Service parts for the HDKAQ
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
| Alternator | YK Series (4-pole) |
|---|
Maintenance & consumables
| Item | Spec | Capacity | Part # | Interval | |
|---|---|---|---|---|---|
| Air filter | Air Filter | F245-1001 | Amazon eBay | ||
| Fuel filter | Fuel Filter | F245-1002 | Amazon eBay | ||
| Oil filter | Oil Filter | F245-1000 | Amazon eBay | ||
| Belt | Belt | F245-1004 | Amazon eBay | ||
| Coolant filter | Coolant Filter | F245-1003 | Amazon eBay |
Service intervals
32| Item | Action | Hours | Months | Notes |
|---|---|---|---|---|
| Coolant Level | Check | 8 hr | Keep level between COLD and HOT in recovery tank | |
| Engine oil level | Check | 8 hr | ||
| Fuel level | Check | 8 hr | ||
| Generator set | Inspect | 8 hr | Check for oil, fuel, cooling and exhaust system leaks; check exhaust audibly and visually with genset running (footnote 1) | |
| Oil Level | Check | 8 hr | Every Day / 8 Hr per Table 7-1 | |
| Air cleaner dust cap | Check | 50 hr | Clean if required; also serviced at a second interval; perform more often in extremely dusty conditions (footnote 3) | |
| Battery charging system | Check | 50 hr | ||
| Spark arrester | Clean | 50 hr | Clean out spark arrester | |
| Air Cleaner Dust Boot | Clean | 100 hr | 1 mo | Perform more often in dusty conditions (footnote 5) |
| Air cleaner element | Clean | 100 hr | ||
| Battery | Check | 100 hr | 1 mo | See battery manufacturer's recommendations (footnote 2) |
| Battery specific gravity | Check | 100 hr | ||
| Drive belt tension | Check | 100 hr | Visually check belts for evidence of slippage (footnote 4) | |
| Crankcase oil and filter | Change | 200 hr | First service — Change every 200 hours (footnote 7); perform after first 50 hours of operation on new genset (footnote 2) | |
| Anti-freeze | Check | 250 hr | ||
| Fuel filter element | Change | 250 hr | ||
| Fuel filter water/sediment | Drain | 250 hr | Drain one cup of fuel to remove water and sediment (footnote 5) | |
| Fuel shut-off linkage | Check | 250 hr | ||
| Generator assembly | Clean | 250 hr | ||
| 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) |
| Air Cleaner Element | Change | 500 hr | 12 mo | Perform more often in dusty conditions (footnote 5) |
| Cooling system | Clean | 500 hr | ||
| Engine Oil and Oil Filter | Change | 500 hr | 12 mo | First service — Perform more often in dusty conditions (footnote 5) |
| Fuel Filter | Change | 500 hr | 12 mo | Perform every 250 hours when using B20 Bio-diesel fuel (footnote 7) |
| Generator brushes | Check | 500 hr | To be performed by authorized service technician (footnote 6) | |
| Valve Lash | Adjust | 500 hr | 12 mo | Must be performed by an authorized Cummins dealer (footnote 6) |
| Valve clearance | Check | 500 hr | To be performed by authorized service technician (footnote 6) | |
| Coolant | Change | 24 mo | Every 2 Years | |
| Generator Bearing | Replace | 60 mo | Every 5 years; bearing grease deteriorates due to oxidation. Inspect for outer case rotation every 1000 hours. Must be performed by an authorized Cummins dealer (footnote 6) | |
| Pressure Cap | Replace | 60 mo | Every 5 years | |
| Slip Rings and Brushes | Inspect | 6 mo | Generator set should be inspected for brush wear and cleaning every six months |
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 |
|---|---|---|---|---|
| Clearance | Exhaust system distance from combustible material | 3 | in | |
| Clearance | Minimum clearance between genset and compartment insulation | 1 | in | |
| Clearance | Minimum space between engine exhaust components and compartment insulation | 3 | in | |
