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Cummins/Onan DFGB Generator Set

The Cummins/Onan DFGB is a 600 kW (750 kVA) Diesel standby generator set powered by a Cummins/Onan VTA28-G5 engine. It is available at 120/240 V, 110/220 V, 118/230 V, 120/208 V, 127/220 V, 110/180 V, 118/200 V, 220/380 V, 240/416 V, 254/440 V, 277/480 V, 230/400 V and 347/600 V, 3-phase, 60 Hz and rated 902 A. It holds about 84 L (22.2 gal) of oil and 167 L (44.1 gal) of coolant, with a maximum ambient rating of 50 °C. Starting uses 2 group-8 batteries rated 1400 CCA at 24 V. The set measures 4305×1830×2242 mm (169.5×72.0×88.3 in) and weighs about 6169 kg (13600 lb). The same VTA28-G5 engine also powers generator sets from Katolight.

600 kW
Standby
28.0 L
Displacement
84.0 L
Oil capacity
5
Document types

How to read your Cummins/Onan serial & model number →

Typical fuel consumption for 600–605 kW Diesel generators →

Compare with other 600–605 kW Diesel generators →

Service parts for the DFGB

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

Air intake

1 required

Oil system

1 required

Belts

1 required
130-3843Beltsee priceAmazon

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

Specifications

FuelDiesel
Frequency60.0 Hz
Standby power600 kW
Standby kVA750
Prime power545 kW
ControllerPCC2100, PowerCommand, PowerCommand PCC2100
Oil capacity84.0 L
Voltage options110/190 V, 120/208 V, 127/220 V, 139/240 V, 220/380 V, 240/416 V, 254/440 V, 277/480 V, 347/600 V
Phase3
Rated current902 A
Battery group8D
Battery cranking1400 CCA
Battery voltage24 V
Battery quantity2
Starting system24 V DC
Coolant capacity167 L
Max ambient50 °C
Dimensions (L×W×H)4305×1830×2242 mm
Dry weight6169 kg
Wet weight6423 kg

Engine

Cummins/Onan VTA28-G5
Oil capacity84.0 L
Coolant capacity167.0 L
Displacement28.0 L
AspirationTurbocharged and Aftercooled
Rated speed1800 rpm

Filters for the Cummins/Onan VTA28-G5

4

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.

SystemFilterDescriptionCross-references
Oil filterP550777Lube Filter, Spin-On BypassCUMMINS 3021658, CUMMINS 33004232, NAPA 1749, BALDWIN B7577 FridayParts $43.56
Oil filterP551670Lube Filter, Spin-On Full FlowCUMMINS 298670, CUMMINS 299670, NAPA 1970, CARBOCOL 0026 FridayParts $26.68

Listed for this engine in only one kind of machine, so they may depend on how the engine was installed:

SystemFilterDescriptionCross-references
Fuel filterP557440Fuel Filter, Spin-On SecondaryCUMMINS BM78672, BALDWIN BF970, LPM 00013505994, WALGAHN-MOTORENTECHN 00811464 FridayParts $189.69
Fuel / water separatorP558000Fuel Filter, Water Separator Spin-On Twist&DrainCUMMINS 3308638, CUMMINS 3308683, NAPA 3405, NAPA 3693 KuduParts $24.00 FridayParts $25.66

Same engine, other brands

1 brand

The Cummins/Onan VTA28-G5 in this set also powers 1 generator set sold under 1 other brand. Service parts and maintenance intervals for the engine are shared; enclosure, alternator, controller and ratings are not.

BrandModels
KatolightD600FNZ4

Maintenance & consumables

for the Cummins/Onan VTA28-G5
ItemSpecCapacityPart #Interval
Air filterCleaner, Air (Includes Replacement Elements) 140−2465140-2301 Amazon eBay
Fuel filterChange Fuel Filters—100 hr
Oil filterHead, Oil Filter122-0702 Amazon eBay
BatteryCheck the condition of the starting batteries (see Figure 5-7) at the interval specified in the Maintenance Table. See that connections are clean and tight. A light coating of non-conductive grease will retard corrosion at terminals. Keep the electrolyte at the proper level above the plates by adding distilled water. Check specific gravity using a hydrometer and recharge if below 1.260.—
BeltGuard, Belt − Right Side130-3843 Amazon eBay
Coolant167.0 L—500 hr
Coolant filter—
OilChange the oil and filters at the intervals recommended in Table 5-1.89.0 Quarts—8 hr
Spark plug—

Service intervals

4
ItemActionHoursMonthsNotes
crankcase oilChange50 hrFirst service — Drain and replace the crankcase oil after the first 50 hours of operation on new generator sets (break-in)
Battery Electrolyte LevelCheck200 hrCheck level of electrolyte at least every 200 hours of operation.
Crankcase Oil and FilterChange250 hr12 moX6: If genset is used for standby applications, change oil every 12 months or 250 hours, whichever comes first.
Rupture basin leak detect switchTest12 moSome areas may require weekly inspections by safety code.

