Specifications
Ratings spec sheet not in our library yet — see the documents below.
Filters & service parts
model family| 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 | — | ||||
| Coolant filter | — | 5060 hr | |||
| Oil | Refer to Cummins engine Operation and Maintenance Manual | 36.0 L | — | 50 hr | |
| Spark plug | — |
Compiled from this model's family documentation — may include parts for closely-related variants. Confirm the exact part for your serial number.
Service intervals
1| Item | Action | Hours | Months | Notes |
|---|---|---|---|---|
| Rupture basin leak detect switch | Test | 12 mo | Check once a year; in some areas weekly inspections may be required by safety code regulations |
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 | Angular alignment maximum T.I.R. | 0.001 | inch per inch of radius (center of shaft to indicator axis) | measuring deflection to bolt heads |
| 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 |
| Gap | MPU sensor to flywheel ring gear tooth | back it out one quarter turn | turn | sensor threaded in until it just touches gear tooth |
| Other | AVR Droop setting | 5 | % at full load, 0 PF | |
| Other | AVR voltage regulation (load regulation) | approximately ±0.5 | % RMS | |
| Other | Angular alignment maximum T.I.R. | .001 inches per inch of radius | in/in | center of shaft to indicator axis |
| 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 | Battery specific gravity, fully charged | approximately 1.260 | specific gravity | at 80 F (27 C) |
| Other | Fuel lift height limit | 6 | feet | (1.8 meters) between fuel lift pump and bottom of dip tube |
| Other | GOV GAIN default value for paralleling applications | 70 | % | |
| Other | Maximum cranking voltage drop | 2 | volts | difference between battery and starter terminals while cranking |
| 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 | |
| Other | Under-frequency roll-off threshold (UFRO) | typically 59 Hz for 60 Hz applications and 49 Hz for 50 Hz applications | Hz | AVR UFRO pot preset |
| 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 service limit while cranking | 10 | psi | service lubricating system if below |
| Pressure | Low oil pressure shutdown | below 14 | psi (97 kPa) | time delayed ~10 seconds following starter disconnect |
| Pressure | Low oil pressure shutdown threshold | 14 | psi | less than this value shuts down |
| 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 | Oil pressure - K19 engine idle | 20 | psi (138 kPa) | idle |
| Pressure | Oil pressure - K19 engine normal | 50-70 | psi (345-482 kPa) | normal operating |
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 | 2.74 oz (81 ml) | Generator end bearing. Temperature range -22F to +248F (-30C to +120C). Grease should be equally divided between the bearing, bearing cap cavity, and bearing cartridge cavity. | |
| 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
61| 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. Can be reset only at the PCC front panel. |
| 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 has risen above the shutdown trip point: 215 F (102 C) - standby or 207 F (97 C) - primary). | Shutdown | Check for obstructions to cooling airflow; check fan belt; check coolant mixture; check blower fan and circulation pumps; reset control and restart. |
| 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 battery cable connections; recharge or replace the 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 governor module/digital board duty cycle. |
| 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 the initial start setup procedure; if the set shuts down on the same EEPROM ERROR message, replace the digital board (A32). |
| 251 | EEPROM ERROR | PCC memory error; data corruption of noncritical operating parameters. | Warning | Perform the adjustment procedures; if the same message occurs, perform calibration procedures; if the message persists, replace the digital board (A32). |
| 252 | EEPROM ERROR | PCC memory error; data corruption of noncritical operating parameters. | Warning | Verify values/choices selected and repeat the save operation; if the same message occurs, replace the digital board (A32). |
| 260 | CUSTOMER FAULT 1 | When this customer defined input is closed to ground, the corresponding fault message is displayed. Programmable to initiate a shutdown or a warning. | 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 | Set display to GEN, VOLTS, L-N; determine if the output voltage the control sees is low or high; isolate PCC/alternator/excitation circuit. |
| 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 (Red) | Undedicated customer-defined fault; may be programmed as timed or non-timed shutdown or fault light only. | Shutdown | Service as required by the customer-supplied fault indicating switches. |
| FAULT 2 | Fault 2 (Red) | Undedicated customer-defined fault, same features as Fault 1. | Shutdown | Service as required by the customer-supplied fault indicating switches. |