| 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) |
| 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 rating | 425 | CCA | |
| Other | Battery rating | 625 | CCA | below 32°F (0°C) |
| Other | Battery specific gravity charge threshold | 1.215 | charge battery if specific gravity is less than this | |
| 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 | Circuit breaker rating | 35 | A | 2 pole, 60 Hz |
| Other | Compartment depth | 25 | in | |
| Other | Compartment height | 25 | in | |
| Other | Compartment width | 38.4 | in | |
| Other | Compression ratio | 23 to 1 | ||
| Other | Cooling air requirement - Generator Inlet | 100 | in2 | |
| Other | Cooling air requirement - Radiator | 200 | in2 | |
| Other | Cooling system capacity | 4.73 | L | |
| Other | Cranking time that triggers fault | 35 | seconds | cranking time exceeded fault (4 blinks) |
| Other | Cyclic horizontal forces | ±500 | lbs | ±1 g-force |
| Other | Cyclic vertical forces | ±1500 | lbs | ±3 g-force |
| Other | Displacement | 1001 | cm3 | |
| Other | Displacement | 898 | cm3 | |
| Other | Electrolyte specific gravity, fully charged battery | about 1.260 | specific gravity | at 80 F (27 C) |
| Other | Engine power (max) at 1800 r/min | 11.9 | bhp | at 1800 r/min |
| Other | Engine power (max) at 1800 r/min | 13.1 | bhp | at 1800 r/min |
| Other | Engine power (max) at 1800 r/min | 13.1 bhp HDKAL/HDKAQ; 11.9 bhp HDKAR/HDKAS | bhp | at 1800 r/min |
| Other | Fan belt tension | 22 pounds (10 kg) finger pressure deflects belt about 0.4 inch (10 mm) | in (mm) | at middle of belt |
| Other | Ideal 60 Hz output voltage setting | 120 VAC at 60-61 hz | VAC | measured at the power input of the application |
| Other | Lube oil capacity | 4.25 | L | including filter |
| Other | Maximum cranking time per attempt | 30 | seconds | allow two minutes cooling before next attempt |
| Other | Preheat time | 10 to 20 | seconds | depends on ambient temperature; max 20 seconds |
| Other | Sound level | 78 | dB(a) | @ 3 m rated load |
| Other | Starter current draw | 100 to 150 | A | at 72°F (22°C) |
| Other | Starter inrush current | 300 to 400 | A | |
| Other | Stroke | 73.6 | mm | |
| Other | Tailpipe extension beyond vehicle perimeter | 1 | in | minimum |
| Other | Tailpipe size | 1-1/2 | in I.D. | 18 gauge rigid steel tubing |
| Pressure | Control Power Latch Switch S6 closes | 5 psi (34 kPa) | psi | |
| Pressure | Engine oil pressure | 40 to 60 | psi (276 to 414 kPa) | engine at operating temperature |
| Pressure | Low Oil Pressure Switch S1 closes | 9 psi (62 kPa) | psi | |
| Pressure | Maximum allowable exhaust back pressure | 2 | in Hg | at exhaust manifold |
| Pressure | Oil pressure meter range (optional) | 0 to 100 | psi (0 to 700 kPa) | |
| Pressure | Oil pressure switch actuation (low oil pressure shutdown) | 7 | psi (49 kPa) | pressure drops below |
| Resistance | A053U842 (7.5 kw) Main winding T1-Gnd | .23 | ohms | 10% at 25 C (77 F) |
| Resistance | A053U842 (7.5 kw) Main winding T1-T2 | .43 | ohms | 10% at 25 C (77 F) |
| Resistance | A053U842 (7.5 kw) Main winding T2-Gnd | .22 | ohms | 10% at 25 C (77 F) |
| Resistance | A053U842 (7.5 kw) Quad winding Q1-Q2 | 1.3 | ohms | 10% at 25 C (77 F) |
| Resistance | A053U842 (7.5 kw) Rotor resistance | 18.5 | ohms | 10% at 25 C (77 F) |
| Resistance | Rotor insulation resistance to shaft (minimum) | 100,000 | ohms | test with 500 VDC or more |
| Resistance | Rotor resistance F1-F2 (50 Hz) | 20.7 | ohms | 10% at 25 C |
| Resistance | Rotor resistance F1-F2 (60 Hz) | 18.2 | ohms | 10% at 25 C |
| Resistance | Stator resistance 50 Hz single-phase Q1-Q50 | 2.322 | ohms | 10% at 25 C |
