Service parts for the HDKAR
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 |
| 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. |
| 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. |
| 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 |
| 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). | |||
| 22 | Second-level shutdown code No. 22. Not assigned a first-level fault (avoid confusion with first-level Code 2). | |||
| 33 | Code 33 has not been assigned a fault to avoid misinterpreting first-level Code 3. | |||
| 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 comes on the Cummins/Onan HDKAR?
The Cummins/Onan HDKAR uses a YK Series alternator. It has 4 poles.
What oil filter does the Cummins/Onan HDKAR use?
The Cummins/Onan HDKAR uses oil filter part number F245-1000.
What fuel filter fits the Cummins/Onan HDKAR?
The Cummins/Onan HDKAR uses fuel filter part number F245-1002.
What air filter does the Cummins/Onan HDKAR use?
The Cummins/Onan HDKAR uses air filter part number F245-1001.
Troubleshooting
37Fault codes
| Code | Meaning |
|---|---|
| 1 | Shutdown due to high engine coolant temperature |
| 2 | Shutdown due to a loss of engine oil pressure |
| 3 | Service fault — press Stop once to cause the two-digit, second-level shutdown code to blink |
| 4 | Cranking time exceeded 35 seconds |
Symptoms & remedies
| Symptom | Cause | Remedy |
|---|---|---|
| Engine does not crank | Battery dead | Check battery per Checkout [A] and recharge or replace; Check battery charger operation per Checkout [C] |
| Engine does not crank | CB11 circuit breaker open or B+ wiring to starter solenoid faulty | Check CB11 circuit breaker; if okay, jumper battery cable B+ connection to B1 starter solenoid terminal; check B+ wiring between K11 and B1 solenoid terminal and replace if bad; check K1 plunger travel for freedom to bottom in solenoid (necessary to open pull coil circuit) |
| Engine does not crank | No battery voltage between K11 terminal S and ground with S11 in Start position | Check B+ wiring to S11, and between S11 and K11; check NC contacts of A11-K15 and replace if bad |
| Engine does not crank | K11 does not energize | Test per Checkout [D] and replace if bad |
| Engine does not crank | No battery voltage at B1 solenoid terminal with S11 in Start position | Check battery cables for clean tight connections (ref. Checkout [B]); check B1 starter solenoid and motor: if bad, repair or replace |
| Engine cranks but does not start | Engine not getting fuel (exhaust smoke should be blue-white and fuel flow steady from fuel return line) | Check fuel system: fuel tank level, shut-off valves, fuel lines and connections, fuel filters, fuel pump and injection pump |
| Engine cranks but does not start | Incorrect fuel | See Operator's Manual recommendations |
| Engine cranks but does not start | Battery B+ not applied to glow plug heaters when switch S11 is in Preheat and Start positions | Check switch S11 per Checkout [G]; check heater relay per Checkout [E]; check heater wiring |
| Engine cranks but does not start | K14 fuel solenoid does not energize when S11 is in Start position | Check B+ circuit through S11; test S11 per Checkout [G]; test K14 per Checkout [F] |
| Engine starts but stops after running several seconds | Fault condition indicated by fault breaker CB12 on control panel | Check for a possible fault condition; if none, check fault monitors S1 through S4 and fault breaker CB12 for improper wiring |
| Engine starts but stops after running several seconds | Relay K12 not good | Check relay K12 per Checkout [H] and replace if bad |
| Engine starts but stops after running several seconds | DC control breaker trips after generator set is started | Check all B+ wiring for shorts to ground |
| Engine starts but stops after running several seconds | S6 power latch switch not closing or K1 solenoid rod not adjusted to correct length to allow the hold-in coil of K1 to latch | Check for closing of S6 power latch switch; if switch is OK, check mechanical adjustment of K1 solenoid: is rod adjusted to correct length to allow the hold-in coil of K1 to latch; if K1 adjustment is OK and problem remains, replace engine monitor PC board; check fuel solenoid adjustment |
| No AC output voltage at rated engine RPM | Load circuit breakers open | Locate cause of overload and correct as required; reset breaker, or replace if bad |
| No AC output voltage at rated engine RPM | Circuit open between brush block and voltage regulator | Check continuity of circuit breakers and replace if necessary; check for continuity and correct if circuit is open |
| No AC output voltage at rated engine RPM | Brushes stuck in holder or not making good contact with slip rings | Release brushes if jammed in holder; clean slip rings if dirty |
| No AC output voltage at rated engine RPM | Opens or grounds in rotor or stator | Test continuity of rotor, stator per Tests [B], [C]; replace component if defective |
| No AC output voltage at rated engine RPM | Incorrect field voltage | Test field voltage per TEST [A]; perform TEST [D] |
| No AC output voltage at rated engine RPM | F1 and F2 leads installed on incorrect terminals | Connect brush leads to correct terminals |
| Unstable voltage, engine speed stable | Broken wires or loose connections on voltage regulator assembly | Repair wiring or replace as required |
| Unstable voltage, engine speed stable | Wiring harness from regulator assembly to end bell faulty | Check wiring harness from regulator assembly to end bell per TEST [F]; repair as required |
| Unstable voltage, engine speed stable | Brushes not OK | Inspect brushes per procedure in Manual Section 4; repair or replace as required |
| Unstable voltage, engine speed stable | Voltage regulator faulty | Replace the voltage regulator per procedure [E] |
| Output voltage too high or too low | Engine not running at correct RPM | Set RPM per instructions in appropriate engine manual |
| Output voltage too high or too low | Voltage Adjust control on the regulator board not adjusted correctly | Set control per Voltage Adjustment [G] |
| Output voltage too high or too low | Voltage regulator connections not secure | Check that voltage regulator connections are secure |
| Output voltage too high or too low | Generator set output leads not properly connected | See TEST [H] |
| Output voltage too high or too low | Bad voltage regulator indicated by correctly functioning rotor/stator | Perform procedure [D]; if correctly functioning rotor/stator indicates a bad voltage regulator, replace it per procedure [E] |
| Output voltage too high or too low | Set AC output overloaded | Remove part of the set load |
| Unbalanced generator set output voltage | Load at generator set terminals causing unbalance | Remove load at generator set terminals |
| Unbalanced generator set output voltage | Generator set leads not connected and grounded properly | Check for correct grounding of generator set and load; correct as necessary |
| Unbalanced generator set output voltage | Generator set stator winding not continuous | Replace stator assembly |
| Unbalanced generator set output voltage | Load ground faults | Check load for ground faults and correct as necessary |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing.
