Specifications
| Fuel | Diesel |
|---|---|
| Frequency | 60.0 Hz |
| Controller | Detector, PowerCommand 3100 |
| Oil capacity | 36.0 L |
| Voltage options | 120/240 V, 208/416 V |
| Phase | 3-phase |
| Rated current | 50 A |
| Power factor | 0.8 |
| Circuit breaker | 75 A |
| Battery group | 8D |
| Battery cranking | 1400 CCA |
| Battery voltage | 24 V |
| Battery quantity | 2 |
| Coolant capacity | 49 L |
| Fuel tank | 100.0 L |
| Tank runtime | 8.33 hr |
Maintenance & consumables
for the Cummins/Onan LTA10| Item | Spec | Capacity | Part # | Interval | |
|---|---|---|---|---|---|
| Air filter | — | ||||
| Fuel filter | — | 4 hr | |||
| Oil filter | — | 250 hr | |||
| Battery | Two 12V Group 8D batteries | — | 5060 hr | ||
| Belt | — | 3 hr | |||
| Coolant | 49.0 L | — | |||
| Coolant filter | — | 5060 hr | |||
| Oil | 36.0 L | — | 250 hr | ||
| Spark plug | — |
Service specifications
60| Type | Item | Value | Unit | Condition |
|---|---|---|---|---|
| Clearance | Float switch assembly float lift clearance below C-clip stop | 1/8 | inch (3 mm) | use a feeler gauge |
| Clearance | Generator-to-engine angular alignment (T.I.R.) | .001 in. per inch of radius (center of shaft to indicator axis), maximum | in | 750 kW gensets and larger |
| Other | AVR Droop setting | 5 | % at full load, 0 PF | |
| Other | AVR voltage regulation (load regulation) | approximately ±0.5 | % RMS | |
| Other | Battery specific gravity (high ambient, above 95F/35C) | 1.225 | recommended to reduce electrolyte loss | |
| Other | Battery specific gravity (recharge threshold) | below 1.260 | ||
| Other | GOV GAIN default value for paralleling applications | 70 | % | |
| Other | Over/Under Frequency Sensor Module - Over Hz Set, 50 Hz nominal | 55 | Hz | reset 53 Hz |
| Other | Over/Under Frequency Sensor Module - Over Hz Set, 60 Hz nominal | 65 | Hz | reset 63 Hz |
| Other | Over/Under Frequency Sensor Module - Under Hz Set, 50 Hz nominal | 45 | Hz | reset 47 Hz |
| Other | Over/Under Frequency Sensor Module - Under Hz Set, 60 Hz nominal | 55 | Hz | reset 57 Hz |
| Other | Over/Under Voltage Sensor Module time delay | typically 25 percent, approximately 2.5 | seconds | |
| Other | Overcrank cranking limit | 75 | seconds | three 15-second cranking cycles with two 15-second rest periods |
| Other | REG VHZ (underfrequency roll-off) adjustable range | 1 through 50; normal range 7 through 21 | ||
| Other | Start delay adjustment range | 0 to 300 | seconds | |
| Other | Stop delay adjustment range | 0 to 600 | seconds | |
| Other | Under Frequency Roll Off (UFRO) knee point, 50 Hz units | 48 to 49 | Hz | |
| Other | Under Frequency Roll Off (UFRO) knee point, 60 Hz units | 58 to 59 | Hz | |
| Pressure | Engine oil pressure - K19 normal | 50-70 | psi (345-482 kPa) | run mode |
| Pressure | Engine oil pressure - K38 normal | 45-65 | psi (310-448 kPa) | run mode |
| Pressure | Engine oil pressure - K50 normal | 50-70 | psi (345-482 kPa) | run mode |
| Pressure | Engine oil pressure - L10/M11 normal | 30-50 | psi (207-345 kPa) | run mode |
| Pressure | Engine oil pressure - NTA 855 normal | 35-50 | psi (241-345 kPa) | run mode |
| Pressure | Engine oil pressure - V28 normal | 50-90 | psi (345-620 kPa) | run mode |
| Pressure | Engine oil pressure shutdown limit - L10/M11 | 20 | psi (138 kPa) | run mode value |
| Pressure | Engine oil pressure shutdown limit - L10/M11 | 8 | psi (55 kPa) | idle mode value |
| Pressure | Engine oil pressure warning limit - L10/M11 | 12 | psi (83 kPa) | idle mode value |
| Pressure | Engine oil pressure warning limit - L10/M11 | 25 | psi (172 kPa) | run mode value |
| Pressure | K19 engine idle oil pressure | 20 | psi (138 kPa) | idle |
| Pressure | K19 engine normal oil pressure | 50-70 | psi (345-482 kPa) | normal run |
| Pressure | K19 oil pressure shutdown/warning limits | shutdown 35 psi (241 kPa) run; warning 40 psi (276 kPa) run; shutdown 10 psi (69 kPa) idle; warning 15 psi (103 kPa) idle | psi (kPa) | |
| Pressure | K38 engine idle oil pressure | 20 | psi (138 kPa) | idle |
| Pressure | K38 engine normal oil pressure | 45-65 | psi (310-448 kPa) | normal run |