| Resistance | Stator resistance 50 Hz single-phase T1-T2, T3-T4 | 0.227 | ohm | 10% at 25 C |
| Resistance | Stator resistance 50 Hz three-phase Q2-T11 | 0.365 | ohm | 10% at 25 C |
| Resistance | Stator resistance 50 Hz three-phase T1-T4, T2-T5, T3-T6, T7-T10, T8-T11, T9-T12 | 0.703 | ohm | 10% at 25 C |
| Resistance | Stator resistance 60 Hz single-phase (100/200 volts only) Q1-Q60 | 2.3 | ohms | 10% at 25 C |
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 mixture of ethylene glycol antifreeze and water | Reliable brand of antifreeze containing a rust and corrosion inhibitor; must not contain a stop-leak additive | above -37°C | 4.73 L (1.25 gal) | A 50/50 mixture provides freeze protection to -34°F (-37°C). Do not exceed 50/50. Use clean, low-mineral, non-corrosive water; distilled or soft water preferred. |
| 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). | ||
| 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.) | |
| 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 | 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. | |
| Fuel | ASTM 2-D (No. 2 Diesel) | minimum Cetane number 45 | Number 2 diesel fuel gives best economy and performance under most conditions. | ||
| Fuel | ASTM 2-D (No. 2 Diesel) or ASTM 1-D (No. 1 Diesel) | Minimum Cetane number of 45; low sulfur content with cloud point at least 10 degrees below lowest expected fuel temperature | Use No. 1 diesel below 32°F (0°C) and during long periods of light load. At temperatures lower than 14°F (-10°C) or altitude above 5000 feet (1500 m) use No. 1 diesel with a cetane rating of at least 40. Shorten oil change interval by half if fuel sulfur content is higher than 0.5%. | ||
| Grease | moly grease only | Regrease O-ring with moly grease only. Renew generator bearing grease if necessary (moly only). |
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
11| Code | Name | Meaning | Severity | Action |
|---|---|---|---|---|
| 1 | High Engine Coolant Temperature | One blink indicates shutdown due to high engine coolant temperature. | Shutdown | Check the engine cooling system and coolant level. |
| 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 | Second-level shutdown code No. 11 (blink once, pause, blink once). Not assigned a first-level fault (avoid confusion with first-level Code 1). | |||
| 2 | Loss of Engine Oil Pressure | Two blinks indicate shutdown due to a loss of engine oil pressure. | Shutdown | Check engine oil level and lubrication system. |
| 22 | Second-level shutdown code No. 22. Not assigned a first-level fault (avoid confusion with first-level Code 2). | |||
| 3 | Service Fault | Three blinks indicate a service fault. Press Stop once to cause the two-digit, second-level shutdown code to blink. | Warning | Press Stop once to blink the two-digit shutdown code (tens digit, pause, units digit). Press Stop again to stop the blinking. |
| 33 | Code 33 has not been assigned a fault to avoid misinterpreting first-level Code 3. | |||
| 4 | Cranking Time Exceeded | Four blinks indicate that cranking time exceeded 35 seconds. | Shutdown | Check starting system and fuel supply. |
| 4 blinks | Cranking time exceeded 35 seconds | Status indicator light repeatedly blinks four times | Shutdown | Check fuel supply and priming before re-cranking |
| 44 | Code 44 has not been assigned a fault to avoid misinterpreting first-level Code 4. | |||
| 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.
Procedures
12Adjusting V-Belt Tension adjustment
⚠ Disconnect negative cable(s) at the battery(ies) to prevent the engine from starting.
