Cummins/Onan DFE — Specs, Engine, Parts & Maintenance

Service parts for the DFE

Grouped by system, with how many of each the parts manual calls for.

Air intake

1 required

Prices captured from merchant listings; some links are affiliate links. Confirm against your serial number before ordering.

Specifications

Fuel	Diesel
Frequency	60.0 Hz
Standby power	500 kW
Standby kVA	563
Prime power	455 kW
Emissions	EPA NSPS Stationary Emergency Tier 2
Controller	HMI320, PowerCommand, PowerCommand (2100); PowerCommand (3200) available, PowerCommand 2.3, PowerCommand 2.3 (PCC 2300), PowerCommand 2100, PowerCommand 2100 (PCC), PowerCommand 3100 (PCC), PowerCommand 3200, PowerCommand 3200 (PCC)
Oil capacity	45.0 L
Alternator	Stamford/AvK HC
Voltage options	24 V
Phase	3
Rated current	753 A
Power factor	0.8
Circuit breaker	800 A
Battery group	8D
Battery cranking	1400 CCA
Battery voltage	24 V
Battery quantity	2
Coolant capacity	91 L
Max ambient	40 °C
Dimensions (L×W×H)	3864×1524×1812 mm
Dry weight	4098 kg
Wet weight	4461 kg
Sound level	76.0 dBA @ 7 m
Fuel tank	3218.0 L
Tank runtime	25 hr

Engine

Cummins/Onan KTA19

Oil capacity	45.0 L
Coolant capacity	91.0 L
Displacement	18.7 L
Rated speed	1800 rpm

Filters for the Cummins/Onan KTA19

Engine-mounted filters the filter manufacturers list for this engine family. These come from the engine, not from this generator set’s own parts list, so confirm against your serial number before ordering.

System	Filter	Description	Cross-references
Oil filter	P550777	Lube Filter, Spin-On Bypass	CUMMINS 3021658, CUMMINS 33004232, NAPA 1749, BALDWIN B7577	FridayParts $43.56
Oil filter	P551670	Lube Filter, Spin-On Full Flow	CUMMINS 298670, CUMMINS 299670, NAPA 1970, CARBOCOL 0026	FridayParts $26.68
Fuel filter	P550105	Fuel Filter, Spin-On Primary	CUMMINS 154700, CUMMINS 154710, NAPA 3109, NAPA 3405	buy
Fuel filter	P550104	Fuel Filter, Spin-On	CUMMINS 127674, CUMMINS 136517, NAPA 3107, NAPA 3405	FridayParts $143.60
Fuel / water separator	P550106	Fuel Filter, Water Separator Spin-On	CUMMINS 154789, CUMMINS 156164, NAPA 3405, BALDWIN BF957-D	FridayParts $285.60
Fuel / water separator	P558000	Fuel Filter, Water Separator Spin-On Twist&Drain	CUMMINS 3308638, CUMMINS 3308683, NAPA 3405, NAPA 3693	KuduParts $24.00 FridayParts $25.66
Coolant filter	P554071	Coolant Filter, Spin-On	CUMMINS 209604, CUMMINS 209606, NAPA 4071, WALGAHN-MOTORENTECHN 00811412	FridayParts $397.60
Coolant filter	P554073	Coolant Filter, Spin-On	CUMMINS 209605, CUMMINS 209607, NAPA 4073, VERSATILE 00104040	KuduParts $40.00

Maintenance & consumables

for the Cummins/Onan KTA19

Item	Spec	Capacity	Part #	Interval
Air filter			L028-2	500 hr	eBay
Fuel filter	New o-ring seal supplied with the new filter. For Biodiesel applications use gasket pack 3950445 S (green) and change with every filter change.		—	500 hr
Oil filter	885 hrs 5/13/25		—	500 hr
Battery	2 8D batteries		—	200 hr
Belt			—	500 hr
Coolant	-35	90.0	—	500 hr
Coolant filter			—	500 hr
Oil		88.0 L	—	500 hr
Spark plug			—	500 hr

