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

Service parts for the DFGE

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

Air intake

1 required

140-2301Air filtersee priceAmazon

Oil system

1 required

122-0702Oil filtersee priceAmazon

Belts

1 required

130-3843Beltsee priceAmazon

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

Specifications

Fuel	Diesel
Frequency	60.0 Hz
Controller	PCC2100, PowerCommand PCC2100
Oil capacity	84.0 L
Battery group	8D
Battery cranking	1400 CCA
Battery voltage	24 V
Battery quantity	2
Coolant capacity	167 L

Engine

Cummins/Onan VTA28-G7

Oil capacity	84.0 L
Coolant capacity	167.0 L

Filters for the Cummins/Onan VTA28-G7

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

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

System	Filter	Description	Cross-references
Fuel filter	P557440	Fuel Filter, Spin-On Secondary	CUMMINS BM78672, BALDWIN BF970, LPM 00013505994, WALGAHN-MOTORENTECHN 00811464	FridayParts $189.69
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

Maintenance & consumables

for the Cummins/Onan VTA28-G7

Item	Spec	Capacity	Part #	Interval
Air filter	Cleaner, Air (Includes Replacement Elements) 140−2465		140-2301		Amazon eBay
Fuel filter			—	100 hr
Oil filter	Head, Oil Filter		122-0702		Amazon eBay
Battery	Check 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.		—
Belt	Guard, Belt − Right Side		130-3843		Amazon eBay
Coolant		167.0	—	500 hr
Coolant filter			—
Oil		89.0	—	8 hr
Spark plug			—

Service intervals

Item	Action	Hours	Months	Notes
Battery Electrolyte Level	Check	200 hr		Check level of electrolyte at least every 200 hours of operation.
Crankcase Oil and Filter	Change	250 hr	12 mo	X6: If genset is used for standby applications, change oil every 12 months or 250 hours, whichever comes first.
Rupture basin leak detect switch	Test		12 mo	Some 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