| Pressure | K38 oil pressure shutdown/warning limits | shutdown 35 psi (241 kPa) run; warning 40 psi (276 kPa) run; shutdown 10 psi (69 kPa) idle; warning 15 psi (103 kPa) idle | psi (kPa) | |
| Pressure | K50 engine idle oil pressure | 20 | psi (138 kPa) | idle |
| Pressure | K50 engine normal oil pressure | 50-70 | psi (345-482 kPa) | normal run |
| Pressure | K50 oil pressure shutdown/warning limits | shutdown 35 psi (241 kPa) run; warning 40 psi (276 kPa) run; shutdown 10 psi (69 kPa) idle; warning 15 psi (103 kPa) idle | psi (kPa) | |
| Pressure | L10/M11 engine idle oil pressure | 15 | psi (103 kPa) | idle |
| Pressure | L10/M11 engine normal oil pressure | 30-50 | psi (207-345 kPa) | normal run |
| Pressure | L10/M11 oil pressure shutdown limit | 20 | psi (138 kPa) | run mode value |
| Pressure | L10/M11 oil pressure shutdown limit | 8 | psi (55 kPa) | idle mode value |
| Pressure | L10/M11 oil pressure warning limit | 12 | psi (83 kPa) | idle mode value |
| Pressure | L10/M11 oil pressure warning limit | 25 | psi (172 kPa) | run mode value |
| Pressure | Low oil pressure shutdown | below 14 | psi (97 kPa) | time delayed ~10 seconds following starter disconnect |
| Pressure | NTA 855 engine normal oil pressure | 35-50 | psi (241-345 kPa) | normal run |
| Pressure | NTA 855 oil pressure shutdown limit | 25 | psi (172 kPa) | run mode value |
| Pressure | NTA 855 oil pressure shutdown limit | 8 | psi (55 kPa) | idle mode value |
| Pressure | NTA 855 oil pressure warning limit | 12 | psi (83 kPa) | idle mode value |
| Pressure | NTA 855 oil pressure warning limit | 30 | psi (207 kPa) | run mode value |
| Pressure | Pre-low oil pressure warning | 20 or less | psi (138 kPa) | |
| Pressure | V28 engine idle oil pressure | 20 | psi (138 kPa) | idle |
| Pressure | V28 engine normal oil pressure | 50-90 | psi (345-620 kPa) | normal run |
| Pressure | V28 oil pressure shutdown/warning limits | shutdown 35 psi (241 kPa) run; warning 40 psi (276 kPa) run; shutdown 10 psi (69 kPa) idle; warning 15 psi (103 kPa) idle | psi (kPa) | |
| Resistance | Circuit breaker insulation resistance (ground indication) | less than 100,000 | ohms | tested with 500V insulation resistance meter |
| Resistance | Coolant temperature sender resistance | 500 to 2k | ohms | |
| Resistance | Current transformer (PT) primary | 1K-2.5K | ohms | |
| Resistance | Current transformer (PT) secondary | 140-225 | ohms | |
| Resistance | Exciter rotor winding resistance (per pair) | approximately 0.136 | ohms | |
| Resistance | Exciter stator winding - frame size 4C/4D/4E/4F | 0.136 | ohms | at 68°F (20°C) + 10% |
| Resistance | PMG stator resistance (HC4) | 4.6 | ohms |
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 | soft water / E.G. / DCA mixture | Cooling system to be filled with soft water/E.G./DCA mixture (on-site review checklist). | |||
| Fuel | Diesel | Day tank fuel transfer pump maintains reservoir of diesel fuel in the day tank. | |||
| Grease | Lithium based grease, Mobilux No. 2 or Shell Alvania R3 | -30°C to 120°C | 2.74 oz (81 ml) | End bearing lubricant; grease equally divided between bearing, bearing cap cavity and bearing cartridge cavity. |
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
52| Code | Name | Meaning | Severity | Action |
|---|---|---|---|---|
| 101 | IDLE MODE | Indicates that the engine is operating in idle mode. Grounding the engine idle input causes generator build-up to be inhibited and the engine to be governed at 800 RPM. | Warning | Remove ground from engine idle input to return to normal speed and voltage. |
| 102 | EMERGENCY STOP | Indicates local or remote Emergency Stop. | Shutdown | Turn the switch clockwise and allow it to pop out (local only). Move the Run/Off/Auto switch to Off. Press the Reset switch. Select Run or Auto, as required. |
| 200 | LOW OIL PRESSURE | Indicates engine oil pressure has dropped to an unacceptable level. | Warning | If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then follow 201-SHUTDOWN procedure. Access the Oil Pressure menu prior to clearing the fault. |