| GF | Ground Fault Alarm (Optional) | Ground fault relay monitors neutral to ground connection and line to neutral, activating a fault alarm when the connection is broken or a ground fault is sensed. | Warning | Clear fault condition by pushing the Run/Stop (Reset)/Remote switch to Reset (auto reset link set at factory). |
| HET | High Engine Temperature (Red) | Engine shut down because of excessively high engine coolant temperature (greater than 230 deg F). | Shutdown | Check coolant level and leaks; service cooling system; reset engine control. |
| HI ENG TEMP | High Engine Temperature | Engine shut down due to critically high coolant temperature (above 215F/102C). | Shutdown | |
| LET | Low Engine Temperature (Yellow) | Engine temperature is less than 70 deg F and the engine might not start. | Warning | Plug in, repair or install engine coolant and oil heaters. |
| 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 | |
| LOP | Low Oil Pressure (Red) | Engine shut down because of excessively low engine oil pressure (less than 14 psi). | Shutdown | Check oil level and oil leaks; service lubricating system; reset engine control. |
| LOW ENG TEMP | Low Engine Temperature | Engine water jacket temperature is 70F/21C or lower; indicates possible inoperative coolant heater (Detector-12). | Warning | |
| LOW FUEL | Low Fuel (Yellow) | Fuel level in the supply tank has dropped below the reserve necessary to run the set at full load for the prescribed number of hours. | Warning | Fill the main fuel supply tank with the appropriate grade of fuel. |
| OC | Overcrank (Red) | Engine shut down because it did not start during the timed cranking period (approximately 75 seconds, including two rest periods). | Shutdown | Service the set as necessary; reset engine control. |
| OS | Overspeed (Red) | Engine shut down because of overspeed. | Shutdown | Adjust the Electronic Overspeed Module; check governor for binding; reset engine control. |
| 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. |
| PRE-HET | Pre High Engine Temperature (Yellow) | Engine coolant temperature is abnormally high (greater than 220 deg F). | Warning | Shut down if possible or disconnect non-critical loads; service cooling system. |
| PRE-LOP | Pre Low Oil Pressure (Yellow) | Engine oil pressure is abnormally low (less than 20 psi). | Warning | Shut down if possible or disconnect non-critical loads; service lubricating system. |
| RUN | Run (Green) | Green lamp comes on when both primary and secondary starter circuits open after unit starts. | Info | |
| SWITCH OFF | Switch-off (Flashing Red) | The Run/Stop/Remote switch is in the Stop position, preventing remote automatic operation. | Info | Push the Run-Stop-Remote switch to Remote. |
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 adjustment
⚠ Accidental starting of the generator set during this procedure presents the hazard of severe personal injury or death. Make sure to disconnect the negative (-) battery cable(s) before beginning.
Tools: Dial indicator, Wooden shims
- Disconnect the negative (-) battery cable(s) before beginning.
- Fasten a dial indicator to the generator shaft or cooling fan with sensing point on capscrew head or flat surface of drive disc at 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.
- Record maximum positive and negative dial indicator readings as the engine completes one revolution.
- T.I.R. equals the sum of the maximum positive and negative readings.
- Maximum T.I.R. should not be more than .001 inch for each inch of radius.
- Remove equal shims from under both generator mounting feet to lower the generator.
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.
Governor Calibration Checks adjustment
Tools: Frequency meter or tachometer, Jumper wire
- Start the generator set.
- Adjust engine no-load speed to the desired allowable speed droop using the Run Speed potentiometer.
- With no load, turn GAIN clockwise slowly until engine speed oscillates.
- Reduce GAIN slowly counterclockwise until engine speed is stable.
- Upset the governor by momentarily shorting terminals 7 and 10 on the governor control.
- Apply and remove loads to check generator set response.
HC4-7 Axial Alignment Procedure adjustment
Tools: Dial indicator with magnetic base or clamp
- Check only when an objectionable vibration is present.
- Fasten dial indicator holding device to skid base, engine block, or generator shell with magnetic base or clamp.
- Position sensor point on the generator shaft hub.
- Bar the engine over in a clockwise rotation as viewed from engine flywheel through a couple of rotations.
- Record indicator readings in eight equally spaced points around the shaft diameter.
- Remove the capscrews connecting drive discs and flywheel and mark discs and flywheel.
- Rotate engine or generator so drive disc holes are repositioned 180 degrees from original location.
- Put capscrews back in and retorque. Recheck shaft alignment.
- If runout unchanged, rotate discs to 30, 60 or 90 degrees from original location.