Tools: Belt tension gauge / weights
- Disconnect the negative (-) cable(s) at the battery(ies) and remove the top belt guard.
- Loosen the alternator pivot bolt first and then the adjusting bracket bolt on top.
- Tighten belt tension by pivoting the alternator outwards; hold tension by tightening the adjusting bracket bolt.
- Apply 20 pounds (10 kg) to the middle of the pulley span and measure belt deflection, which should be 0.4 inch (10 mm).
- Tighten the alternator bolts when tension is correct.
- Secure the belt guard and reconnect the battery cables (negative [-] last).
Fan Belt Adjustment adjustment
⚠ Do not operate the genset without the belt guard in place.
⚠ Accidental starting can cause severe personal injury or death; disconnect the starting battery cables.
- Remove the generator set starting battery cables, negative (-) cable first.
- Remove the belt guard from the front of the set.
- Loosen the bolt that passes through the long slot in the alternator mounting bracket.
- Slide the alternator until the belt tension is correct.
Voltage Adjustment [G] adjustment
⚠ Disconnect both battery cables, negative (-) cable first, when repairs are made.
⚠ Contact with high voltage can cause severe personal injury or death.
Tools: Voltmeter, Flat-blade screwdriver
- Attach a voltmeter securely to the L1 and L2 leads.
- Start the generator set and place a typical load on its output.
- Use a flat-blade screwdriver to set the voltage adjust potentiometer for correct voltage.
- For most 60 Hz applications, the ideal setting is 120 VAC at 60-61 hz.
- Retighten the locking nut when complete.
Dynamic Rotor/Stator Test [D] diagnostic
⚠ Electrical shock can cause severe personal injury or death; do not touch electrical wiring or components during testing.
Tools: Voltmeter, Jumper leads, 12-volt battery
- Stop the generator set.
- Unplug the voltage regulator from the wiring harness.
- Using jumpers, connect a 12-volt battery to the F1/F2 terminals.
- Start the generator set and measure outputs at J4-4 - J4-6, L1 - L2, L1 - L0, L2 - L0, Q60 - Q1 (Q50-Q1 for 50 Hz), and S1 - S2.
- Compare readings: J4-4 - J4-6: 75 VAC 20; L1 - L2: 147 VAC 20; L1 - L0: 74 VAC 20; L2 - L0: 74 VAC 20; Q60 - Q1: 111 VAC 20; Q50 - Q1: 99 VAC 20; S1 - S2: 75 VAC 20.
- If these voltages are measured, the generator set is operating correctly and the problem is elsewhere.
Fuel Solenoid Check (K14) diagnostic
- Watch for solenoid actuation when B+ is applied (start switch in start or run position).
- If there is no actuation when B+ is applied, the fuel solenoid must be replaced.
- When B+ is removed, the solenoid must de-activate.
Heater (Glow Plug) Relay Check (K13) diagnostic
Tools: Voltmeter, Jumper leads
- Connect the relay coil voltage across the relay coil terminals; the relay should activate if coil is okay.
- Connect a voltage source to one side of relay contacts.
- Connect a voltmeter to other side of relay contact and voltage source.
- If voltage appears when relay energizes, the contact is good.
Power Relay Check (A11-K12) diagnostic
Tools: Continuity tester, Jumper leads
- Unplug CB12-2A from the circuit breaker, noting wire markings to select the correct one.
- Locate S6 (oil pressure switch) and find the grounded side using a continuity tester.
- Use a jumper to ground the non-grounded side of S6.
- Use a second jumper from B+ on the control board to apply B+ to the SW B+ terminal; fuel pump E5 should start and run.
- Remove the B+ jumper. If the fuel pump continues to run, K12 is good; if it stops, replace the A11 control board.
- Push the generator set STOP button.
- Remove the jumpers and reconnect CB12-2A.
Start Solenoid Check (K11) diagnostic
Tools: Jumper leads, Voltmeter
- Apply battery positive (B+) to the terminal marked S.
- Connect a ground wire to the solenoid terminal marked I. The solenoid should activate.