| 201 | LOW OIL PRESSURE | Indicates engine oil pressure has dropped below the shutdown trip point. | Shutdown | Check oil level, lines and filters; replenish if low; reset control and restart. |
| 204 | OIL PRES SENDER | Indicates that the control has sensed that the engine oil pressure sender is out of its working range. | Warning | Check that the engine oil pressure sender is properly connected. |
| 210 | LOW COOLANT TEMP | Warning occurs when engine coolant temperature is 70°F (21°C) or lower. | Warning | Indicates engine coolant heater is not operating or is not circulating coolant. Check coolant heater power supply, low coolant level, and heater element current draw. |
| 211 | HIGH COOLANT TEMP | Indicates the engine coolant temperature is getting close to the recommended maximum temperature limit: 215° F (102° C) − standby or 207° F (97° C) − primary. | Warning | Reduce load if possible; check air inlets and outlets and remove obstructions to airflow. |
| 212 | HIGH COOLANT TEMP | Indicates engine has overheated (coolant temperature above 215° F (102° C) − standby or 207° F (97° C) − primary). | Shutdown | Allow engine to cool; check airflow, fan belt, coolant mixture, blower fan and circulation pumps. |
| 213 | COOLANT SENDER | Resistance of the coolant temperature sender is out of range. | Warning | Check the resistance of the sender; should be 500 to 2k ohms. |
| 214 | LOW COOLANT LVL | Indicates engine coolant level has fallen below the trip point. | Warning | Check coolant level in radiator and coolant recovery bottle; replenish if low; look for leaks. |
| 215 | LOW COOLANT LVL | Indicates engine coolant level has fallen below the trip point. | Shutdown | Allow engine to cool; check coolant level and leakage points; reset control and restart. |
| 220 | MAG PICKUP | Mag pickup speed indication is not being sensed or does not match generator set output frequency. | Shutdown | Restart and check RPM; check PCC model setting; inspect and test MPU. |
| 221 | FAIL TO CRANK | Possible fault with control or starting system. | Shutdown | Check fuse F3 on the Engine Interface board. Check for poor battery cable connections; clean battery cable terminals and tighten. Recharge or replace a discharged or defective battery. |
| 222 | OVERCRANK | Possible fuel system problem. | Shutdown | Check for empty fuel tank, leaks, plugged fuel lines; replace dirty fuel or air filter; reset and restart. |
| 223 | OVERSPEED | Indicates engine has exceeded normal operating speed. (115% ±1% of nominal). | Shutdown | Check mechanical fuel linkage and actuator; check governor output module (A38) and digital board (A32). |
| 224 | FAIL TO SYNCHRONIZE | Generator set has not synchronized to the system bus within the allowable time frame. | Warning | Check governor system stability; adjust governing and synchronizer parameters; check fuel system. |
| 226 | FAIL TO CLOSE | Paralleling breaker has been given a signal to close, but has not closed properly. | Shutdown | Verify breaker charging mechanism; check close signal; verify auxiliary contact signals. |
| 230 | LOW DC VOLTAGE | Indicates battery voltage is below 10 VDC. | Warning | Recharge or replace the battery; check the battery charger fuse. Clean and tighten battery cable connections. Check engine DC alternator; replace if normal charging voltage is not obtained. Check float level if applicable. |
| 231 | HIGH DC VOLTAGE | Indicates battery voltage exceeds 32 VDC. | Warning | Lower battery charger float level if applicable; check engine DC alternator. |
| 232 | WEAK BATTERY | Indicates battery voltage drops below 60% of nominal for two seconds, during starting. | Warning | See LOW DC VOLTAGE 230. |
| 240 | LOW FUEL−DAY | Indicates day tank fuel supply is running low. | Warning | Check fuel supply and replenish as required. |
| 241 | LOW FUEL | Low fuel signal received. | Warning | Check fuel supply and replenish; check for short to ground in external wiring. |
| 250 | EEPROM ERROR | PCC memory error; data corruption of critical operating parameters. | Shutdown | Perform initial start setup procedure; replace digital board (A32) if fault repeats. |