- If T.I.R. does not improve, inspect flywheel pilot and drive disc runouts.
P7 Axial Alignment Procedure adjustment
- Check only when an objectionable vibration is present.
- Remove the capscrews connecting drive discs and flywheel.
- Mark the drive discs and flywheel with respect to each other.
- Rotate engine or generator so drive discs holes are repositioned two bolt holes from original location.
- Put capscrews back in and retorque. Recheck/record vibration levels.
- Repeat this test until drive disc holes are repositioned 180 degrees from original location.
- Review vibration data and position drive disc in lowest recorded level location.
UFRO Adjustments adjustment
⚠ Use an insulated handle screw driver to prevent electrical shock.
Tools: Insulated handle screwdriver, Frequency meter or tachometer
- Make a note of the no-load frequency.
- Determine roll-off frequency by turning the governor speed pot until the LED lights; if okay go to step 5.
- Adjust the governor speed pot to the proper roll-off frequency.
- Turn the UFRO pot until LED goes off, then slowly turn it back until the LED just goes on.
- Adjust the governor speed pot back to the initial frequency setting.
Voltage and Voltage Stability Adjustments adjustment
⚠ Touching uninsulated high voltage parts inside the control and power output boxes can result in severe personal injury or death.
Tools: Insulated handle screwdriver, AC voltmeter
- Use the control panel mounted voltage trimmer, if provided, for small voltage adjustments.
- Measure generator output voltage while running without load at nominal frequency.
- If trimmer is insufficient, lock it at midpoint.
- Turn the VOLTS pot fully counterclockwise and the STABILITY pot to its midpoint.
- If the red LED lights, refer to Jumper Reconnections and UFRO Adjustments.
- Turn the VOLTS pot clockwise until rated voltage is obtained.
- If voltage becomes unstable with a large load, turn the STABILITY pot clockwise until stable.
- Check and readjust the VOLTS pot each time the STABILITY pot is readjusted.
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.
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.
Parts
140model family| Part # | Description | Qty | System | |
|---|---|---|---|---|
| 300-0749 | 12 VDC Positive Signal | 1 | Sensor | buy |
| 300-0750 | 24 VDC Positive Signal | 1 | Sensor | buy |
| 300-1295 | 24 VDC Ground Signal | 1 | Sensor | buy |
| 300-1591 | 12 VDC Ground Signal | 1 | Sensor | buy |
| 300-1749 | 24 VDC Ground Signal w/Key | 1 | Sensor | buy |
| 300-1846 | 12 VDC Positive Signal | 1 | Sensor | buy |
| 300-1847 | 24 VDC Positive Signal | 1 | Sensor | buy |
| 300-2751 | ANN 12/24 VDC Negative Signal | 1 | Sensor | buy |
| 300-2752 | ANP 12/24 VDC Positive Signal | 1 | Sensor | buy |
| 300-4510-02 | Negative Signal Net Mod. 12/24 VDC | 2 | Sensor | buy |
| 4-21 | FAIL TO CRANK | Sensor | Amazon eBay | |
| 4-24 | LOW OIL PRESSURE | Sensor | Amazon eBay | |
| 4-25 | OIL PRES SENDER | Thermostat | Amazon eBay | |
| 4-26 | HIGH COOLANT TEMP | Sensor | Amazon eBay | |
| 4-27 | HIGH COOLANT TEMP | Sensor | Amazon eBay | |
| 4-28 | LOW COOLANT LVL | Sensor | Amazon eBay | |
| 900-0100 | Battery charger | 8 | Battery charger | buy |
| 900-0170 | Sensor | 3 | Sensor | buy |
| 900-0209 | Sensor | 4 | Sensor | buy |
| 900-0228 | Sensor | 3 | Sensor | buy |
| 900-0239 | Sensor | 4 | Sensor | buy |
| 900-0336 | Oil filter | Oil filter | buy | |
| 900-0339 | Oil filter | Oil filter | buy | |
| 903-0503 | Oil filter | Oil filter | buy | |
| 919-0100 | Engine Control Module | 1 | ECM / ECU | buy |