- If contacts are good, battery voltage should be read between terminal 1 and ground.
- Voltage drop across the contacts should never exceed one volt in circuit application.
Start/Stop Switch Check (S11) diagnostic
Tools: Ohmmeter
- Remove battery B+ cable.
- Place ohmmeter leads across switch.
- Open and close switch while observing the ohmmeter. A normally open (NO) switch should indicate infinite resistance when open and continuity when closed.
- A normally closed (NC) switch should indicate continuity when closed and infinite resistance when open.
- Replace switch if defective.
Testing Field Voltage [A] diagnostic
⚠ Disconnect starting battery negative (-) cable before handling electrical wiring or components.
Tools: DC voltmeter
- Test field voltage at the brush holder terminals with a DC voltmeter.
- Field voltage should fall between 18 and 60 volts.
- Test at no load and at full load.
Testing Generator Rotor [B] diagnostic
Tools: Megger or insulation resistance meter (500 VDC or more), Digital ohmmeter
- Isolate the rotor windings by disconnecting the two leads to the brush holder.
- Testing for grounds: connect test leads between each ring and the rotor shaft in turn; meter should register 100,000 ohms or greater.
- If less than 100,000 ohms, thoroughly dry the rotor and retest; replace a grounded rotor with a new identical part.
- Testing for open/shorted windings: check resistance between F1 and F2 slip rings with an ohmmeter.
- Rotor resistance 60 Hz is 18.2 ohms; 50 Hz is 20.7 ohms (10% at 25 C).
- If there is a large difference, replace the defective rotor with a new, identical part.
Testing Generator Stator [C] diagnostic
Tools: Megger or insulation resistance meter, Wheatstone Bridge
- Isolate the stator windings by disconnecting all six stator leads.
- Test for open circuits between T1-T2, T3-T4 and Q1-Q2.
- Test for grounded circuits between T1, T3 and B1 and the stator laminations or other unpainted grounding point.
- Use a megger or insulation resistance meter (not more than 500 VDC); a reading less than 100,000 ohms indicates a questionable stator.
- Test for continuity between coil leads; all pairs should have equal resistance.
- If a winding is shorted, open or grounded, replace the stator assembly; check leads for broken wires or insulation first.
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 |
|---|---|---|---|---|
| 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 | single-phase | 50 Hz; see 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-phase | 50 Hz; see reconnection chart | ||
| 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-phase | as shown | ||
| 115/230 | single | As shown (60 Hz) | T1, T2, T3, T4; L0(N), L1, L2 | 60 Hz wiring diagram 612-6637 / 612-6742 |
| 115/230 | single | See reconnection chart (50 Hz) | T1, T2, T3, T4; L0, L1 | 50 Hz |
| 115/230 | single-phase | as shown | ||
| 120 | single-phase | 60 Hz; see reconnection chart | ||
| 120/240 | single | As shown (60 Hz) | T1, T2, T3, T4; L0(N), L1, L2 | 60 Hz; 110/220 V, 115/230 V & 120/240 V as shown; see reconnection chart for other voltages |
| 120/240 | single | See reconnection chart (50 Hz) | T1, T2, T3, T4; L0, L1 | 50 Hz; 110/220 V, 115/230 V & 120/240 V as shown; see reconnection chart for other voltages |
| 120/240 | single-phase | 60 Hz; see reconnection chart | ||
| 200 | single-phase | 50 Hz; see reconnection chart | ||
| 240 | single-phase | 60 Hz; see reconnection chart |
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
What alternator does the Cummins/Onan HDKAQ use?
The Cummins/Onan HDKAQ uses a YK Series alternator. It has 4 poles.
What oil filter does the Cummins/Onan HDKAQ use?
The Cummins/Onan HDKAQ uses oil filter part number F245-1000.
What fuel filter does the Cummins/Onan HDKAQ use?
The Cummins/Onan HDKAQ uses fuel filter part number F245-1002.
What air filter fits the Cummins/Onan HDKAQ?