| 251 | EEPROM ERROR | PCC memory error; data corruption of noncritical operating parameters. | Warning | Perform adjustment and calibration procedures; replace digital board (A32) if fault repeats. |
| 252 | EEPROM ERROR | PCC memory error; data corruption of noncritical operating parameters. | Warning | Verify selected values; repeat save operation; replace digital board (A32) if fault repeats. |
| 260 | CUSTOMER FAULT 1 | When a customer defined input is closed to ground, the corresponding fault message is displayed. Default message; editable for customer site requirements. | Warning | Isolate source of false signal; repair external wiring or replace A34. |
| 261 | GROUND FAULT | When a customer defined input is closed to ground, the corresponding fault message is displayed. Default message; editable for customer site requirements. | Warning | Isolate source of false signal; repair external wiring or replace A34. |
| 262 | RUPTURE BASIN | When a customer defined input is closed to ground, the corresponding fault message is displayed. Default message; editable for customer site requirements. | Warning | Isolate source of false signal; repair external wiring or replace A34. |
| 263 | HIGH GEN TEMP | When a customer defined input is closed to ground, the corresponding fault message is displayed. Default message; editable for customer site requirements. | Warning | Isolate source of false signal; repair external wiring or replace A34. |
| 270 | PHASE ROTATION | The phase relationship between the generator set and the system bus is not matched. | Shutdown | Verify genset phase rotation matches bus; verify control wiring to bus PT module. |
| 272 | FIRST START | PowerCommand control is not receiving a proper signal from the system master first start sensor. | Warning | Verify Master First Start Sensor and interconnection wiring. |
| 301 | HIGH AC VOLTAGE | One or more phase voltages exceeded 130% of nominal, or exceeded 110% of nominal for 10 seconds. | Shutdown | Check PCC, alternator, excitation circuit, and PT/CT module wiring. |
| 303 | LOW AC VOLTAGE | One or more phase voltages dropped below 85% of nominal for 10 seconds. | Shutdown | Check PMG/field wiring, rotating rectifier, load and connectors. |
| 313 | UNDER FREQUENCY | Indicates that engine speed has dropped below 90% of nominal for 10 seconds. Five seconds before shutdown, a Load Dump signal is initiated. | Shutdown | Check fuel supply, intake air supply and load. |
| 320 | OVERCURRENT | Indicates that generator output current has exceeded 110% of rated for 60 seconds. | Warning | Check load and load lead connections. |
| 321 | OVERCURRENT | Indicates that generator output current has exceeded 110% of rated, and that a PCC time/current calculation has initiated an overcurrent shutdown. | Shutdown | Check load and load lead connections. |
| 322 | SHORT CIRCUIT | Indicates that generator output current has exceeded 175% of rated. | Shutdown | Check load and load lead connections. |
| 330 | OVERLOAD | Three-phase power output exceeds 105% of standby (or 115% of prime) rating. | Warning | Check load and load lead connections. |
| 335 | REVERSE POWER | Power is flowing into the generator set rather than out from the unit. | Shutdown | Verify CT connections, load sharing lines, and generator set frequency/voltage. |
| 337 | LOSS OF EXCITATION | Alternator excitation system is improperly adjusted or has failed. | Shutdown | Check output voltage calibration, load sharing lines, and leading power factor loads. |
| FAULT 1 | Fault 1 | Undedicated customer-defined fault; may be programmed as timed or non-timed shutdown or fault light only. | ||
| FAULT 2 | Fault 2 | Undedicated customer-defined fault, same features as Fault 1. | ||
| HI ENG TEMP | High Engine Temperature | Engine shut down due to critically high coolant temperature (above 215F/102C). | Shutdown | |
| LO FUEL | Low Fuel | Fuel supply is marginally low, if equipped (Detector-12). | Warning | |
| LO OIL PRES | Low Oil Pressure | Engine shut down due to critically low oil pressure (below 14 psi/97 kPa). | Shutdown | |