| 919-0308 | Belt-Driven Two Bearing Alternators | 1 | Belt | buy |
| 928-0120 | Air Filter | 4 | Air filter | buy |
| 928-0220 | Air Filter | 4 | Air filter | buy |
| 934-0120 | Oil filter | Oil filter | buy | |
| 934-0125 | Oil filter | Oil filter | buy | |
| 934-0222 | Oil filter | Oil filter | buy | |
| 934-0229 | Fuel filter | Fuel filter | buy | |
| 934-0233 | Oil filter | Oil filter | buy | |
| 934-0236 | Oil filter | Oil filter | buy | |
| 934-0600 | Oil filter | Oil filter | buy | |
| 940-0120 | Oil Filter | 1 | Oil filter | Amazon eBay |
| 943-0005 | Generator Parts Catalog | 1 | Catalog | Amazon eBay |
| 943-0018 | Voltage Regulator VRAS-2 | 1 | Voltage regulator | Amazon eBay |
| 943-0019 | Engine Control Module | 2 | ECM / ECU | buy |
| 943-0020 | Oil filter | Oil filter | buy | |
| 960-0100 | Air filter | Air filter | buy | |
| 960-0181 | Service manual | Service manual | Amazon eBay | |
| 960-0268 | Oil filter | Oil filter | buy | |
| 960-0302 | Service manual | Service manual | Amazon eBay | |
| 960-0504 | PCC Control Service Manual | * | Service manual | Amazon eBay |
| 960-0507 | Detector Control Service Manual | ** | Service manual | Amazon eBay $49.00 |
| 965-0019 | Engine Control Module | 1 | ECM / ECU | buy |
| 965-0100 | Engine Control Module | 4 | ECM / ECU | buy |
| 965-0131 | Operator manual | Operator manual | Amazon eBay | |
| 965-0203 | Engine Control Module | 2 | ECM / ECU | buy |
| 981-0122 | Air filter | Air filter | buy | |
| 981-0123 | Recoil Starter Control Panel | 1 | Recoil starter | Amazon eBay |
| 981-0124 | Oil Filter | 3 | Oil filter | buy |
| 981-0125 | Oil Filter | 3 | Oil filter | buy |
| 981-0126 | Oil Filter | 3 | Oil filter | buy |
| 981-0127 | Oil Filter | 3 | Oil filter | buy |
| 981-0139 | Air Filter | 2 | Air filter | Amazon eBay |
| 981-0241 | Alternator | 1 | Alternator | buy |
| 981-0242B | Engine Control Module | 6 | ECM / ECU | buy |
| 981-0243 | Engine Control Module | 2 | ECM / ECU | buy |
| 981-0244 | Engine Control Module | 2 | ECM / ECU | buy |
| 981-0249 | Engine Control Module | 1 | ECM / ECU | buy |
| 982-0001 | Oil Filter | 3 | Oil filter | buy |
| 982-0003 | Fuel Filter | 2 | Fuel filter | buy |
| 982-0200 | Air Filter | 6 | Air filter | Amazon eBay |
| 982-0201 | Oil Filter | 3 | Oil filter | buy |
| 982-0202 | Air Filter | 6 | Air filter | buy |
| 982-0204 | Air Filter | 6 | Air filter | buy |
| 982-0205 | Air Filter | 6 | Air filter | buy |
| 982-0228 | Alternator | 1 | Alternator | buy |
| 982-0229 | Alternator | 1 | Alternator | buy |
| 982-0600 | Belt | 3 | Belt | buy |
| 982-0602 | Belt | 3 | Belt | buy |
| 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 eBay | |
| LS-14M | Fuel Transfer Pump and Control | Day tank fuel transfer pump | Amazon eBay | |
| P1-3 | Amperemeter | 1 | Ammeter | Amazon eBay |
| W1859s | CRANKING POTENTIOMETER | Cranking potentiometer | Amazon eBay | |
| 300-4510 | ANN 12/24 VDC Negative Signal | 1 | Service part / kit | buy |
| 300-4511 | ANP 12/24 VDC Positive Signal | 1 | Service part / kit | buy |
| 4-10 | Coolant Pressure Caps | Service part / kit | Amazon eBay | |
| 4-29 | FAIL TO CRANK | Service part / kit | Amazon eBay | |
| 4-30 | OVERSPEED | Service part / kit | Amazon eBay | |
| 4-31 | HIGH DC VOLTAGE | Service part / kit | Amazon eBay | |
| 4-35 | WEAK BATTERY | Service part / kit | Amazon eBay | |
| 4-36 | CUSTOMER FAULT 1* | Service part / kit | Amazon eBay | |
| 4-37 | LOW FUEL | Service part / kit | Amazon eBay | |
| 4-38 | EEPROM ERROR | Service part / kit | Amazon eBay | |
| 4-39 | DAY TANK* | Service part / kit | Amazon eBay | |