Service intervals

Item	Action	Hours	Months	Notes
Air cleaner	Check	250 hr	6 mo	X1; replace as necessary; refer to QSX15 engine manual
All hardware (fittings, clamps, fasteners, etc.)	Check	100 hr		Daily or after 8 hours
Anti-freeze and DCA concentration	Check	250 hr	6 mo	X1; refer to QSX15 engine manual
Coolant heater(s)	Check	100 hr		Daily or after 8 hours
Drive belt	Check	250 hr	6 mo	X1; refer to Cummins QSX15 Series Engine Operation and Maintenance Manual for interval/procedure
Engine oil level	Check	8 hr		Daily or after 8 hours
Fuel filter(s)	Drain	250 hr	6 mo	X1; refer to QSX15 engine manual
Genset	Inspect	8 hr		Daily; check for oil, fuel, cooling and exhaust system leaks
Radiator hoses for wear and cracks	Check	250 hr		Daily or after 8 hours
Charge Air Piping	Check	50 hr		Weekly
Coolant heater	Check	50 hr		Weekly or after 50 hours
Coolant level	Check	50 hr		Weekly or after 50 hours
Exhaust condensate trap	Drain	100 hr		Drain water to prevent it flowing back into the engine
Fuel level	Check	50 hr		Weekly or after 50 hours
Oil level	Check	50 hr		Weekly or after 50 hours
Air cleaner	Clean	100 hr		Monthly or after 100 hours; clean if required, perform more often in dusty conditions
Battery charging system	Check	100 hr		Monthly or after 100 hours
Battery electrolyte level	Check	200 hr		Monthly or After 100 Hrs
Fuel tank water and sediment	Drain	100 hr		Monthly or after 100 hours
General set inspection	Inspect	100 hr		Monthly or after 100 hours (Table 5-1, footnote X2): check for oil, fuel, cooling and exhaust system leaks; check exhaust system audibly and visually with set running
Generator air outlet	Check	100 hr		Monthly or After 100 Hrs
Radiator hoses	Check	500 hr	12 mo	Monthly or After 100 Hrs; check for wear and cracks
Starting batteries	Check	100 hr		Check condition and terminals
Air cleaner	Replace	250 hr		Check air cleaner; replace as necessary. Refer to QSX15 manual.
Crankcase oil and filter	Change	250 hr	12 mo	Prime power: every 6 months or 250 hours; standby: every 12 months or 250 hours, whichever comes first
Drive belt tension	Check	250 hr	6 mo	Visually check belt for wear or slippage; replace if hard or brittle
Engine oil and filter	Replace	250 hr	6 mo	X1; 6 Months or After 250 Hrs; refer to QSX15 engine manual
Radiator Hoses	Inspect	250 hr	6 mo	Check for wear & cracks
Water coolant filter	Replace	250 hr	6 mo	X1; 6 Months or After 250 Hrs
Air cleaner element	Change	500 hr	12 mo	Yearly or after 500 hours; clean if required more often
Coolant filter	Change	500 hr	12 mo	Yearly or after 500 hours; refer to engine operation and maintenance manual
Cooling system	Clean	500 hr	12 mo	Yearly or after 500 hours; drain and replace coolant mixture
Crankcase breather	Clean	500 hr	12 mo	Yearly or after 500 hours
Engine oil and filter	Change	500 hr	12 mo	Table 5-1, footnote X1
Fuel filter	Change	500 hr	12 mo	Table 5-1, footnote X1
Fuel filters	Change	500 hr	12 mo	Yearly or after 500 hours
Generator insulation resistance	Test	500 hr	12 mo	Follow periodically throughout life of set or if generator has set idle with no heaters; contact authorized service center
Water coolant filter	Change	500 hr	12 mo	Table 5-1, footnote X1
Cooling systems	Clean	500 hr	12 mo	X1; 1 Year
Fuel filter	Replace		12 mo	X1; 1 Year