| LOW ENG TEMP | Low Engine Temperature | Engine water jacket temperature is 70F/21C or lower; indicates possible inoperative coolant heater (Detector-12). | Warning | |
| OVERCRANK | Overcrank | Starter locked out because of excessive cranking time (limited to 75 seconds). | Shutdown | |
| OVERSPEED | Overspeed | Engine shut down because of excessive speed. | Shutdown | |
| PRE HI ENG TEMP | Pre-High Engine Temperature | Coolant temperature is marginally high (205F/97C or higher). | Warning | Attend to when generator set is shut down. |
| PRE LO OIL PRES | Pre-Low Oil Pressure | Engine oil pressure is marginally low (20 psi/138 kPa or less). | Warning | Attend to when generator set is shut down. |
| RUN | Run | Green lamp comes on when both primary and secondary starter circuits open after unit starts. | Info | |
| SWITCH OFF | Switch Off | Generator set is not in automatic start operation mode (flashing red). | Info |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Procedures
12Aligning Generator with Engine (Angular Alignment) adjustment
⚠ Accidental starting of the generator set during this procedure presents the hazard of severe personal injury or death.
Tools: Dial indicator, Shims
- Disconnect the negative (-) battery cable(s) before beginning.
- Fasten a dial indicator to the generator shaft or cooling fan with the sensing point on the capscrew head or flat surface of the drive disc at the bolt circle diameter.
- Bar the engine over in a clockwise rotation as viewed from engine flywheel; do not allow it to roll back on compression.
- Determine the total indicator reading (T.I.R.) as the sum of the maximum positive and negative dial indicator readings over one revolution.
- Measure the distance from the center of the generator shaft to the indicator measuring point.
- Measure the distance from the generator side of the flex discs to the center of the generator mounting bolt.
- Compare the distances; multiply this ratio times one half the T.I.R. to approximate the amount of shims to remove or add.
Angular Alignment Procedure (Generator to Engine) adjustment
⚠ Accidental starting during this procedure presents the hazard of severe personal injury or death.
⚠ Do not bar engine over by prying on fan blade.
Tools: dial indicator
- Disconnect the negative (-) battery cable(s) before beginning.
- Fasten a dial indicator to the generator shaft or cooling fan with sensing point resting on the drive disc capscrew head/flat surface at the bolt circle diameter.
- Bar the engine over in a clockwise rotation as viewed from the engine flywheel; do not allow it to roll back on compression at the end of travel of each reading.
- Record the total indicator reading (T.I.R.) as the sum of the maximum positive and negative dial indicator readings over one engine revolution.
- Compare the measured T.I.R. to the maximum allowed (.001 in. per inch of radius from center of shaft to indicator axis); add or remove shims under the generator mounting feet to correct.
Axial Alignment Procedure (Generator to Engine) adjustment
Tools: dial indicator
- Fasten a dial indicator holding device to the skid base, engine block, or generator shell with the sensor point resting on the generator shaft hub.
- Bar the engine over in a clockwise rotation through a couple of rotations, recording indicator readings at eight equally spaced points around the shaft diameter to obtain axial T.I.R.
- Reduce the measured T.I.R. runout by one half if excessive vibration remains after angular alignment.
Generator/PCC Control Isolation Procedure diagnostic
⚠ HIGH VOLTAGE. Touching uninsulated high voltage parts inside the control box can result in severe personal injury or death.
Tools: Voltmeter, Jumpers, 12 volt battery
- Throw the line circuit breaker OFF and shut down the set.
- Remove accessory box cover; remove plug P10 from A37 J10.
- Prepare to measure output voltage across generator terminals.
- Connect 12V battery jumpers to X (P10-6 red) and XX (P10-3 brown).
- Check polarity; incorrect polarity makes the test inconclusive.