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
TypeItemValueUnitCondition
ClearanceAngular alignment maximum T.I.R.0.001inch per inch of radius (center of shaft to indicator axis)measuring deflection to bolt heads
ClearanceClearance between exhaust pipes and combustible materials12inches (305 mm)minimum
ClearanceExhaust thimble diameter12inches (305 mm)larger than diameter of exhaust pipe
ClearanceFloat switch assembly float lift clearance below C-clip stop1/8inch (3 mm)use a feeler gauge
ClearanceGenerator-to-engine angular alignment (T.I.R.).001 in. per inch of radius (center of shaft to indicator axis), maximumin750 kW gensets and larger
ClearanceMPU sensor to gear tooth adjustmentback out one quarter turnturnafter contacting gear tooth
ClearanceMounting base above floor6inches (152 mm)minimum for maintenance access
GapFloat switch lift to test open1/8inchbelow C-clip stop
GapMPU sensor to flywheel ring gear toothback it out one quarter turnturnsensor threaded in until it just touches gear tooth
OtherAVR Droop setting5% at full load, 0 PF
OtherAVR voltage regulation (load regulation)approximately ±0.5% RMS
OtherAngular alignment maximum T.I.R..001 inches per inch of radiusin/incenter of shaft to indicator axis
OtherB+ output fuse10ampF1, Base board, 12/24 volt
OtherBattery specific gravity (high ambient, above 95F/35C)1.225recommended to reduce electrolyte loss
OtherBattery specific gravity (recharge threshold)below 1.260
OtherBattery specific gravity, fully chargedapproximately 1.260specific gravityat 80 F (27 C)
OtherCustomer Output relay contact rating2amps at 30 VDCTB1 customer outputs 1-4, normally open
OtherFuel lift height limit6feet(1.8 meters) between fuel lift pump and bottom of dip tube
OtherGOV GAIN default value for paralleling applications70%
OtherGenerator frequency50 or 60Hzas nameplate rating
OtherGenset frequency / RPM nameplate rating50 or 60 Hz / 1500 or 1800 RPM
OtherGround Fault Relay current setting5 to 1200amperesoptional GFR
OtherGround Fault Relay time delay setting0 to 1secondoptional GFR
OtherMaximum cranking voltage drop2voltsdifference between battery and starter terminals while cranking
OtherOptional control relay (K11/K12/K13) contact rating10amps at 600 VAC
OtherOver/Under Frequency Sensor Module - Over Hz Set, 50 Hz nominal55Hzreset 53 Hz
OtherOver/Under Frequency Sensor Module - Over Hz Set, 60 Hz nominal65Hzreset 63 Hz
OtherOver/Under Frequency Sensor Module - Under Hz Set, 50 Hz nominal45Hzreset 47 Hz
OtherOver/Under Frequency Sensor Module - Under Hz Set, 60 Hz nominal55Hzreset 57 Hz
OtherOver/Under Voltage Sensor Module time delaytypically 25 percent, approximately 2.5seconds
OtherOvercrank cranking limit75secondsthree 15-second cranking cycles with two 15-second rest periods
OtherREG VHZ (underfrequency roll-off) adjustable range1 through 50; normal range 7 through 21
OtherStart delay adjustment range0 to 300seconds
OtherStop delay adjustment range0 to 600seconds
OtherSwitched B+ output fuse5ampF2, Base board, 12/24 volt
OtherUnder Frequency Roll Off (UFRO) knee point, 50 Hz units48 to 49Hz
OtherUnder Frequency Roll Off (UFRO) knee point, 60 Hz units58 to 59Hz
OtherUnder-frequency roll-off threshold (UFRO)typically 59 Hz for 60 Hz applications and 49 Hz for 50 Hz applicationsHzAVR UFRO pot preset
PressureAir cleaner element cleaning compressed air30psi
PressureEngine oil pressure - K19 normal50-70psi (345-482 kPa)run mode
PressureEngine oil pressure - K38 normal45-65psi (310-448 kPa)run mode
PressureEngine oil pressure - K50 normal50-70psi (345-482 kPa)run mode
PressureEngine oil pressure - L10/M11 normal30-50psi (207-345 kPa)run mode
PressureEngine oil pressure - NTA 855 normal35-50psi (241-345 kPa)run mode
PressureEngine oil pressure - V28 normal50-90psi (345-620 kPa)run mode
PressureEngine oil pressure shutdown limit - L10/M1120psi (138 kPa)run mode value
PressureEngine oil pressure shutdown limit - L10/M118psi (55 kPa)idle mode value
PressureEngine oil pressure warning limit - L10/M1112psi (83 kPa)idle mode value
PressureEngine oil pressure warning limit - L10/M1125psi (172 kPa)run mode value
PressureIdle Oil Pressure20psiidle
PressureIdle Oil Pressure Shutdown Limit10psiidle
PressureIdle Oil Pressure Warning Limit15psiidle
PressureK19 engine idle oil pressure20psi (138 kPa)idle
PressureK19 engine normal oil pressure50-70psi (345-482 kPa)normal run
PressureK19 oil pressure shutdown/warning limitsshutdown 35 psi (241 kPa) run; warning 40 psi (276 kPa) run; shutdown 10 psi (69 kPa) idle; warning 15 psi (103 kPa) idlepsi (kPa)
PressureK38 engine idle oil pressure20psi (138 kPa)idle
PressureK38 engine normal oil pressure45-65psi (310-448 kPa)normal run
PressureK38 oil pressure shutdown/warning limitsshutdown 35 psi (241 kPa) run; warning 40 psi (276 kPa) run; shutdown 10 psi (69 kPa) idle; warning 15 psi (103 kPa) idlepsi (kPa)
PressureK50 engine idle oil pressure20psi (138 kPa)idle
PressureK50 engine normal oil pressure50-70psi (345-482 kPa)normal run