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

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	Exhaust pipe clearance from combustible wall or partition	12	inches (305 mm)	minimum
Clearance	Exhaust pipe clearance to combustible wall/partition	12	inches (305 mm)
Clearance	Float switch assembly float lift clearance below C-clip stop	1/8	inch (3 mm)	use a feeler gauge
Clearance	Fuel line clearance from electrical wiring	1/2	inch (12.7 mm)
Clearance	Fuel line clearance from hot exhaust parts	2	inch (51 mm)
Clearance	Generator mount pre-load steel spacer thickness	1 3/4	inch	two spacers under both stator foot brackets
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
Clearance	MPU installation gap adjustment	back out 1/4 turn after touching gear tooth	turn
Clearance	Vibration isolator base elevation difference	0.25	inch (6 mm)	shimmed or grouted within this of each other
Clearance	Vibration isolator clearance	0.25	inch (6 mm)
Clearance	Vibration isolator nominal clearance (leveling bolt)	0.25	inch (6 mm)	minimum, or greater
Gap	Coolant level below radiator cap lower sealing surface	3/4 inch (18 mm)	inch (mm)
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	Ambient temperature below which coolant heaters recommended (NFPA 110)	40	°F
Other	Angular alignment maximum T.I.R.	.001 inches per inch of radius	in/in	center of shaft to indicator axis
Other	Battery CCA (minimum)	1400	CCA	Cold Soak @ 0° F (-18° C)
Other	Battery charging alternator output	35	Amps
Other	Battery specific gravity (fully charged)	1.26	specific gravity	at 80 F (27 C)
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 charge threshold	1.215	corrected	charge battery if reading below
Other	Battery specific gravity fully charged	1.260	corrected	add 0.004 per 10 F above 80 F (27 C)
Other	Battery specific gravity, fully charged	approximately 1.260	specific gravity	at 80 F (27 C)
Other	Battery terminal cleaning solution	1/4 pound baking soda to 1 quart water
Other	CAN datalink main trunk maximum length	40	meters	no more than 30 devices
Other	CAN datalink stub maximum length	1	meter	stub from main trunk to each module
Other	CAN datalink transmission speed	250	KBaud
Other	Charge battery if specific gravity below	1.215	specific gravity
Other	Compression ratio	17.0:1
Other	Frequency regulation	Isochronous
Other	Fuel lift height limit	6	feet	(1.8 meters) between fuel lift pump and bottom of dip tube
Other	Fully charged battery corrected specific gravity	1.260	specific gravity	corrected reading @ 80 F (27 C)
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	Mounting bolt size	5/8	inch or 16 mm
Other	Mounting bolts	5/8 inch or 16 mm	inch / mm	anchored mounting bolts
Other	Optional run/alarm relay contact rating	10 amps at 28 VDC or 120 VAC, 80%PF; 6 amps at 240 VAC, 80%PF; 3 amps at 480/600 VAC, 80%PF	amps
Other	Output frequency adjustment (PCC)	+/- 5	%	set running under normal parameters
Other	Over current warning threshold	110	% of rated
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	Overspeed limit	2150 ± 50	rpm
Other	REG VHZ (underfrequency roll-off) adjustable range	1 through 50; normal range 7 through 21
Other	Random frequency variation	± 0.25	%
Other	Short circuit shutdown threshold	175	% of rated current
Other	Specific gravity correction	0.004	gravity point per 10 F above 80 F (27 C)
Other	Start delay adjustment range	0 to 300	seconds
Other	Start delay adjustment range (PCC)	0 to 300	seconds	Auto mode remote starting
Other	Stop delay adjustment range	0 to 600	seconds
Other	Stop delay adjustment range (PCC)	0 to 600	seconds	Auto mode remote stopping
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

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		Refer to Cummins QSX15 Series Engines Operation and Maintenance Manual for coolant recommendations/specifications		58.0 L	Cooling System (Capacity Std. Radiator) printed as 15.3 Gal (58 L); check anti-freeze and DCA concentration
Coolant	Balanced coolant mixture of water and antifreeze	Refer to Cummins engine Operation and Maintenance Manual		90.0 L	Capacity with standard radiator 24 Gal (90 L); drain and replace mixture every year or after 500 hours; add until 3/4 inch (18 mm) below radiator cap lower sealing surface
Coolant	soft water / E.G. / DCA mixture				Cooling system to be filled with soft water/E.G./DCA mixture (on-site review checklist).
Engine oil		Refer to Cummins QSX15 Series Engines Operation and Maintenance Manual for lubricating oil classification/viscosity		58.0 L	Oil Cap. w/Filters printed as 26 Gallons (58 L); gense is shipped filled with correct type and quantity of oil
Fuel	ASTM D975 No. 2-D	Cetane number 40-50, 300-500 ppm Sulfur			Diesel fuel specifications
Fuel	ASTM No. 2 diesel				Cummins engines normally use ASTM No. 2 diesel fuel.
Fuel	Diesel				Day tank fuel transfer pump maintains reservoir of diesel fuel in the day tank.
Fuel	diesel				Refer to Cummins QSX15 Series Engines Operation and Maintenance Manual for fuel recommendations; do not use zinc coated or copper fuel lines with diesel fuel; keep fuel supply tanks as full as possible
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.
Other	Donaldsons D1400 solvent				Soak air cleaner filter element at least 15 minutes in water and D1400 solvent to remove soot, carbon and dirt

