
28. Remove the left end panel.
29. Preparing for Service
30. Remove the 4 screws holding the service door on the engine side enclosure panel. Make sure that
31. Pull the service door straight out until the 2 studs are free from the insulation.
32. Set the service door aside and use a box cutter to cut the insulation along the edge of the
33. Pull the insulation out and use push nuts to secure the cutout piece of insulation onto the service
34. Reinstall the service door with the attached piece of insulation onto the engine side enclosure panel.
35. Installation is the reverse of the removal.
36. Use wire ties to secure the engine and AC harness to the left end panel.
37. Tighten the panel screws according to torque specifications.
38. Preparing for Service
39. Generator Set Control
40. Generator Set Control
41. Energizes fuel pump.
42. Flashes the status indicator to indicate preheat and crank.
43. Energizes the glow plugs for temperature-dependent durations.
44. Energizes the governor actuator (moves toward full rack).
45. Energizes the starter when preheat is complete.
46. De-energizes the starter at 800 RPM.
47. Turns on the status indicator to indicate start disconnect.
48. Turns on switched B+ (remote connector pin J8-F).
49. Enables the inverter (output voltage).
50. Disables output voltage.
51. De-energizes the fuel pump and the governor actuator.
52. Turns off the status indicator.
53. Writes session data (number of cranks, minutes of operation, last fault, etc.) to non-volatile
54. Removes processor power when idle 5 minutes (battery saver function).
55. Energizes the fuel pump.
56. Turns on the status indicator for as long as Stop is held.
57. 2300 RPM is commanded during the first minute of operation.
58. 1950 RPM is commanded during minute 2.
59. 1600 RPM (idle speed) is command for every minute thereafter.
60. Generator Set Control
61. Maintains normal output voltage during steady state.
62. Adjusts the voltage setpoints for transient loads to allow engine recovery.
63. Start the generator set and allow the voltage and frequency to stabilize for 3 to 5
64. Rapidly press the Start switch 6 times during the first minute after startup to put the
65. Press and quickly release the Start switch to increase voltage approximately 0.6 volts.
66. Wait about 20 seconds for the amber status light to stop blinking and press the Stop
67. Start the generator set and allow the voltage and frequency to stabilize for 3 to 5
68. Rapidly press the Start switch 6 times during the first minute after startup to put the
69. Press and holding the Start switch for about 1 second to decrease voltage approximately
70. Wait about 20 seconds for the amber status light to stop blinking and press the Stop
71. Generator Set Control
72. Generator Set Control
73. Disconnect the negative (–) battery cable f
74. Remove the generator set housing panels (front, top and left).
75. Disconnect all external wiring connections and ground straps from the housing.
76. Remove the screw securing the housing to the radiator frame.
77. Remove the 6 screws securing the housing to the inlet baffle assembly.
78. Remove the 5 screws along the lower back of the housing.
79. Lift the control-inverter housing out of the generator set.

Source: manual:0981-0522-i32-hdkax-service-manual.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.