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

FluidGradeStandardAmbientCapacityNotes
Coolantsoft water / E.G. / DCA mixtureCooling system to be filled with soft water/E.G./DCA mixture (on-site review checklist).
FuelASTM No. 2 DieselCheck the engine manual for fuel specifications to determine acceptability. Never use galvanized or copper fuel lines, fittings or fuel tanks with diesel fuel systems.
FuelASTM No. 2 dieselASTMAlternate diesel fuels per Cummins engine O&M Manual specifications
FuelDieselDay tank fuel transfer pump maintains reservoir of diesel fuel in the day tank.
FuelNumber 2 diesel fuelFuel system: direct injection, number 2 diesel fuel; fuel filter; automatic electric fuel shutoff
GreaseLithium based greaseMobilux No. 2 or Shell Alvania R32.74 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.
GreaseLithium based-30°C to 120°C81.0 mlMobilux No. 2 or Shell Alvania R3; generator end bearing; temperature range -22 F to +248 F (-30 C to +120 C); grease divided between bearing, bearing cap cavity and cartridge cavity.
GreaseLithium based grease, Mobilux No. 2 or Shell Alvania R3-30°C to 120°C2.74 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

80
CodeNameMeaningSeverityAction
1FAULT 2 - INPUT NON-TIMEDEngine monitor TB2 terminal assignment
10PRE-HIGH ENGINE TEMPERATUREEngine monitor TB2 terminal assignment
101IDLE MODEIndicates 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.WarningRemove ground from engine idle input to return to normal speed and voltage.
102EMERGENCY STOPIndicates local or remote Emergency Stop.ShutdownTurn 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.
11PRE-LOW OIL PRESSUREEngine monitor TB2 terminal assignment
1122Rated/Idle TransInfo
1123Shutdown After Battle ShortShutdown fault occurred while Battle Short was enabled and then disabled.ShutdownReview Fault History and perform corrective action.
1124Delayed ShutdownShutdown fault became active while Delayed Shutdown feature was enabled.WarningReview Fault History and perform corrective action.
1131Battle Sh ActiveControl is in Battle Short mode.WarningWarning status indicator is lit when Battle Short mode is enabled. Refer to Battle Short Mode description in Section 3.
12SWITCH OFFEngine monitor TB2 terminal assignment
121Speed Signal LostMag pickup speed indication is not being sensed.ShutdownRestart and check RPM on the digital display.
13LOW ENGINE TEMPERATUREEngine monitor TB2 terminal assignment
1311Customer Input #1Default display name Customer Fault 1; default status NoneThe nature of the fault is an optional customer selection (e.g. Low Fuel Day Tank, Water In Fuel, Ground Fault, Low Starting Hydraulic Pressure, Low Starting Air Pressure). Each fault function can be programmed using service tool.
1311, 1312, 1317, 1318CUSTOMER INPUT #1 - #4Optional customer-selected fault input is active.WarningCheck external wiring and active input (closed/open) selection.
1312Customer Input #2Default display name Ground Fault; default WarningThe nature of the fault is an optional customer selection. Each fault function can be programmed using service tool.
1317Customer Input #3Default display name Low Fuel; default WarningThe nature of the fault is an optional customer selection. Each fault function can be programmed using service tool.
1318Customer Input #4Default display name Rupture Basin Fault; default WarningThe nature of the fault is an optional customer selection. Each fault function can be programmed using service tool.
1334Crit Scaler Out Of RangeIncorrect feature or calibration entered into control.ShutdownReload correct calibration.
1335Noncrit Scaler Out Of RangeIncorrect feature or calibration entered into control.WarningReload correct calibration.
1337No MessageInfo
135Oil Pressure Sensor HEngine oil pressure sender signal is shorted high.WarningCheck sender/connectors/wires.
14LOW FUEL - INPUTEngine monitor TB2 terminal assignment
141Oil Pressure Sensor LEngine oil pressure sender signal is shorted low.WarningCheck sender/connectors/wires.
1416Fail To ShutdownGenset continues to run after shutdown command.WarningWith Battle Short mode enabled and an overridden shutdown fault occurring, the fault is announced but the genset does not shut down. Refer to Battle Short Mode description in Section 3.
1417Powr Down ErrorController cannot power down.WarningIndicates that the controller can not power down because of some unknown condition. Possible drain on battery. Contact an authorized service center for service.
143Pre-Low Oil PresEngine oil pressure has dropped to an unacceptable level.WarningIndicates engine oil pressure has dropped below the warning trip point. If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then follow code 415 procedure.
1433Emergency StopLocal Emergency Stop.ShutdownPull button out; move switch to O; press Fault Acknowledge/Reset; select Manual or Auto.
1434Remote E-StopRemote Emergency Stop.ShutdownSee code 1433 to reset.
1435Low Coolant TempWarning LED illuminates when engine jacket water coolant temperature falls below 70°F (21°C); per NFPA 110 requirement, indicates engine may not accept load within 10 secondsWarningIndicates engine coolant heater is not operating or is not circulating coolant. a. Coolant heater not connected to power supply; check for blown fuse or disconnected heater cord. b. Check for low coolant level and replenish if required; look for possible coolant leaks and repair.
1438Fail To CrankEngine failed to crank after PCC received a start signal.ShutdownIndicates possible fault with control, speed sensing or starting system. See code 441 for corrective action.
144Coolant Sensor HighEngine coolant temperature signal is shorted high.WarningCheck sender/connectors/wires.
1442Weak BatteryBattery voltage at or below weak battery warning trip point during cranking.WarningSee code 441 for corrective action.
1443Battery FailedDead battery - engine will not start.ShutdownSee code 441 for corrective action.
1444KW OverloadGenerator output power exceeded 105% of genset rating.WarningCheck load and load lead connections; check CTs.
1445Short CircuitGenerator output current has exceeded 175% of rated.ShutdownCheck load and load lead connections.
1446High AC VoltageOne or more phase voltages exceeded 130% of nominal.ShutdownCheck fault simulation, load removal, threshold settings, Base board/generator.
1447Low AC VoltagePhase voltages dropped below 85% of nominal for 10 seconds.ShutdownCheck overload, output terminal connections, PMG/field wiring, rectifier diodes.
1448Under FrequencyEngine speed dropped below 90% of nominal for 10 seconds.ShutdownCheck fuel supply, intake air supply and load.