- Start set and connect battery negative to the XX lead.
- Rated or higher balanced voltage means generator circuitry is OK.
- Unbalanced voltage: troubleshoot main stator; low voltage: exciter/field.
Insulation Resistance (Megger) & Polarization Index (PI) Testing diagnostic
⚠ The windings of medium-voltage (601 through 15,000 volts) generator sets must be dry before the generator is operated.
Tools: Megger or insulation resistance meter, Grounding cluster, High voltage gloves
- Perform the Generator Set Grounding Procedure.
- Disconnect plug J10 from A37 and AC control leads 4,5,6,7,8.
- If RTD option installed, ground all six RTD temperature leads (18 leads).
- Perform Insulation Resistance Test and PI Test for desired windings.
- Megger test: apply voltage for up to one minute.
- PI test: apply voltage for ten minutes; record 1-minute and 10-minute readings.
- PI ratio of 2 or greater is good for new and in-service sets.
- Investigate and correct low readings before returning set to service.
Megger and PI Test diagnostic
⚠ Medium-voltage (601 to 15,000 volts) windings must be dry before the generator is operated.
Tools: Megger or Insulation Resistance Meter, Wheatstone bridge or digital ohmmeter, Grounding Cluster
- Perform the Generator Set Grounding Procedure.
- Disconnect plug J10 from the voltage regulator output module and the AC control leads (marked 4, 5, 6, 7, 8).
- If RTD option installed, ground all six RTD temperature leads (18 leads total).
- Perform the Winding Resistance Test for the desired windings.
- Perform the Insulation Resistance (Megger) Test and PI Test for the desired windings.
- Megger test: apply voltage for up to one minute.
- PI test: apply voltage for ten minutes; record resistance at one minute and ten minutes.
- PI is the ten-minute reading divided by the one-minute reading; ratio of two or greater is good.
Testing Diodes diagnostic
⚠ Layers of dust can cause diodes to overheat and fail. Brush dust off regularly.
Tools: Ohmmeter
- Disconnect the diode pigtails from the terminal posts.
- Using an ohmmeter, measure resistance between pigtail and mounting plate.
- Reverse meter test probes and repeat the tests.
- Resistance should be high in one direction and low in the other.
- If high or low in both directions, replace the diode.
Testing the Float Switch Assembly diagnostic
Tools: Ohmmeter, Feeler gauge
- Remove the fuel pump control cover, disconnect the wiring jack and unscrew the assembly from the top of the day tank.
- With an ohmmeter, test for electrical continuity between each pair of colored leads while holding the assembly vertical; all readings should be zero.
- Lift each float, in turn, to 1/8 inch (3 mm) below the C-clip stop above it and test for continuity; all readings should be infinity.
- Use pipe thread sealant when replacing the assembly.
Testing the PMG diagnostic
⚠ HAZARDOUS VOLTAGE. Touching uninsulated parts inside the control housing and power output boxes can result in severe personal injury or death.
Tools: Digital multimeter, Wheatstone bridge or digital ohmmeter
- Disconnect PMG leads PMG 2, PMG 3, PMG 4 from connectors in AC harness.
- Start the engine and let speed stabilize.
- Measure voltage across lead pairs PMG 2&3, 3&4, 4&2.
- Voltage should be at least 150 VAC for 50 Hz sets, 180 VAC for 60 Hz.
- Stop set; measure resistance across the lead pairs with a Wheatstone bridge.
Current Transformer (CT) Installation installation
⚠ Improper installation of CTs will cause a “335 Reverse Power” shutdown error.
- Orient CT dot toward the generator (conventional current into dot).
- Route U/A, V/B, W/C load leads through CT21, CT22, CT23.
- 6 lead sets: route generator output leads through the CTs.
- 12 lead sets: route load wires through the CTs.
- Connect CT secondary wire 1 to CT pin 1; 2/3 to pin 2 (high voltage) or pin 3 (low voltage).
Fuel Transfer Pump Motor Connections installation
- Remove the end bell cover for access to the motor wiring terminals.
- Disconnect the brown lead from motor terminal P103-3 and connect it to terminal P103-6.
- Disconnect the red lead from motor terminal P103-2; reconnect to the piggy-back terminal on the lead at motor terminal P103-3.
- Cut the white lead from its ring connector at motor terminal P103-4 and strip 1/2 inch (12 mm) of insulation for splicing to harness lead P103-WHITE.