The Cummins/Onan HDKAQ uses air filter part number F245-1001.
Troubleshooting
4Symptoms & remedies
| Symptom | Cause | Remedy |
|---|---|---|
| NO AC OUTPUT VOLTAGE AT RATED ENGINE RPM | Load circuit breakers closed, overload in the load circuit, open circuit between brush block and voltage regulator, brushes stuck or not making good contact with slip rings, opens or grounds in rotor or stator, incorrect field voltage, wrong connections of F1 and F2 leads | 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? Check for continuity and correct if circuit is open. Are brushes stuck in holder or not making good contact with slip rings? 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? Replace component if defective. Test field voltage per TEST [A]. Is there correct field voltage? 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 not OK | Are there any broken wires or loose connections on voltage regulator assembly? 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. |
| Engine does not crank. | Is battery dead? Check CB11 circuit breaker. If okay, jumper battery cable B+ connection to B1 starter so- lenoid terminal. Does engine crank? With S11 in Start position, is battery voltage present between K11 terminal S and ground? If K11 does not energize, test per Checkout [D] and replace if bad. Is battery voltage present at B1 solenoid terminal with S11 in Start position? Check battery per Checkout [A] and recharge or replace. Check battery charger operation per Checkout [C]. Check battery cables for clean tight connections (ref. Checkout [B]). Check B1 starter so- lidoid and motor: if bad, repair or replace. Check B+ wiring to S11, and between S11 and K11. Check NC contacts of A11-K15. Replace if bad. | |
| Unbalanced generator set output voltage | Remove load at generator set terminals. Are generator set leads connected and grounded properly? See Test [C]. Is generator set stator winding continuous per TEST [C]? Check load for ground faults and correct as necessary. Check for correct grounding of generator set and load. Correct as necessary. Replace stator assembly. |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing.
Parts
65| Part # | Description | Qty | System | |
|---|---|---|---|---|
| 185-2284 | Gasket * −Parts Included in Control Plate Assy. | 1 | Gasket | Amazon eBay |
| 185-2291 | Gasket | 3 | Gasket | Amazon eBay |
| 185-2338 | *Gasket | 1 | Gasket | Amazon eBay |
| 185-2411 | *Cap, Sealing | 1 | Seal | Amazon eBay |
| 185-2413 | *Cap, Sealing | 2 | Seal | Amazon eBay |
| 185-2461 | Seal (Part 185-2461) | 1 | Seal | Amazon eBay $8.99 |
| 185-2578 | Gasket | 1 | Gasket | Amazon eBay |
| 185-2884 | Gasket | 1 | Gasket | Amazon eBay |
| 185-5337 | Gasket | 3 | Gasket | Amazon eBay |
| 185-5407 | Cover, Oil Fill | 1 | Fluid | Amazon eBay |
| 185-5458 | Thermostat | 1 | Thermostat | Amazon eBay |
| 185-5641 | Gasket, Delivery Valve | 3 | Gasket | Amazon eBay |
| 185-5661 | Gasket | 2 | Gasket | Amazon eBay |
| 185-5663 | Gasket | 1 | Gasket | Amazon eBay |
| 185-5714 | *Seal Assy, Mechanical | 1 | Seal | Amazon eBay |
| 185-5745 | Bolt * −Parts Included in Water Pump Assy. | 2 | Pump | Amazon eBay |