1449Over FrequencyFrequency is 10% above base frequency for 20 seconds.WarningCheck fuel or air delivery; check connections.
145Coolant Sensor LowEngine coolant temperature signal is shorted low.WarningCheck sender/connectors/wires.
1452Gen CB Not CloseGenset circuit breaker (S2) failed to close when PTC is enabled.WarningRefer to Section 5 troubleshooting charts.
1453Gen CB Not OpenGenset circuit breaker (S2) failed to open when PTC is enabled.WarningRefer to Section 5 troubleshooting charts.
1459Reverse PowerImproper CT phasing.ShutdownCheck wiring to voltage sense circuit; refer to CT Installation in Section 6.
146Pre-High Coolant TempEngine has begun to overheat.WarningReduce load; check air inlets/outlets; follow code 151 if engine can be stopped.
1461Loss Of FieldLoss of field (electric) due to reverse kVAR.ShutdownCheck excitation circuit.
1466Modem FailureControl cannot communicate with the modem.WarningCheck for open, short to ground and loose connections to the modem.
1468Network ErrorMomentary loss of communication from the LonWorks Network.WarningRefer to LonWorks Network publications.
1469Speed/Hz MatchMeasured speed and measured AC output frequency do not agree.ShutdownCheck calibration file.
1471Over CurrentGenerator output current exceeded 110% of rated for 60 seconds.WarningCheck load and load lead connections.
1472Over CurrentOutput current exceeded 110% of rated and time/current calculation initiated shutdown.ShutdownCheck load and load lead connections.
15LOW FUEL - OUTPUTEngine monitor TB2 terminal assignment
151High Coolant TempEngine has overheated above the shutdown trip point.ShutdownIndicates engine has overheated (coolant temperature above shutdown trip point). Allow engine to cool down completely. a. Check coolant level and replenish if low; look for coolant leaks and repair. b. Check for obstructions to cooling airflow. c. Check fan belt and repair or tighten if necessary. d. Check blower fan and circulation pumps on remote radiator installations. e. Reset control and restart after locating and correcting problem.
16SHUT-DOWNEngine monitor TB2 terminal assignment
197Low Coolant LevelOptionalWarningIndicates engine coolant level has fallen below the warning trip point. If generator is powering critical loads and cannot be shut down, wait until next shutdown period, then follow code 235 procedure.
2FAULT 2 - OUTPUT SHUTDOWNEngine monitor TB2 terminal assignment
200LOW OIL PRESSUREIndicates engine oil pressure has dropped to an unacceptable level.WarningIf 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.
201LOW OIL PRESSUREIndicates engine oil pressure has dropped below the shutdown trip point.ShutdownCheck oil level, lines and filters; replenish if low; reset control and restart.
204OIL PRES SENDERIndicates that the control has sensed that the engine oil pressure sender is out of its working range.WarningCheck that the engine oil pressure sender is properly connected.
210LOW COOLANT TEMPWarning occurs when engine coolant temperature is 70°F (21°C) or lower.WarningIndicates engine coolant heater is not operating or is not circulating coolant. Check coolant heater power supply, low coolant level, and heater element current draw.
211HIGH COOLANT TEMPIndicates the engine coolant temperature is getting close to the recommended maximum temperature limit: 215° F (102° C) − standby or 207° F (97° C) − primary.WarningReduce load if possible; check air inlets and outlets and remove obstructions to airflow.
212Oil Temp Sensor HIndicates engine has overheated (coolant temperature has risen above the shutdown trip point: 215 F (102 C) - standby or 207 F (97 C) - primary).WarningCheck sender/connectors/wires.
213Oil Temp Sensor LResistance of the coolant temperature sender is out of range.WarningCheck the resistance of the sender; should be 500 to 2k ohms.
214LOW COOLANT LVLIndicates engine coolant level has fallen below the trip point.WarningCheck coolant level in radiator and coolant recovery bottle; replenish if low; look for leaks.
215LOW COOLANT LVLIndicates engine coolant level has fallen below the trip point.ShutdownAllow engine to cool; check coolant level and leakage points; reset control and restart.
220MAG PICKUPMag pickup speed indication is not being sensed or does not match generator set output frequency.ShutdownRestart and check RPM; check PCC model setting; inspect and test MPU.
221FAIL TO CRANKPossible fault with control or starting system.ShutdownCheck fuse F3 on the Engine Interface board; check battery cable connections; recharge or replace the battery.
222OVERCRANKPossible fuel system problem.ShutdownCheck for empty fuel tank, leaks, plugged fuel lines; replace dirty fuel or air filter; reset and restart.
223OVERSPEEDIndicates engine has exceeded normal operating speed. (115% ±1% of nominal).ShutdownCheck mechanical fuel linkage and governor module/digital board duty cycle.
224FAIL TO SYNCHRONIZEGenerator set has not synchronized to the system bus within the allowable time frame.WarningCheck governor system stability; adjust governing and synchronizer parameters; check fuel system.
226FAIL TO CLOSEParalleling breaker has been given a signal to close, but has not closed properly.ShutdownVerify breaker charging mechanism; check close signal; verify auxiliary contact signals.
230LOW DC VOLTAGEIndicates battery voltage is below 10 VDC.WarningRecharge 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.
231HIGH DC VOLTAGEIndicates battery voltage exceeds 32 VDC.WarningLower battery charger float level if applicable; check engine DC alternator.
232WEAK BATTERYIndicates battery voltage drops below 60% of nominal for two seconds, during starting.WarningSee LOW DC VOLTAGE 230.
2327PTC FaultPTC module or communication link is not working properly.WarningCheck PTC module power, ground shield, cycle control power.
2329Low S1 FrequencyLow utility (S1) frequency.WarningCheck S1 AC inputs and wiring to PTC at TB5; check sensor set points.
2331Low S1 VoltageLow utility (S1) voltage.WarningCheck S1 AC inputs and wiring to PTC at TB5; check pickup/dropout set points.
2335Excitation FaultLoss of all three voltage sense leads or failure in excitation circuit.ShutdownCheck field wiring (X1 and X2) for shorts or opens.
2336Memory ErrorControl memory error; data corruption of critical operating parameters.ShutdownTry reloading calibration file.
2337Pwr Tran DisabledPTC module available but PTC feature not enabled.WarningEnable PTC feature with InPower; cycle control power.
2338Pwr Tran FailureControl could not communicate with the PTC module.WarningCheck PTC module power and cable ground shield; cycle control power.