Repair guides
24- Air Cleaner Element Replacement
- Battery Charging Check
- Battery Check (BT1)
- Cooling System Flushing and Filling
- Disconnecting Generator Set Systems (Set Removal)
- Dynamic Rotor/Stator Test [D]
- Exhaust Installation Guidelines
- Exhaust Systems
- Fuel Line Connection
- Fuel Solenoid Check (K14)
- Fuel/Water Separator Element Replacement
- Generator Bearing Service
- Generator Set Storage (Out-of-Service Protection)
- Heater (Glow Plug) Relay Check (K13)
- Power Relay Check (A11-K12)
- Rotor Reassembly
- Start Solenoid Check (K11)
- Start/Stop Switch Check (S11)
- Testing Field Voltage [A]
- Testing Generator Rotor [B]
Step-by-step procedures compiled from the Cummins/Onan service manual for this model.
Parts
65| Part # | Description | Qty | System | |
|---|---|---|---|---|
| 185-2284 | Gasket | 2 | 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, Oil | 1 | Seal | Amazon eBay $8.99 |
| 185-2578 | Gasket | 2 | Gasket | Amazon eBay |
| 185-2884 | Gasket | 1 | Gasket | Amazon eBay |
| 185-5337 | Gasket | 2 | Gasket | Amazon eBay |
| 185-5407 | Cover, Oil Fill | 1 | Fluid | Amazon eBay eBay |
| 185-5458 | Thermostat | 1 | Thermostat | Amazon eBay |
| 185-5484 | Cap, Sealing | 4 | Seal | Amazon eBay |
| 185-5641 | Gasket, Delivery Valve | 2 | Gasket | Amazon eBay |
| 185-5661 | Gasket | 1 | 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 eBay $21.78 NAPA $3.59 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, Oil | 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 | Fuel pump | Amazon eBay |
| 185-6580 | Gasket, Hole Cover | 1 | Gasket | 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, Water Pump | 1 | Impeller | 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 | Gasket | Amazon eBay |
| 185-7300 | Seal, Valve Stem | 6 | Seal | Amazon eBay |
| 185-7313 | Gasket | 1 | Gasket | Amazon eBay |
| 193-0244 | Sender, Oil Pressure (E1) | 1 | Sensor | Amazon eBay |
| 193-0318 | Sender, Water Temperature | 1 | Sensor | Amazon 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 | 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 |
| 185-6500 | Plate, Lower Breather Element | 1 | Service part / kit | Amazon eBay |
| 185-6501 | Plate, Upper Breather Element | 1 | Service part / kit | Amazon eBay |
| 185-6721 | Element, Breather | 1 | Service part / kit | Amazon eBay |
| 185-6874 | Crankshaft | 1 | Service part / kit | Amazon eBay |
| 185-7417 | Cylinder Block Assy (Begin Spec B) | 1 | Service part / kit | Amazon eBay |
| 333-0594 | Heater, Engine | 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.
Available documents
Owner's manual — HDKAL, HDKAQ, HDKAR, HDKAS Operators Manual (Cummins/Onan)Parts manual — 0932-0112 Onan Post-Sale Literature Index (07-1998) (Cummins/Onan)Parts manual — Cummins Onan HDKAL HDKAS - Parts Manual (Cummins/Onan)Service manual — 981-0612 Onan HDKAL HDKAQ HDKAR RV Genset Installation manual (10-1997) (Cummins/Onan)Service manual — HDKAL, HDKAQ, HDKAR, HDKAS Service Manual (Cummins/Onan)
This page was generated from the 5 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.