Type	Item	Value	Unit	Condition
Clearance	Float switch assembly float lift clearance below C-clip stop	1/8	inch (3 mm)	use a feeler gauge
Clearance	Generator-to-engine angular alignment (T.I.R.)	.001 in. per inch of radius (center of shaft to indicator axis), maximum	in	750 kW gensets and larger
Clearance	MPU sensor to gear tooth adjustment	back out one quarter turn	turn	after contacting gear tooth
Gap	Float switch lift to test open	1/8	inch	below C-clip stop
Other	B+ output fuse	10	amp	F1, Base board, 12/24 volt
Other	Customer Output relay contact rating	2	amps at 30 VDC	TB1 customer outputs 1-4, normally open
Other	Genset frequency / RPM nameplate rating	50 or 60 Hz / 1500 or 1800 RPM
Other	Ground Fault Relay current setting	5 to 1200	amperes	optional GFR
Other	Ground Fault Relay time delay setting	0 to 1	second	optional GFR
Other	Optional control relay (K11/K12/K13) contact rating	10	amps at 600 VAC
Other	Switched B+ output fuse	5	amp	F2, Base board, 12/24 volt
Pressure	Air cleaner element cleaning compressed air	30	psi
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	Idle Oil Pressure	20	psi	idle
Pressure	Idle Oil Pressure Shutdown Limit	10	psi	idle
Pressure	Idle Oil Pressure Warning Limit	15	psi	idle
Pressure	Max. Allowable Exhaust Back Pressure	27	in. H2O (6.7 kPa)	6 in. NPT outlet
Pressure	Max. Allowable Exhaust Back Pressure	41	in. H2O (10.2 kPa)	5 in. NPT outlet (DFGB/DFGE), 6 in. NPT outlet (DFLB/DFLC)
Pressure	Max. Fuel Inlet Restriction	4	in. Hg (13.5 kPa)
Pressure	Max. Fuel Return Restriction	6.5	in. Hg (22 kPa)
Pressure	Normal Oil Pressure	50-90	psi
Pressure	Oil Pressure Shutdown Limit	35	psi
Pressure	Oil Pressure Warning Limit	40	psi
Pressure	Radiator cleaning compressed air	35	psi	maximum
Resistance	Battery specific gravity, fully charged	1.260	specific gravity	corrected to 80 F (27 C)
Resistance	Charge battery if specific gravity below	1.215	specific gravity
Resistance	Coolant heater coil resistance	10 to 60	ohms	thermostat closed
Resistance	Coolant temperature sender resistance	500 to 2k	ohms
Resistance	Current transformer (PT) primary	1K-2.5K	ohms
Resistance	Current transformer (PT) secondary	140-225	ohms
Resistance	Exciter stator winding - frame size 4C/4D/4E/4F	0.136	ohms	at 68°F (20°C) + 10%
Resistance	Exciter stator winding insulation resistance	1	megohm	replace if less than
Resistance	Fuel solenoid coil resistance	30	ohms	indicates coil OK
Resistance	Governor actuator circuit resistance	7.5	ohms	indicates OK
Resistance	Harness open-circuit check	10 or less	ohms	OK
Resistance	Harness short-circuit check	more than 200k	ohms	OK
Resistance	Main rotor winding insulation resistance	1	megohm	replace if less than
Resistance	Main stator winding insulation resistance	1	megohm	replace if less than
Resistance	PMG stator resistance	2/6	ohms
Resistance	PMG stator resistance	4.6	ohms
Resistance	PMG stator resistance - frame size HC4	2/6	ohms
Resistance	PMG stator resistance - frame size HC5/HC6/HC7	4.6	ohms
Resistance	PT/CT module 3-ohm resistors	3	ohms	J8-15 to 14, J8-22 to 23, J8-7 to 8
Resistance	Thermistor relay trip point (thermistor chain resistance)	3000 ±500	ohms
Speed	Frequency Adjust range	±5	percent of nominal frequency	example: 60.0 Hz nominal adjustable 57.0-63.0 Hz
Speed	Idle speed adjust	700 to 1100	RPM	default 800 RPM
Speed	Idle speed adjustment	800 ±100	RPM	default 800 RPM
Speed	Overspeed shutdown threshold	115% ±1%	% of nominal
Temperature	Cold Soak for battery CCA rating	0	F	-18 C
Temperature	Engine Cold warning threshold (Code 1435)	70	°F (21°C)	jacket water coolant temperature
Temperature	Engine jacket water coolant heater minimum maintained temperature	90	°F (32°C)	per NFPA 110

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
Fuel	ASTM No. 2 diesel	ASTM			Alternate diesel fuels per Cummins engine O&M Manual specifications
Fuel	Diesel				Do not use zinc coated or copper fuel lines with diesel fuel. Be sure all fuel supplies have a positive shutoff valve.
Grease	Lithium based		-30°C to 120°C	81.0 ml	Mobilux 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.
Grease	Lithium based grease, Mobilux No. 2 or Shell Alvania R3		-30°C to 120°C	81.0 ml	Generator end bearing lubricant; temperature range -22°F to +248°F (-30°C to +120°C); 2.74 oz. (81 ml) equally divided between the bearing, the bearing cap cavity, and the 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