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

Procedures

12
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

  1. Disconnect the negative (-) battery cable(s) before beginning.
  2. 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.
  3. Bar the engine over in a clockwise rotation as viewed from engine flywheel; do not allow it to roll back on compression.
  4. Determine the total indicator reading (T.I.R.) as the sum of the maximum positive and negative dial indicator readings over one revolution.
  5. Measure the distance from the center of the generator shaft to the indicator measuring point.
  6. Measure the distance from the generator side of the flex discs to the center of the generator mounting bolt.
  7. 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

  1. Disconnect the negative (-) battery cable(s) before beginning.
  2. 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.
  3. Bar the engine over in a clockwise rotation as viewed from engine flywheel; do not allow it to roll back on compression.
  4. Record maximum positive and negative dial indicator readings as the engine completes one revolution.
  5. T.I.R. equals the sum of the maximum positive and negative readings.
  6. Maximum T.I.R. should not be more than .001 inch for each inch of radius.
  7. Remove equal shims from under both generator mounting feet to lower the generator.
Angular Alignment Procedure (750 kW gensets and larger) adjustment

⚠ Accidental starting during this procedure presents hazard of severe injury or death

⚠ Do not bar engine over by prying on fan blade

Tools: dial indicator

  1. Disconnect negative battery cable(s) before beginning
  2. Fasten dial indicator to generator shaft or cooling fan, sensing point on capscrew head or drive disc flat surface
  3. Bar engine over in clockwise rotation as viewed from flywheel, do not allow roll-back at end of travel
  4. Record total indicator reading (T.I.R.) as sum of max positive and negative readings over one revolution
  5. Calculate shim correction using ratio of generator shaft-to-indicator distance vs generator mounting bolt distance
  6. Add or remove shims from both generator mounting feet as calculated
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

  1. Disconnect the negative (-) battery cable(s) before beginning.
  2. 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.
  3. 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.
  4. Record the total indicator reading (T.I.R.) as the sum of the maximum positive and negative dial indicator readings over one engine revolution.
  5. 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 (750 kW gensets and larger) adjustment

Tools: dial indicator

  1. Check axial alignment only when objectionable vibration is present after angular alignment
  2. Fasten dial indicator holding device to skid base/engine block/generator shell, sensor on generator shaft hub
  3. Bar engine over clockwise through a couple of rotations, recording readings at eight equally spaced points
  4. If out of tolerance, remove capscrews connecting drive discs and flywheel, mark discs, reposition holes 180 degrees
  5. Reinstall capscrews and retorque; recheck alignment; try 30/60/90 degree repositioning if unchanged
Axial Alignment Procedure (Generator to Engine) adjustment

Tools: dial indicator

  1. 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.
  2. 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.
  3. 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

  1. Start the generator set.
  2. Adjust engine no-load speed to the desired allowable speed droop using the Run Speed potentiometer.
  3. With no load, turn GAIN clockwise slowly until engine speed oscillates.
  4. Reduce GAIN slowly counterclockwise until engine speed is stable.
  5. Upset the governor by momentarily shorting terminals 7 and 10 on the governor control.
  6. Apply and remove loads to check generator set response.
HC4-7 Axial Alignment Procedure adjustment

Tools: Dial indicator with magnetic base or clamp

  1. Check only when an objectionable vibration is present.
  2. Fasten dial indicator holding device to skid base, engine block, or generator shell with magnetic base or clamp.
  3. Position sensor point on the generator shaft hub.
  4. Bar the engine over in a clockwise rotation as viewed from engine flywheel through a couple of rotations.
  5. Record indicator readings in eight equally spaced points around the shaft diameter.
  6. Remove the capscrews connecting drive discs and flywheel and mark discs and flywheel.
  7. Rotate engine or generator so drive disc holes are repositioned 180 degrees from original location.
  8. Put capscrews back in and retorque. Recheck shaft alignment.
  9. If runout unchanged, rotate discs to 30, 60 or 90 degrees from original location.
  10. If T.I.R. does not improve, inspect flywheel pilot and drive disc runouts.
P7 Axial Alignment Procedure adjustment
  1. Check only when an objectionable vibration is present.
  2. Remove the capscrews connecting drive discs and flywheel.
  3. Mark the drive discs and flywheel with respect to each other.
  4. Rotate engine or generator so drive discs holes are repositioned two bolt holes from original location.
  5. Put capscrews back in and retorque. Recheck/record vibration levels.
  6. Repeat this test until drive disc holes are repositioned 180 degrees from original location.
  7. 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