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

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	Local or remote Emergency Stop; engine shuts down and will not crank	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.
111	Internal ECM error	Internal ECM error	Shutdown
1118		Prelube relay driver	Warning
112	Actuator not responding	Category A	Shutdown
1121		Failed to Disconnect	Warning
1122	Rated/Idle Trans		Info
1123	Shutdown After Battle Short	A shutdown fault occurred while Battle Short was enabled and Battle Short transitioned from enabled to disabled	Warning	Review the Fault History and perform corrective action
1124	Delayed Shutdown	Provides advanced warning of an impending generator set shutdown to loads which cannot handle sudden power loss	Warning	A shutdown fault is present; review fault history
113	Actuator sensor fault	Category B	Warning
1131	Battle Short Active	Battle short mode has been activated	Warning	Battle short function enabled
115	No speed signal	No speed signal	Shutdown
116	Time press sensor high	Time press sensor high	Shutdown
117	Time press sensor low	Time press sensor low	Shutdown
118	Pump press sensor high	Pump press sensor high	Warning
119	Pump press sensor low	Pump press sensor low	Warning
121	Speed Signal Lost	No engine speed signal	Warning
1219		Utility CB tripped	Warning
122	Manifold air press sensor	Manifold air press sensor	Warning
1222		Power transfer not in auto	Warning
1223		Utility frequency sensor	Warning
1224		Gen over voltage sensor	Warning
1225		Gen under voltage sensor	Warning
1226		genset frequency sensor	Warning
123	Manifold air press sensor	Manifold air press sensor	Warning
1245	CAN - Engine Shutdown	The PCC received a shutdown message from the ECM	Shutdown	Refer to the E-Controls service tool and the engine service manual
1246	CAN - Unknown Engine Fault	The PCC received an unknown message from the ECM	Warning	Refer to the E-Controls service tool and the engine service manual
1247	CAN - Engine Unannounced Fault	The PCC received an unknown message from the ECM	Warning	Refer to the E-Controls service tool and the engine service manual
1248	CAN - Engine Warning Fault	The PCC received an unknown message from the ECM	Warning	Refer to the E-Controls service tool and the engine service manual
1311	Customer input #1	Optional customer-selected fault, e.g. Low Fuel Day Tank, Water In Fuel, Ground Fault, Low Starting Hydraulic/Air Pressure		Programmable via service tool: enable/disable, status/warning/shutdown, active closed/open, custom display name
1311, 1312, 1317, 1318	Customer Input	Nature of the fault is an optional customer selection		Disconnect signal lead from TB1 (CUST_IN1 TB1-4, CUST_IN2 TB1-5, CUST_IN3 TB1-6, CUST_IN4 TB1-7) and reset the control; if the message clears, external wiring has a short/open or the active input selection (closed/open) is not correct
1312	Customer input #2	Optional customer-selected fault		Customer defined fault; message editable by the customer; can be programmed to initiate a shutdown or warning.
1313	Network Fault 1 thru 4	Network Fault 1		Customer defined fault; message editable by the customer; can be programmed to initiate a shutdown or warning.
1313-1316	Network Fault 1 Through 4	Indicates network input (#1-#4) is in an active state		Each fault function can be programmed (using the service tool) as Status, Warning, or Shutdown; change display name using up to 19 characters
1314	Network Fault 2	Network Fault 2		Customer defined fault; message editable by the customer; can be programmed to initiate a shutdown or warning.
1315	Network Fault 3	Network Fault 3		Customer defined fault; message editable by the customer; can be programmed to initiate a shutdown or warning.