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
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.
1122	Rated/Idle Trans		Info
1123	Shutdown After Battle Short	Shutdown fault occurred while Battle Short was enabled and then disabled.	Shutdown	Review Fault History and perform corrective action.
1124	Delayed Shutdown	Shutdown fault became active while Delayed Shutdown feature was enabled.	Warning	Review Fault History and perform corrective action.
1131	Battle Sh Active	Control is in Battle Short mode.	Warning	Warning status indicator is lit when Battle Short mode is enabled. Refer to Battle Short Mode description in Section 3.
121	Speed Signal Lost	Mag pickup speed indication is not being sensed.	Shutdown	Restart and check RPM on the digital display.
1311	Customer Input #1	Default display name Customer Fault 1; default status None		The 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, 1318	CUSTOMER INPUT #1 - #4	Optional customer-selected fault input is active.	Warning	Check external wiring and active input (closed/open) selection.
1312	Customer Input #2	Default display name Ground Fault; default Warning		The nature of the fault is an optional customer selection. Each fault function can be programmed using service tool.
1317	Customer Input #3	Default display name Low Fuel; default Warning		The nature of the fault is an optional customer selection. Each fault function can be programmed using service tool.
1318	Customer Input #4	Default display name Rupture Basin Fault; default Warning		The nature of the fault is an optional customer selection. Each fault function can be programmed using service tool.
1334	Crit Scaler Out Of Range	Incorrect feature or calibration entered into control.	Shutdown	Reload correct calibration.
1335	Noncrit Scaler Out Of Range	Incorrect feature or calibration entered into control.	Warning	Reload correct calibration.
1337	No Message		Info
135	Oil Pressure Sensor H	Engine oil pressure sender signal is shorted high.	Warning	Check sender/connectors/wires.
141	Oil Pressure Sensor L	Engine oil pressure sender signal is shorted low.	Warning	Check sender/connectors/wires.
1416	Fail To Shutdown	Genset continues to run after shutdown command.	Warning	With 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.
1417	Powr Down Error	Controller cannot power down.	Warning	Indicates that the controller can not power down because of some unknown condition. Possible drain on battery. Contact an authorized service center for service.
143	Pre-Low Oil Pres	Engine oil pressure has dropped to an unacceptable level.	Warning	Indicates 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.
1433	Emergency Stop	Local Emergency Stop.	Shutdown	Pull button out; move switch to O; press Fault Acknowledge/Reset; select Manual or Auto.
1434	Remote E-Stop	Remote Emergency Stop.	Shutdown	See code 1433 to reset.
1435	Low Coolant Temp	Warning 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 seconds	Warning	Indicates 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.
1438	Fail To Crank	Engine failed to crank after PCC received a start signal.	Shutdown	Indicates possible fault with control, speed sensing or starting system. See code 441 for corrective action.
144	Coolant Sensor High	Engine coolant temperature signal is shorted high.	Warning	Check sender/connectors/wires.
1442	Weak Battery	Battery voltage at or below weak battery warning trip point during cranking.	Warning	See code 441 for corrective action.
1443	Battery Failed	Dead battery - engine will not start.	Shutdown	See code 441 for corrective action.
1444	KW Overload	Generator output power exceeded 105% of genset rating.	Warning	Check load and load lead connections; check CTs.
1445	Short Circuit	Generator output current has exceeded 175% of rated.	Shutdown	Check load and load lead connections.
1446	High AC Voltage	One or more phase voltages exceeded 130% of nominal.	Shutdown	Check fault simulation, load removal, threshold settings, Base board/generator.
1447	Low AC Voltage	Phase voltages dropped below 85% of nominal for 10 seconds.	Shutdown	Check overload, output terminal connections, PMG/field wiring, rectifier diodes.
1448	Under Frequency	Engine speed dropped below 90% of nominal for 10 seconds.	Shutdown	Check fuel supply, intake air supply and load.
1449	Over Frequency	Frequency is 10% above base frequency for 20 seconds.	Warning	Check fuel or air delivery; check connections.
145	Coolant Sensor Low	Engine coolant temperature signal is shorted low.	Warning	Check sender/connectors/wires.
1452	Gen CB Not Close	Genset circuit breaker (S2) failed to close when PTC is enabled.	Warning	Refer to Section 5 troubleshooting charts.
1453	Gen CB Not Open	Genset circuit breaker (S2) failed to open when PTC is enabled.	Warning	Refer to Section 5 troubleshooting charts.
1459	Reverse Power	Improper CT phasing.	Shutdown	Check wiring to voltage sense circuit; refer to CT Installation in Section 6.
146	Pre-High Coolant Temp	Engine has begun to overheat.	Warning	Reduce load; check air inlets/outlets; follow code 151 if engine can be stopped.
1461	Loss Of Field	Loss of field (electric) due to reverse kVAR.	Shutdown	Check excitation circuit.
1466	Modem Failure	Control cannot communicate with the modem.	Warning	Check for open, short to ground and loose connections to the modem.
1468	Network Error	Momentary loss of communication from the LonWorks Network.	Warning	Refer to LonWorks Network publications.
1469	Speed/Hz Match	Measured speed and measured AC output frequency do not agree.	Shutdown	Check calibration file.
1471	Over Current	Generator output current exceeded 110% of rated for 60 seconds.	Warning	Check load and load lead connections.