  1. Make a note of the no-load frequency.
  2. Determine roll-off frequency by turning the governor speed pot until the LED lights; if okay go to step 5.
  3. Adjust the governor speed pot to the proper roll-off frequency.
  4. Turn the UFRO pot until LED goes off, then slowly turn it back until the LED just goes on.
  5. 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

  1. Use the control panel mounted voltage trimmer, if provided, for small voltage adjustments.
  2. Measure generator output voltage while running without load at nominal frequency.
  3. If trimmer is insufficient, lock it at midpoint.
  4. Turn the VOLTS pot fully counterclockwise and the STABILITY pot to its midpoint.
  5. If the red LED lights, refer to Jumper Reconnections and UFRO Adjustments.
  6. Turn the VOLTS pot clockwise until rated voltage is obtained.
  7. If voltage becomes unstable with a large load, turn the STABILITY pot clockwise until stable.
  8. Check and readjust the VOLTS pot each time the STABILITY pot is readjusted.
Generator/Base Board Isolation Procedure diagnostic

⚠ This test involves unregulated excitation of the generator.

⚠ Hazardous voltage; use insulated tools and stand on dry platform.

Tools: Voltmeter, Jumper leads, 12V battery

  1. Throw line circuit breaker OFF and shut down the set.
  2. Disconnect exciter stator leads X and XX from AC harness.
  3. Prepare to measure output voltage across generator terminals.
  4. Bring 12V battery jumpers to X (Field +) and XX (Field -).
  5. Verify polarity is correct before connecting.
  6. Start set; connect battery negative to XX lead.
  7. If rated voltage and balanced phases, generator is OK.
  8. If unbalanced troubleshoot main stator; if low troubleshoot exciter circuits.

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

VoltagePhaseConnectionLeadsNotes
12 lead generator setsLoad wires are routed through the CTsReconnectable 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 setsGenerator output leads are routed through the CTsNon-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)CT21U load leads (A phase)CT dot must face the generator; CT terminal 1 connects to metering circuit, terminal 2/3 to ground.
B (V)CT22V load leads (B phase)CT dot must face the generator; terminal 1 to metering circuit, terminal 2/3 to ground.
C (W)CT23W load leads (C phase)CT dot must face the generator; terminal 1 to metering circuit, terminal 2/3 to ground.
110 V - 120 V L-N1Single phase, 2-wirePTC module jumper locations
110/1803Reconnection diagram (Figure 5-2); 50 Hz
110/2201Reconnection diagram (Figure 5-2); 50 Hz
118/2003Reconnection diagram (Figure 5-2); 50 Hz
118/2303Reconnection diagram (Figure 5-2); 50 Hz
120/2083Reconnection diagram (Figure 5-2); 60 Hz
120/2401Reconnection diagram (Figure 5-2); phase sequence U-V-W
127/2203Reconnection diagram (Figure 5-2); 60 Hz
190 V - 240 V L-L3Three phaseUse PTC module 0300-5382-01; 50/60 Hz
200 V - 240 V L-L1Single phase, 3-wirePTC module jumper locations
220/3803Reconnection diagram (Figure 5-2); 60 Hz
230/4003Reconnection diagram (Figure 5-2); 50 Hz
240/4163Reconnection diagram (Figure 5-2); 60 Hz
254/4403Reconnection diagram (Figure 5-2); 60 Hz
277/4803Reconnection diagram (Figure 5-2); 60 Hz
347/6003Reconnection diagram (Figure 5-2); 60 Hz
380 V - 600 V L-L3Three phaseUse PTC module 0300-5382-02; 50/60 Hz

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 DFGB?

The Cummins/Onan DFGB is rated 600 kW standby (750.0 kVA).

What engine is in the Cummins/Onan DFGB?

The Cummins/Onan DFGB is powered by the Cummins/Onan VTA28-G5 engine.

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

The Cummins/Onan DFGB runs on Diesel.

What's the oil capacity on a Cummins/Onan DFGB?

The Cummins/Onan VTA28-G5 engine in the Cummins/Onan DFGB has an oil capacity of 84.0 liters.

What is the coolant capacity of the Cummins/Onan DFGB?

The Cummins/Onan DFGB cooling system holds 167 liters (44.1 US gallons) for the radiator system including the engine, per the manufacturer specification sheet.

What is the prime power rating of the Cummins/Onan DFGB?

The Cummins/Onan DFGB is rated 545 kW prime (681 kVA), against 600 kW standby.

How much does the Cummins/Onan DFGB weigh?

The Cummins/Onan DFGB has a dry weight of 6169 kg (13600 lb).

What voltages is the Cummins/Onan DFGB available in?

The Cummins/Onan DFGB is offered in 110/190 V, 120/208 V, 127/220 V, 139/240 V, 220/380 V, 240/416 V, 3-phase.

How many cold cranking amps does the Cummins/Onan DFGB require?

The Cummins/Onan DFGB uses 2 batteryies, 24 V each, 1400 CCA, group 8D, per the manufacturer specification sheet. The starting system is 24 V DC.

Which oil filter part number does the Cummins/Onan DFGB take?

The Cummins/Onan DFGB uses oil filter part number 122-0702.

Which air filter part number does the Cummins/Onan DFGB take?