1316	Network Fault 4	Network Fault 4		Customer defined fault; message editable by the customer; can be programmed to initiate a shutdown or warning.
1317	Customer input #3	Customer input #3		Customer defined fault; message editable by the customer; can be programmed to initiate a shutdown or warning.
1318	Customer input #4	Customer input #4		Customer defined fault; message editable by the customer; can be programmed to initiate a shutdown or warning.
1319	High alternator temp	High alternator temp	Warning
1321	Common warning driver	Common warning driver	Warning
1322	Load gov kW setpoint oor hi	Load gov kW setpoint oor hi	Shutdown
1323	Load gov kW setpoint oor lo	Load gov kW setpoint oor lo	Shutdown
1324	Load gov kVAR oor hi	Load gov kVAR oor hi	Warning
1325	Load gov kVAR oor lo	Load gov kVAR oor lo	Warning
1326	Backup starter disconnect	Category B	Warning
1327	Load gov kW analog oor	Load gov kW analog oor	Shutdown
1328	Genset CB tripped	Genset CB tripped	Warning
1329	AVR DC power failure	Category B	Warning
1331	AVR driver shorted	Category A	Shutdown
1332	Manual switch oor lo	Manual switch oor lo	Shutdown
1333	Manual switch oor hi	Manual switch oor hi	Shutdown
1334	Critical scaler oor	Critical scaler oor	Shutdown	Correct the feature/calibration entered into the control
1335	Noncrit Scaler Out Of Range	Non critical scaler oor	Warning	Correct the feature/calibration entered into the control
1336	Cooldown complete	Cooldown complete	Shutdown
1337	No Message	Network wink	Info
1341	Load demand stop	Load demand stop	Shutdown
1342	Slot 0 card	Slot 0 card	Shutdown
1343	Slot 1 card	Slot 1 card	Shutdown
1344	Slot 2 card	Category A	Shutdown
1345	Slot 3 card	Slot 3 card	Shutdown
1346	Slot 4 incorrect	Slot 4 incorrect	Shutdown
1347	Slot 5 card	Category A	Shutdown
1348	Slot 6 card	Category A	Shutdown
1349	Slot 7 card	Category A	Shutdown
135	Oil pressure sensor	Oil pressure sensor	Warning	Verify fault simulation not enabled (InPower); inspect sensor and engine harness connector pins; use oil pressure sensor simulator to check control response, replace sensor if it responds; check P7-13, 17, 21 for short (>200k ohms OK) and open (10 ohms or less OK)
1351	Slot 4 / network enabled	Slot 4 / network enabled	Warning
141	Oil pressure sensor	Oil pressure sensor	Warning	Verify fault simulation not enabled; inspect sensor/harness connector pins; use simulator to check control response; check P7-13, 17, 21 short/open
1414	Run relay contact	Run relay contact	Warning
1415	Run relay driver	Run relay driver	Warning
1416	Fail to shutdown	Fail to shutdown	Warning	Status - indicates the Fault Bypass mode is enabled (used primarily by service personnel for troubleshooting). The genset ignores the majority of system shutdown faults.
1417	Powr Down Error	The control has failed to go to sleep	Warning	Possible base board fault
1419	Fuel rail driver	Fuel rail driver	Warning
1421	Timing rail driver #1	Timing rail driver #1	Warning
1422	Timing rail driver #2	Timing rail driver #2	Warning
1424	High side driver	High side driver	Warning
1427	Overspeed relay driver	Overspeed relay driver	Warning
1428	LOP shutdown relay driver	LOP shutdown relay driver	Warning
143	Pre-Low Oil Pressure	Low oil pressure	Warning	Verify fault simulation not enabled; check oil level, lines and filters; use oil pressure sensor simulator; check +5 VDC at sensor (E1-A) and at P7-21; use simulator to P7-13 (OP OUT) and P7-17 (OP COMM); isolate to harness or base board
1433	Emergency stop - local	Local Emergency Stop	Shutdown	Pull the Emergency stop button out; move the O/Manual/Auto switch to O; press the front panel Fault Acknowledge/Reset button; select Manual or Auto as required