1472	Over Current	Output current exceeded 110% of rated and time/current calculation initiated shutdown.	Shutdown	Check load and load lead connections.
151	High Coolant Temp	Engine has overheated above the shutdown trip point.	Shutdown	Indicates 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.
197	Low Coolant Level	Optional	Warning	Indicates 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.
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. If oil system is OK but oil level is low, replenish. Reset control and restart. Oil pressure limits are listed in Table 4-3.
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	Set is not operating. 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 by turning off non-critical loads. Check air inlets and outlets and remove any obstructions to airflow. If engine can be stopped, follow 212-SHUTDOWN procedure.
212	Oil Temp Sensor H	Indicates engine has overheated (coolant temperature above 215° F (102° C) − standby or 207° F (97° C) − primary).	Warning	Check sender/connectors/wires.
213	Oil Temp Sensor L	Indicates that the resistance of the coolant temperature sender is out of range.	Warning	Check the resistance of the sender. Resistance should be 500 to 2k ohms.
214	LOW COOLANT LVL	Indicates engine coolant level has fallen below the trip point.	Warning	Allow engine to cool down completely. Check coolant level in both radiator and coolant recovery bottle and replenish if low. Look for coolant leakage points and repair if necessary.
215	LOW COOLANT LVL	Indicates engine coolant level has fallen below the trip point.	Shutdown	Allow engine to cool down completely. Check coolant level in both radiator and coolant recovery bottle and replenish if low. Reset control and restart after correcting problem. Shutdown will not occur if genset is in Idle mode (low coolant warning only).
220	MAG PICKUP	Indicates mag pickup speed indication is not being sensed or does not match generator set output frequency.	Shutdown	Restart and check RPM on the digital display.
221	FAIL TO CRANK	Indicates possible fault with control or starting system.	Shutdown	Check fuse F3 on the Engine Interface board. Check for poor battery cable connections; clean battery cable terminals and tighten. Recharge or replace a discharged or defective battery.
222	OVERCRANK	Indicates possible fuel system problem.	Shutdown	Check for empty fuel tank, fuel leaks, or plugged fuel lines. Check for dirty fuel filter and replace if necessary. Check for dirty or plugged air filter and replace if necessary. Reset the control and restart after correcting the problem.
223	OVERSPEED	Indicates engine has exceeded normal operating speed. (115% ±1% of nominal).	Shutdown
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	Check float level on battery charger if applicable (lower float level). Check engine DC alternator; replace if normal battery charging voltage is not obtained.
232	WEAK BATTERY	Indicates battery voltage drops below 60% of nominal for two seconds, during starting.	Warning	Discharged or defective battery. See Warning message 230, LOW DC VOLTAGE.
2327	PTC Fault	PTC module or communication link is not working properly.	Warning	Check PTC module power, ground shield, cycle control power.
2329	Low S1 Frequency	Low utility (S1) frequency.	Warning	Check S1 AC inputs and wiring to PTC at TB5; check sensor set points.
2331	Low S1 Voltage	Low utility (S1) voltage.	Warning	Check S1 AC inputs and wiring to PTC at TB5; check pickup/dropout set points.
2335	Excitation Fault	Loss of all three voltage sense leads or failure in excitation circuit.	Shutdown	Check field wiring (X1 and X2) for shorts or opens.
2336	Memory Error	Control memory error; data corruption of critical operating parameters.	Shutdown	Try reloading calibration file.
2337	Pwr Tran Disabled	PTC module available but PTC feature not enabled.	Warning	Enable PTC feature with InPower; cycle control power.
2338	Pwr Tran Failure	Control could not communicate with the PTC module.	Warning	Check PTC module power and cable ground shield; cycle control power.
2339	Pwr Down Enabled	Power Down (sleep) enabled but PTC module or network board is active.	Warning	None required.
234	Overspeed	Engine has exceeded normal operating speed.	Shutdown	Check for large block load removal, flammable vapors or leaking turbocharger seals.
2341	High Control Temp	Control temperature above 158 F (70 C) for longer than set time.	Warning	Check genset room air flow.
2342	Too Long In Idle (10 min.)	Genset has been in Idle mode too long.	Warning	Indicates genset has been in Idle mode too long (10 minutes maximum).
235	Low Coolant Level	Optional	Shutdown	Indicates engine coolant level has fallen below the shutdown trip point. Allow engine to cool down completely. a. Check coolant level and replenish if low; look for possible coolant leakage points and repair. b. Reset control and restart.
2358	High S1 Voltage	Utility (S1) voltage increased above the over-voltage threshold.	Warning	Measure S1 AC inputs at PTC module; check sensor set points.
2396	S1 CB Not Close	Utility contact (S1) failed to close with PTC enabled.	Warning	Refer to Section 5 troubleshooting charts.
2397	S1 CB Not Open	Utility contact (S1) failed to open with PTC enabled.	Warning	Refer to Section 5 troubleshooting charts.
240	LOW FUEL−DAY	Indicates day tank fuel supply is running low.	Warning	Check fuel supply and replenish as required.
241	LOW FUEL	Indicates day tank fuel supply is running low.	Warning	Check fuel supply and replenish as required.
250	EEPROM ERROR	Indicates PCC memory error. Data corruption of critical operating parameters.	Shutdown