| 185-5820 | Gasket | 1 | Gasket | Amazon eBay |
| 185-5835 | Filter, Oil | 1 | Oil filter | Amazon $33.27 eBay $21.78 FridayParts $20.19 |
| 185-5985 | Seal, Heat | 3 | Seal | Amazon eBay |
| 185-6485 | *Rotor, Oil Pump | 1 | Pump | Amazon eBay |
| 185-6486 | *Cover, Oil Pump | 1 | Pump | Amazon eBay |
| 185-6503 | Shield, Breather Oil | 1 | Fluid | Amazon eBay |
| 185-6510 | Seal (Part 185-6510) | 1 | Seal | Amazon eBay |
| 185-6511 | Gasket, Bearing Case Cover | 1 | Gasket | Amazon eBay |
| 185-6542 | *Gear, Oil Pump Drive | 1 | Pump | Amazon eBay |
| 185-6558 | Gear, Injection Pump | 1 | Pump | Amazon eBay |
| 185-6580 | Gasket, Fuel Pump | 1 | Pump | Amazon eBay |
| 185-6603 | Gasket | 1 | Gasket | Amazon eBay |
| 185-6671 | Pump Assy, Water (Includes Parts Marked *) | 1 | Pump | Amazon eBay $145.00 FridayParts $42.60 |
| 185-6672 | *Flange, Pump Water | 1 | Pump | Amazon eBay |
| 185-6674 | *Impeller, Pump Water | 1 | Pump | Amazon eBay |
| 185-6845 | Shim, Injection Pump | 2 | Pump | Amazon eBay |
| 185-6863 | Gasket, Gearcase | 1 | Gasket | Amazon eBay |
| 185-6864 | Seal, Oil | 1 | Seal | Amazon eBay |
| 185-6868 | Gasket, Cylinder Head Cover | 1 | Gasket | Amazon eBay |
| 185-6882 | Pump Assy, Injection (See Separate Page for Components) | 1 | Pump | Amazon eBay |
| 185-6884 | Plunger, Pump | 3 | Pump | Amazon eBay |
| 185-6894 | Gasket | 1 | Gasket | Amazon eBay |
| 185-6899 | Cord, Glow Plug | 1 | Glow plug | Amazon eBay |
| 185-6922 | Gasket, Water Flange | 1 | Gasket | Amazon eBay |
| 185-6935 | Cover, Thermostat | 1 | Thermostat | Amazon eBay |
| 185-7242 | Gasket Thermostat | 1 | Gasket | Amazon eBay |
| 185-7299 | Gasket, Water Pump | 1 | Pump | Amazon eBay |
| 185-7300 | Seal, Valve Stem | 6 | Seal | Amazon eBay |
| 185-7313 | Gasket * −Parts Included in Governor Lever Assy. | 1 | Gasket | Amazon eBay |
| 193-0244 | Sender, Pressure - 0i1 | 1 | Sensor | Amazon eBay |
| 193-0318 | Sender, Water Temperature | 1 | Sensor | Amazon $58.99 eBay $73.95 |
| 503-2708 | Clamp, Hose | 1 | Hose | Amazon eBay |
| 503-2709 | Clamp, Hose | 1 | Hose | Amazon eBay |
| ES1676 | BRUSH BLOCK ASSEMBLY | 1 | Brush block assembly | Amazon eBay |
| F245-1000 | Oil Filter | 1 | Oil filter | Amazon eBay |
| F245-1001 | Air Filter | 1 | Air filter | Amazon eBay |
| F245-1002 | Fuel Filter | 1 | Fuel filter | Amazon eBay |
| F245-1003 | Coolant Filter | 1 | Coolant filter | Amazon eBay |
| F245-1004 | Belt | 1 | Belt | Amazon eBay |
| F245-1005 | Battery | 1 | Battery | Amazon eBay |
| F245-1006 | Spark Plug | 1 | Spark plug | Amazon eBay |
| 185-2412 | Cap, Sealing | 1 | Service part / kit | Amazon eBay |
| 185-5484 | Cap, Sealing | 6 | Service part / kit | Amazon eBay |
| 185-6500 | Plate, Lower Breather Element | 1 | Service part / kit | Amazon eBay |
| 185-6501 | Plate, Upper Breather Element | 1 | Service part / kit | Amazon eBay |
| 185-6721 | Breather Filter Element | 1 | Service part / kit | Amazon eBay |
| 185-6874 | Crankshaft | 1 | Service part / kit | Amazon eBay |
| 185-7092 | Cylinder Block Assy | 1 | Service part / kit | Amazon eBay |
| 333-0594 | Heater, Engine * −Parts Included in Cylinder Block Assy. | 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.