- Connect each lead of the five-lead wiring harness to the motor terminal or lead marked on it.
- Connect the red motor lead to the piggy-back terminal at motor terminal P103-3.
- Secure the end bell cover.
Magnetic Speed Pickup Unit (MPU) Installation installation
⚠ Do not use fan blade to bar over engine. That can damage blades and cause property damage and personal injury.
- Bar the engine until a flywheel gear tooth lines up in center of mounting hole.
- Thread the sensor in gently by hand until it just touches the gear tooth.
- Back it out one quarter turn.
- Set the locknut.
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 |
|---|---|---|---|---|
| 12 lead generator sets | Load wires are routed through the CTs | Reconnectable gensets (12 leads) have dual secondary CTs (3 pins); CT wire 2/3 to pin 2 (high voltage) or pin 3 (low voltage). | ||
| 6 lead generator sets | Generator output leads are routed through the CTs | Non-reconnectable gensets (6 leads) have single secondary CTs (2 pins). | ||
| Cummins PowerCommand generic AC Reconnect Wiring Diagram 625-2755 (Rev. D) and 625-3100 (Rev. F) | Applies to models DFAA, DFAB, DFAC, DFBF, DFCB, DFCC, DFEB, DFEC, DFFB, DFGA, DFGB, DFJA, DFJB, DFJC, DFJD, DFLB, DFLC, DFLD, DFMB (625-2755) and models DFAA-DFMB plus DFCE, DFED, DQAA, DQAB, DQBA, DQBB (625-3100). | |||
| A (U) | CT21 | U load leads (A phase) | CT dot must face the generator; CT terminal 1 connects to metering circuit, terminal 2/3 to ground. | |
| B (V) | CT22 | V load leads (B phase) | CT dot must face the generator; terminal 1 to metering circuit, terminal 2/3 to ground. | |
| C (W) | CT23 | W load leads (C phase) | CT dot must face the generator; terminal 1 to metering circuit, terminal 2/3 to ground. |
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 engine is in the Cummins/Onan DFAA?
The Cummins/Onan DFAA is powered by the Cummins/Onan LTA10 engine.
What fuel does the Cummins/Onan DFAA use?
The Cummins/Onan DFAA runs on Diesel.
What is the oil capacity of the Cummins/Onan DFAA?
The Cummins/Onan LTA10 engine in the Cummins/Onan DFAA has an oil capacity of 36.0 liters.
Troubleshooting
6Symptoms & remedies
| Symptom | Remedy |
|---|---|
| Green RUN lamp lights following engine startup. | Indicates all engine systems are normal. No corrective action required. |
| PREHI ENGINE TEMP lamplights. Engine continues to operate. | Indicates engine has begun to overheat and engine temperature has risen to approximately 215°F (102°C) or coolant level is low on optionally wired sets. If generator is powering non-critical and critical loads and cannot be shut down, use the following: a. Reduce load if possible by turning off non-critical loads. b. Check air inlets and outlets and remove any obstructions to airflow. if engine can be stopped, follow procedure in step 3. |
| HI ENG TEMP lamp lights. Engine shuts down. | Indicates engine has overheated (engine temperature has risen above 222°F/106°C) or coolant level is low. Allow engine to cool down completely before proceeding with the following checks: a. Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check for a slipping fan belt and tighten if loose. d. Reset control and restart after locating and correcting problem. Contact an authorized service center if none of the above. |
| PRELO OIL PRES lamp lights. Engine continues to operate. | Indicates engine oil pressure has dropped to 20 psi (138 kPa). If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then foliow step 5 procedure. If engine can be stopped, follow procedures in step 5. |