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Procedures

Aligning 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 adjustment

Tools: Dial indicator with holding device (magnetic base or clamp)

Fasten dial indicator holding device to skid base, engine block, or generator shell with magnetic base or clamp.
Position so the sensor point rests on the generator shaft hub.
Bar the engine over clockwise (viewed from engine flywheel) through a couple of rotations.
Record indicator readings in eight equally spaced points around the shaft diameter to provide a T.I.R.
To correct an out-of-tolerance T.I.R., remove capscrews connecting drive discs and flywheel.
Mark the drive discs and flywheel with respect to each other.
Rotate engine or generator so drive disc holes are repositioned 180 degrees from original location.
Reinstall drive disc capscrews and retorque; re-check shaft alignment.
If T.I.R. 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.

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.

Bus Voltage Calibration (C) adjustment

⚠ Contacting hazardous voltage components can cause electrocution, resulting in severe personal injury or death.

⚠ Improper calibration or adjustment of the PowerCommand control can cause equipment malfunction or damage.

Tools: Calibrated RMS multimeter (Fluke models 87 or 8060A)

Display the Bus Voltage Calibration submenu.
With all gensets OFF, attach a calibrated voltmeter to TB1-A (L1) and TB1-B (L2) of the bus PT module.
Start another genset and allow it to reach normal operating speed and voltage; connect to the bus.
Calibrate the voltage reading for Bus Volts L1 so display matches the calibrated meter.
Shut the generator set OFF.
Repeat steps 2 through 5 for Bus Volts L2 and L3.
Exit menu to Save changes.

Generator Mount Pre-load Adjustment adjustment

⚠ Accidental starting of the generator set during this procedure presents the hazard of severe personal injury or death. Disconnect the negative (-) battery cable(s) before beginning.

Tools: Two 1 3/4" T x 2" W x 6" L steel spacers, Adequate lifting device

Turn off and disconnect battery charger (if equipped).
Disconnect the negative (-) battery cable(s) to prevent accidental starting.
Unscrew bolt (Item 2) from skid but do not remove from either rear engine vibration isolator.
Loosen the three screws that secure the engine mount brackets to the engine.
Loosen but do not remove the hex nut (Item 1) from the M20 screw of the generator vibration isolators.
Lift the generator until mounting feet brackets are high enough to insert a 1 3/4 inch steel spacer under both stator foot brackets.
Insert spacers and lower the generator so full weight rests on the mounting foot brackets.
Make sure no gap is present between skid and lower mount of rear engine vibration isolators.
Tighten the three screws to secure the bracket to the engine to 190-200 ft-lbs (260-270 N-m).
Lift the generator to remove the two 1 3/4 inch steel spacers.
Start the threads of the rear engine vibration isolator bolts (Item 2) before lowering.
Lower the generator and tighten the two rear engine vibration isolator bolts to 270-330 ft-lbs (365-447 N-m).
Secure the generator foot brackets to the vibration isolators and tighten to 270-330 ft-lbs (365-447 N-m).

Genset Ammeter Display Calibration (B) adjustment

⚠ Contacting hazardous voltage components can cause electrocution, resulting in severe personal injury or death.

⚠ Improper calibration or adjustment of the PowerCommand control can cause equipment malfunction or damage.

Tools: Calibrated RMS multimeter (Fluke models 87 or 8060A)

Display the Current Calibration submenu.
With the genset OFF, attach a calibrated ammeter to L1.
Start the genset and allow it to reach normal operating speed.
Load the genset to maximum rated kVA at rated voltage.
Calibrate the reading for L1 current so display agrees with calibrated ammeter.
Repeat steps 2 through 5 for L2 and L3.
Exit menu to Save changes.

Genset Voltage Display Calibration (A) adjustment

⚠ Contacting hazardous voltage components can cause electrocution, resulting in severe personal injury or death.

⚠ Improper calibration or adjustment of the PowerCommand control can cause equipment malfunction or damage.

Tools: Calibrated RMS multimeter (Fluke models 87 or 8060A)

Display the Voltage Calibration submenu.
With the genset OFF, attach a calibrated voltmeter to the AC output from L1 to L2 (L1 to Neutral for single phase).
Start the genset and allow it to reach normal operating speed.
Calibrate voltage reading for L1 so display agrees with the calibrated voltmeter.
Shut the generator set OFF.
Repeat steps 2 through 5 for L2 and L3.
Exit menu to Save changes.

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.

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.
110/190	3		12	Full load current at Standby rating: 1901 A
110/220	3		12	Full load current at Standby rating: 1642 A
115/230	3		12	Full load current at Standby rating: 1571 A
120/208	3		12	Full load current at Standby rating: 1737 A
139/240	3		12	Full load current at Standby rating: 1505 A
220/380	3		12	Full load current at Standby rating: 951 A
230/400	3		12	Full load current at Standby rating: 903 A
240/416	3		12	Full load current at Standby rating: 868 A
255/440	3		12	Full load current at Standby rating: 821 A
277/480	3	Wye, 4 Wire	12	Full load current at Standby rating: 753 A
277/480	3	Wye, 4 wire	12	Alternator 60 Hz, 12 lead, limited range, 125 °C; single phase power may be taken at up to 40% of nameplate kW at unity power factor
347/600	3		12	Full load current at Standby rating: 602 A

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 is the power rating of the Cummins/Onan DFE?

The Cummins/Onan DFE is rated 500 kW standby (563.0 kVA).

What engine is in the Cummins/Onan DFE?

The Cummins/Onan DFE is powered by the Cummins/Onan KTA19 engine.

What kind of fuel does the Cummins/Onan DFE run on?

The Cummins/Onan DFE runs on Diesel.