The Cummins/Onan DFGB uses air filter part number 140-2301.

Troubleshooting

6

Fault codes

CodeMeaningCauseRemedy
1131Battle Short Active.This feature must only be used during supervised, temporary operation of the genset. The faults that are overridden during Battle Short mode consist of faults that can affect genset performance or cause permanent engine, alternator, or connected equipment damage.
1416Fail To Shut Down is displayed.The Fault Acknowledgement/Reset button will clear the fault message, but will remain in the Fault/History file with an asterisk sign (* equals active fault) as long as Battle Short mode is enabled.
1123Shutdown After Battle Short will be displayed for this type of shutdown.Battle Short is suspended and a shutdown occurs immediately if any of the following critical shutdown faults occur: Overspeed − Fault code 234, Emergency Stop − Fault code 1433, Remote Emergency Stop − Fault code 1434, Speed Signal Lost − Fault code 121, Excitation Fault − Fault code 2335. Moving the customer installed Battle Short switch to OFF with an active but overridden shutdown fault or a shutdown fault that was overridden at any time.

Symptoms & remedies

SymptomRemedy
Make sure the fuel tanks have sufficient fuel and that fuel system is primed.Check to make sure there are no leaks and that all fittings are tight.
Make sure the generator set cooling inlet/outlet and exhaust ventilation openings are clear (not blocked) and operational.Remove all loose debris from surrounding area of generator set. Air flow from the radiator fan can blow loose items around and into ventilation openings.
Status Indicators are not functioning properly.Check the status indicators for any visible damage or loose connections. If the issue persists, refer to the troubleshooting table.

Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing. Full Cummins/Onan DFGB troubleshooting guide (12 entries) →

Parts

83
Part #DescriptionQtySystem
0300-4623-18DFGB (600V)1Current transformer Amazon eBay $205.65
0300-4623-34DFGB BR (0-480V)1Current transformer Amazon eBay
122-0702Head, Oil Filter1Oil filter Amazon eBay
122-0777Filter, Lube Oil1Oil filter Amazon eBay
128-0108Insulation, Hose – Bulk (Order By The Foot – 12 Feet Required)-Hose Amazon eBay
130-1193Gasket, Outlet Adapter1Gasket Amazon eBay
130-3839-01Guard, Belt − Right Side1Belt Amazon eBay
130-3839-02Guard, Belt − Left Side1Belt Amazon eBay
130-3840Guard, Belt − Top1Belt Amazon eBay
130-3841Guard, Belt − Bottom1Belt Amazon eBay
130-3842Guard, Belt − Front1Belt Amazon eBay
130-3843Guard, Belt − Right Side1Belt Amazon eBay
130-3844Guard, Belt − Bottom Back1Belt Amazon eBay
130-3845Guard, Belt − Top Back1Belt Amazon eBay
130-3846Guard, Belt − Left Side1Belt Amazon eBay
130-3874Base, Mounting * − Parts Used On Heat Exchanger Installations With Automatic Water Regulator + − Parts Used On Heat Exchanger Installations Without Automatic Water Regulator # − Cut Off And Discard Swivel Connector End Of Hose So That 1/8 NPT Connector End Measures Length As Indicated Above1Hose Amazon eBay
130-4354Radiator (Includes Cap, Sight Gauge And Overflow Hose) (Also Includes Cover Plates, Gaskets, Screws And Lock Washers For All Water Outlets)1Gasket Amazon eBay
130-4552Cover, Coolant Heater2Fluid Amazon eBay
140-2301Cleaner, Air (Includes Replacement Elements) 140−24652Air filter Amazon eBay
193-0444Sender, Oil Pressure (S1)1Sensor Amazon eBay
193-0468Sender, Low Coolant Level (S7)1Sensor Amazon eBay
193-0529-01Sender, Oil Temperature1Sensor Amazon eBay
309-0649Thermostat (Includes Connector Socket) (S11)1Thermostat Amazon eBay $144.99
323-1445* Seal, Cable (Used With Station 17)2Seal Amazon eBay
330-0141-04Gasket, Cover1Gasket Amazon eBay
330-0142Box, Terminal (Includes Cover and Gasket − Ref No. 19 and 20)1Gasket Amazon eBay
333-0407-05Heater, Oil (300 Watt, 480 Volt)1Fluid Amazon eBay
501-0537-22Hose, Oil (86”)1Hose Amazon eBay
501-0537-23Hose, Oil (22”)1Hose Amazon eBay
501-0744-01Hose, Coolant1Hose Amazon eBay
501-0744-05Hose, Coolant2Hose Amazon eBay
502-0313Elbow, Hose − 90° (1/8” Pipe to 1/4” Hose)1Hose Amazon eBay
502-0395Connector, Hose1Hose Amazon eBay
502-0971Connector, Hose2Hose Amazon eBay
502-1337Adapter, Coolant Heater1Fluid Amazon eBay
502-1530Union, Hose (1”) − Nylon2Hose Amazon eBay
502-1531Connector, Hose2Hose Amazon eBay
503-0189Clamp, Hose1Hose Amazon eBay
503-0249Hose − Bulk (Order by the Foot − 3 Feet Required)1Hose Amazon eBay
503-0569Hose (3−1/2” ID) Bulk (Order By The Foot − 2 Feet Required)1Hose Amazon eBay
503-0685Clamp, Hose1Hose Amazon eBay $15.00
503-0856Hose, Radiator − Lower (3−1/2” ID x 5−1/2”)2Hose Amazon eBay $42.58
503-1418Hose − Bulk (1/4” ID) (Order By The Foot − 18 Feet Required)1Hose Amazon eBay
503-1620Hose – Bulk (3/8" ID) (Order by the Foot)-Hose Amazon eBay
503-1634Hose, Silicon Rubber1Hose Amazon eBay
503-1634-01Hose, Rubber (3/4” ID x 4”)4Hose Amazon eBay
503-1728Hose (3” ID x 5–1/2”)1Hose Amazon eBay
503-1779Hose − Bulk (1” ID) (Order By The Foot − 1 Foot Required)-Hose Amazon eBay
503-1870-07Clamp, Hose2Hose Amazon eBay
503-1870-11Clamp, Hose2Hose Amazon eBay
503-1870-12Clamp, Hose2Hose Amazon eBay
503-1870-14Clamp, Hose2Hose Amazon eBay
503-1872-01Clamp, Hose4Hose Amazon eBay
503-1872-05Clamp, Hose2Hose Amazon eBay
503-1872-07Clamp, Hose6Hose Amazon eBay
503-2157-01Clamp, Hose8Hose Amazon eBay
503-2276Elbow, Hose2Hose Amazon eBay
503-2350-04Hose, Coolant (1” x 5‘)1Hose Amazon eBay
503-2350-05Hose, Coolant (1” x 8‘)2Hose Amazon eBay
505-0759Adapter − Pipe to Hose (1” x 1”)1Hose Amazon eBay
508-0292Washer, Sealing - Copper1Seal Amazon eBay
511-0105Belt−V1Belt Amazon eBay
518-0548-20Clamp, Hose1Hose Amazon eBay
518-0548-24Clamp, Hose2Hose Amazon eBay
960-0504PCC Control Service Manual*Service manual Amazon eBay
960-0507Detector Control Service Manual**Service manual Amazon eBay $49.00
960-0630CPCC2100 PowerCommand Control1Controller Amazon eBay
FF202Fuel, Spin-On2Fuel filter Amazon eBay $34.99 NAPA $43.99
FS1216Fuel/Water Sep Spin-On2Fuel filter Amazon eBay $49.99 NAPA $65.16 FridayParts $48.99
098-7954Label, Information − Element Replacement2Service part / kit Amazon eBay
130-5666-02Tube, Water Heater1Service part / kit Amazon eBay
130-5852-02Tube, Water Heater1Service part / kit Amazon eBay
140-1260Fitting, Safety Filter2Service part / kit Amazon eBay $116.27 NAPA $10.13
140-1260-01Fitting, Safety Filter1Service part / kit Amazon eBay
323-1491* Pin, Contact (Used With Inline G)3Service part / kit Amazon eBay
323-1492* Socket, Contact (Used In Stations 18, 19)4Service part / kit Amazon eBay
323-1718* Pin, Contact (Used In Station 17)2Service part / kit Amazon eBay
332-2634Clamp, Hose1Service part / kit Amazon eBay
518-0548-42Clamp, Retainer 4 Prior To December 1996 Production (Mounted On Top And Side Of Control Box Wrapper)20Service part / kit Amazon eBay
870-0257Nut, Locking (5/16−18) * − Parts Used On Heat Exchanger Installations With Automatic Water Regulator # − Cut Off And Discard Swivel Connector End Of Hose So That 1/8 NPT Connector End Measures Length As Indicated Above + − Parts Used On Heat Exchanger Installations Without Automatic Water Regulator1Service part / kit Amazon eBay
898-1254-25Sleeving – Heater Leads (59”)1Service part / kit Amazon eBay
M-CK4911685PCylinder KitService part / kit Amazon eBay
MCB4911685Piston KitService part / kit Amazon eBay