| LOOIL PRES lamp lights. Engine shuts down. | Indicates engine oil pressure has dropped to 14 psi (97 kPa). Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Reset control and restart. Contact an authorized service center if oil pressure is not in the range of 25 to 40 psi (172 to 275 kPa). |
| OVERCRANK lamp lights and engine stops cranking. | A. Check for empty fuel tank, fuel leaks, or plugged or fuel lines and correct as required. Engine runs, shuts down, and LO OIL b. Check for dirty fuel filter and replace if necessary (see Maintenance section). c. Check for dirty or plugged air filter and replace if necessary (see Maintenance section). d. Reset the control and restart after correcting the problem. Contact an authorized service center for service if none of the above. |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing. Full Cummins/Onan DFAA troubleshooting guide (26 entries) →
Parts
20| Part # | Description | Qty | System | |
|---|---|---|---|---|
| 0300-4623-05 | DFAA (600V) | 1 | Current transformer | Amazon eBay |
| 0300-4623-06 | DFAB (600V) | 1 | Current transformer | Amazon eBay $153.95 |
| 0300-4623-07 | DFAC (600V) | 1 | Current transformer | Amazon eBay |
| 0300-4623-17 | DFAA BR (0-480V) | 1 | Current transformer | Amazon eBay $165.95 |
| 0300-4623-19 | DFAB BR (0-480V) | 1 | Current transformer | Amazon eBay |
| 0300-4623-21 | DFAC BR (0-480V) | 1 | Current transformer | Amazon eBay |
| 960-0167 | Battery, Group Number: 8D, CCA (minimum): 1400, Cold Soak® -40°F (-40°C) | 2 | Battery | Amazon eBay |
| A40-TB1-2 | SWITCHED B+ | Belt | Amazon eBay | |
| A40-TB1-4 | GROUND | Belt | Amazon eBay | |
| A40-TB1-7 | COMMON ALARM | Belt | Amazon eBay | |
| A40-TB1-8 | JUMPER WIRE | Belt | Amazon eBay | |
| ES1855s | TIME DELAY START/STOP MODULE | Time delay start stop module | Amazon | |
| LF3000 | Lube, Spin-On | 1 | Oil filter | Amazon $128.45 eBay $76.00 |
| P1-3 | Amperemeter | 1 | Meter | Amazon eBay |
| TB1-2 | Battery charging alternator terminal TB1-2 | Alternator | Amazon Amazon eBay eBay FridayParts $34.80 | |
| W1859s | CRANKING POTENTIOMETER | Cranking potentiometer | Amazon | |
| 500-2782c1 | RUNNING TIME METER | Service part / kit | Amazon eBay | |
| TB1-8 | Jump TB1-8 to 10 Harness Relay #1 COM Blue N/O White / Blue | 1 | Service part / kit | Amazon eBay FridayParts $87.88 |
| TB1-9 | B+ INPUT | 1 | Service part / kit | Amazon eBay |
| TB21 | TERMINAL BLOCK | 1 | Service part / kit | Amazon Amazon Amazon eBay eBay FridayParts $57.30 |
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 |
|---|---|---|---|
| Standby | 100% | 52.7 | 13.9 |
Available documents
Spec sheet — Cummins-installation-manual-DFAA-DFAB-DFAC-DFBC-DFBF-DFBD-DFBE-DFBF-DFCB-DFCC-DFCE-DFEB-DFEC-DFED-DFFA-DFFB-DFGA-DFGB-DFGC-DFJA-DFJB-DFJC-DFJD-DFLA-DFLB-DFLC-DFLD-DFLE-DFMB-DQAA-DQAB-DQBA-DQBB (Cummins/Onan)Parts manual — 0932-0112 Onan Post-Sale Literature Index (07-1998) (Cummins/Onan)Parts manual — 960-0260 Onan DFAA DFAB DFAC Parts Catalog (6-1997) (Cummins/Onan)Service manual — 9-3Service manual — 960-0149 Onan DFAA DFAB DFAC Operator's Manual (6-1993) (Cummins/Onan)Service manual — 960-0504 Onan DFxx series Generator Control Service Manual 04-1993 (Cummins/Onan)Service manual — 960-0507C Cummins DFAA thru DFMB DQAA Service Manual (2-2004) (Cummins/Onan)Service manual — 960-0619D Cummins DFA DFB DFC DFE DFF DFG DFJ DFL DFM DQA DQB Installation (6-2003) (Cummins/Onan)Service manual — Cummins-3100-PowerCommand-DFAA-DFAB-DFAC-DFBC-DFBD-DFBE-DFBF-DFCB-DFCC-DFCE-DFEB-DFEC-DFED-DFFA-DFFB-DFGA-DFGB-DFGC-DFJA-DFJB-DFJC-DFJD-DFLA-DFLB-DFLC-DFLD-DFLE-DFMB-DQAA-DQAB-DQBB (Cummins/Onan)Service manual — Detector Control Generator Set Service Manual (Cummins/Onan)