What is the oil capacity of the Cummins/Onan DFE?

The Cummins/Onan KTA19 engine in the Cummins/Onan DFE has an oil capacity of 45.0 liters.

How much coolant does the Cummins/Onan DFE hold?

The Cummins/Onan DFE cooling system holds 91 liters (24.0 US gallons) for the radiator system including the engine, per the manufacturer specification sheet.

What is the continuous rating of the Cummins/Onan DFE?

The Cummins/Onan DFE is rated 455 kW prime (513 kVA), against 500 kW standby.

What is the sound level of the Cummins/Onan DFE?

The Cummins/Onan DFE is rated at 76.0 dBA at 7 m, per the manufacturer specification sheet.

How much does the Cummins/Onan DFE weigh?

The Cummins/Onan DFE has a dry weight of 4098 kg (9034 lb).

How big is the fuel tank on the Cummins/Onan DFE?

The Cummins/Onan DFE has a 3218 liter (850 US gallon) fuel tank, giving about 25 hours of runtime.

What voltages is the Cummins/Onan DFE available in?

The Cummins/Onan DFE is offered in 24 V, 3-phase.

What battery does the Cummins/Onan DFE use?

The Cummins/Onan DFE uses 2 batteryies, 24 V each, 1400 CCA, group 8D, per the manufacturer specification sheet.

What alternator does the Cummins/Onan DFE use?

The Cummins/Onan DFE uses a Stamford/AvK HC alternator.

What air filter does the Cummins/Onan DFE use?

The Cummins/Onan DFE uses air filter part number L028-2.

Troubleshooting

Fault codes

Code	Meaning	Cause	Remedy
212	Shutdown lamp lights.	Indicates engine has overheated (coolant temperature has risen above the shutdown trip point: 223° F – standby / 215° F – primary) or the 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 coolant leakage and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check fan belt and repair or tighten if necessary. d. Reset control and restart after locating and correcting problem. Contact an authorized service center if none of the above.

Symptoms & remedies

Symptom	Cause	Remedy
Warning lamp lights.	LOW COOLANT TEMP 210 – WARNING	Set is in standby mode but is not operating. Warning occurs when engine coolant temperature is 70° F (21° C) or lower. NOTE: In applications where the ambient temperature falls below 40°F (4°C), Low Engine Temp may be indicated even though the coolant heaters are operating.
Engine starts from generator control panel but will not start automatically or from a remote panel. (Note: The Run/Off/Auto switch must be in the Auto position for automatic or remote starting).		Check the control wiring between the remote switch and the PCC. Contact an authorized service center.
No AC output voltage.		Contact an authorized service center.
Control does not power up when the Run/Off/Auto switch is set to Run or the Self Test switch is pressed.	There is no DC power to the control.	A. Check for battery disconnected, discharged, or improperly connected. b. Fuse F1 (20A/32V, Type 3AG) may be open. Replace with the same type.
Warning, Shutdown, and Non-Automatic lamps are not lit. Digital display shows main menu or selected menu.	Indicates all engine systems are normal. No corrective action required

Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing. Full Cummins/Onan DFE troubleshooting guide (91 entries) →

Parts

Part #	Description	Qty	System
0179-3536	Coolant heater (Revision E)		Service part / kit	eBay
0402-0222	Vibration isolator (non-seismic rated, does not carry IBC/OSHPD certification)		Service part / kit	eBay
0402-0234	Vibration isolator (non-seismic rated, does not carry IBC/OSHPD certification)		Service part / kit	eBay
0402-0246	Vibration isolator (non-seismic rated, does not carry IBC/OSHPD certification)		Service part / kit	eBay
0402-0427	Vibration isolator (non-seismic rated, does not carry IBC/OSHPD certification)		Service part / kit	eBay $86.02
A035H139	Switch, Pushbutton	1	Service part / kit	eBay
A040U808	Harness, Control − Door (Includes Items 30 & 31)	1	Service part / kit	eBay
A046Y204	Shield, Wiring	1	Service part / kit	eBay
CC2609	Fleetguard Water-Check H2O 3-Way Test Strips	1	Service part / kit	Amazon eBay
D1400	DONALDSONS D1400 SOLVENT		Service part / kit	Amazon eBay FridayParts $48.99
TB3-5	Generator Set Control Panel Terminal Block	1	Service part / kit	Amazon eBay FridayParts $399.75
TB3-6	Generator Set Control Panel Terminal Block	1	Service part / kit	Amazon eBay FridayParts $65.10