Service, wear & replacement parts referenced for this model and its engine — confirm the exact part for your serial number. See the full parts catalog to search and cross-reference.

Fuel consumption

RatingLoadL/hgal/h
Prime25%53.013.9
Prime50%86.022.6
Prime75%118.031.2
Prime100%153.040.3
Standby167.544.2
Standby25%56.014.7
Standby50%92.024.3
Standby75%129.034.1
Standby100%167.544.2

Available documents

Spec sheet — 0080258 (Cummins/Onan)Spec sheet — Cummins-600-DFGB-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)Operator's manual — 960-0103 Cummins DFGA DFGB DFGE Operator's Manual (7-2010) (Cummins/Onan)Operator's manual — 960-0169 Cummins DFGB DFGE Operator's Manual (6-2005) (Cummins/Onan)Reference — F-1960-Advanced-en (Cummins/Onan)Parts manual — 0932-0112 Onan Post-Sale Literature Index (07-1998) (Cummins/Onan)Parts manual — 0960-0204 (Cummins/Onan)Parts manual — 960-0295 Cummins DFGB DFGE Parts Manual (1-2010) (Cummins/Onan)Service manual — 9-3Service manual — 960-0145 Cummins DFGA DFGB Operator's Manual (6-2000) (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 — 960-0519C Cummins DFAB DFB DFC DFG DFLC Series Service Manual (2-2004) (Cummins/Onan)Service manual — 960-0611 Onan DFGA DFGB DFGC Installation Manual (8-1990) (Onan)Service manual — 960-0619D Cummins DFA DFB DFC DFE DFF DFG DFJ DFL DFM DQA DQB Installation (6-2003) (Cummins/Onan)Service manual — 960-0630C Cummins DFGB DFGE DFLB DFLC DFLE 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 — DFxx Generator Set Service Manual PCC3100 (Cummins/Onan)Service manual — Detector Control Generator Set Service Manual (Cummins/Onan)

This page was generated from the 20 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.