| 900-0181 | PCC Control Service Manual | * | Service part / kit | Amazon eBay |
| 903-0124 | NA | NA | Service part / kit | Amazon eBay |
| 903-0125 | NA | NA | Service part / kit | Amazon eBay |
| 903-0126 | NA | NA | Service part / kit | buy |
| 903-0127 | NA | NA | Service part / kit | buy |
| 903-0128 | NA | NA | Service part / kit | Amazon eBay |
| 903-0204 | NA | NA | Service part / kit | Amazon eBay |
| 903-0205 | NA | NA | Service part / kit | Amazon eBay |
| 903-0206 | NA | NA | Service part / kit | buy |
| 903-0207 | NA | NA | Service part / kit | buy |
| 903-0208 | NA | NA | Service part / kit | Amazon eBay |
| 903-0500 | NA | NA | Service part / kit | Amazon eBay |
| 903-0604 | NA | NA | Service part / kit | Amazon eBay |
| 903-0605 | NA | NA | Service part / kit | Amazon eBay |
| 903-0606 | NA | NA | Service part / kit | buy |
| 903-0607 | NA | NA | Service part / kit | buy |
| 903-0608 | NA | NA | Service part / kit | Amazon eBay |
| 934-0121 | SPEC A | Service part / kit | eBay | |
| 934-0501 | Generator and Control | 8 | Service part / kit | Amazon eBay |
| 940-0122 | Operators Manual NHE GenSet | Service part / kit | Amazon eBay | |
| 940-0223 | IQ-949 (sp@e A-R) Replecee 2-M [Spat | 1 | Service part / kit | eBay |
| 940-0610 | Safety precautions manual | Service part / kit | Amazon eBay | |
| 940-0751 | Major Service Manual | Service part / kit | buy | |
| 943-0100 | Generator Set | 8 | Service part / kit | Amazon eBay |
| 944-0122 | NA | NA | Service part / kit | buy |
| 960-0136 | Battery, 24V, 55Ah, AGM | 8 | Service part / kit | Amazon eBay |
| 962-0102 | Switch | Service part / kit | Amazon eBay | |
| 962-0105 | Switch | Service part / kit | Amazon | |
| 962-0109 | Utility-to-Utility Automatic Control | Service part / kit | buy | |
| 962-0113 | Transfer Switch | Service part / kit | Amazon eBay | |
| 962-0504 | Transfer Switches | Service part / kit | buy | |
| 962-0512 | Transfer Switch | 1 | Service part / kit | Amazon eBay $49.00 |
| 962-0600 | Transfer Switch | Service part / kit | Amazon eBay $19.00 | |
| 965-0520 | Cooling Fan | 37 | Service part / kit | Amazon eBay |
| 968-0340 | Generator set control panel | Service part / kit | Amazon eBay | |
| 974-0610 | INSTALLATION GUIDE FOR 12.0 RDJC, RV DIESEL SERIES ELECTRIC GENERATING SETS | Service part / kit | Amazon eBay | |
| 977-0121 | NA | NA | Service part / kit | Amazon eBay |
| 977-0220 | NA | NA | Service part / kit | buy |
| 981-0257 | Part 981-0257 | 1 | Service part / kit | Amazon eBay |
| 981-0514 | Kubota Workshop manual | Service part / kit | Amazon eBay | |
| 981-0625 | Generator Set | 7 | Service part / kit | Amazon eBay |
| 982-0002 | UR Generator with Torque Match-2' Regulator Service Manual | 3 | Service part / kit | Amazon |
| 982-0004 | Cooling Fan | 1 | Service part / kit | buy |
| 982-0601 | Safety Precautions | 5 | Service part / kit | Amazon eBay $19.00 |
| TB1-2 | Battery charging alternator terminal TB1-2 | 2 | Service part / kit | Amazon Amazon eBay eBay FridayParts $34.80 |
| 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 eBay NAPA $224.81 FridayParts $57.30 |
Compiled from this model's family documentation — may include parts for closely-related variants. Confirm the exact part for your serial number. See the full parts catalog to search and cross-reference.
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)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 — DFxx Generator Set Service Manual PCC3100 (Cummins/Onan)Service manual — Detector Control Generator Set Service Manual (Cummins/Onan)
This page was generated from the 8 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.