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
Prime		105.0	27.7
Prime	3%	83.0	21.9
Prime	25%	41.0	10.9
Prime	50%	67.0	17.6
Prime	75%	90.0	23.7
Prime	100%	115.0	30.4
Standby		114.0	30.1
Standby	3%	89.0	23.4
Standby	25%	44.0	11.6
Standby	50%	71.0	18.8
Standby	75%	97.0	25.7
Standby	100%	91.0	24.1

Available documents

Spec sheet — 0c0d7d52 new-Cummins-DFEK-sound-attunated-enclosure-submittal (Cummins/Onan)Spec sheet — 15d57d49 Cummins-500-kW-DFEK-Weather-Submittal (Cummins/Onan)Spec sheet — 400kW-Cummins-DFEH-Spec-Sheet-Woodstock-Power-Company (Cummins/Onan)Spec sheet — CSDG-500-kW-DFEK-2019-Submittal (Cummins/Onan)Spec sheet — Cummins-450-DFEJ (Cummins/Onan)Spec sheet — Cummins-450-DFEK (Cummins/Onan)Spec sheet — Cummins-DFEK-QSX15-g9-engine-EPA-tier-2-emissions-spec-sheet (Cummins/Onan)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)Spec sheet — Cummins 400kW DFEH QSX15 G9 engine spec sheet (Cummins/Onan)Spec sheet — New-Cummins-DFEK-submittal (Cummins/Onan)Spec sheet — WPC-Cummins-DFEG-Spec-Sheet (Cummins/Onan)Spec sheet — s-1521 (Cummins/Onan)Spec sheet — s-1582-DC60 (Cummins/Onan)Spec sheet — s-1582 (Cummins/Onan)Spec sheet — s1279a (Cummins/Onan)Operator's manual — 960-0155 Cummins DFEG DFEH DFEJ DFEK Operator's Manual (7-2010) (Cummins/Onan)Operator's manual — 960-0174B Cummins DFEG DFEH DFEJ DFEK Operators Manual (2-2004) (Cummins/Onan)Operator's manual — 960-0177 Cummins DFEB DFEC DFED Operator's Manuaal (12-2009) (Cummins/Onan)Reference — Cummins-DFEK-SN-E070065437-Load-Test-Report-and-Inspection-Checklist (Cummins/Onan)Reference — F-1960-Advanced-en (Cummins/Onan)Owner's manual — 960-0102B Cummins DFEB,C,DFED Operators (3-2001) (Cummins/Onan)Parts manual — 0932-0112 Onan Post-Sale Literature Index (07-1998) (Cummins/Onan)Parts manual — 0960-0204 (Cummins/Onan)Parts manual — 0960-0279 I4 201109 (Cummins/Onan)Parts manual — 0960-0299-01 I4 200503 (Cummins/Onan)Parts manual — 0960-0299 I12 201405 (Cummins/Onan)Parts manual — 0961-0201 I12 201608 (Cummins/Onan)Parts manual — 960-0240 Onan DFEB DFEC DFFA DFFB KTA KTT Parts Manual (11-1992) (Cummins/Onan)Parts manual — 960-0263 Cummins DFJA DFJB DFJC DFJD Parts Catalog (2-2015) (Cummins/Onan)Parts manual — 960-0286 Cummins DFEB DFEC DFED DFFB Parts Manual (7-2001) (Cummins/Onan)Parts manual — KTA19G JENERATOR KIRLOSKAR (Cummins/Onan)Service manual — 9-3Service 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 — 960-0513 Onan DFEG DFEH DFEJ DFEK Service Manual (11-2000) (Onan)Service manual — 960-0521 Cummins DFEG DFEH DFEJ DFEK 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 — 960-0621C Cummins DFEG DFEH DFEJ DFEK Installation Manual (5-2001) (Cummins/Onan)Service manual — 960-0633B Cummins DFEG DFEH DFEJ DFEK Installation Manual (2-2004) (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 — DFEG-K with QSX15 Engine, PCC 2100 service manual (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 43 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.

Cummins/Onan DFE Generator Set

Service parts for the DFE

Air intake

Specifications

Engine

Filters for the Cummins/Onan KTA19

Maintenance & consumables

Service intervals

Service specifications

Recommended fluids

Fault codes

Procedures

Voltage reconnection

Common questions

Troubleshooting

Fault codes

Symptoms & remedies

Repair guides

Parts

Fuel consumption

Available documents