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 (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

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

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 (750 kW gensets and larger) adjustment

Tools: dial indicator

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

Axial Alignment Procedure (Generator to Engine) adjustment

Tools: dial indicator

Fasten a dial indicator holding device to the skid base, engine block, or generator shell with the sensor point resting on the generator shaft hub.
Bar the engine over in a clockwise rotation through a couple of rotations, recording indicator readings at eight equally spaced points around the shaft diameter to obtain axial T.I.R.
Reduce the measured T.I.R. runout by one half if excessive vibration remains after angular alignment.

Generator/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

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

Generator/PCC Control Isolation Procedure diagnostic

⚠ This test involves unregulated excitation of the generator; make sure all loads have been disconnected.

⚠ HIGH VOLTAGE: touching uninsulated high voltage parts inside the control box can result in severe personal injury or death.

Tools: 12 volt battery, Jumper leads, Voltmeter

Throw the line circuit breaker OFF and shut down the set.
Remove the accessory box housing cover and remove plug P10 from connector J10 of A37.
Prepare to measure output voltage across the generator terminals while the set is running.
Bring two jumpers from a 12 volt battery for connection to X (Field +) and XX (Field -) pins of plug P10.
Check polarity again; polarity must be correct or the test will be inconclusive.
Start the set and connect the jumper from the battery negative terminal to the XX lead.
If rated output voltage or higher is obtained and all phases are balanced, generator circuitry is probably okay; refer to Section 4.
If voltages are unbalanced, troubleshoot the main stator first; if uniformly low, troubleshoot exciter and field circuits first.

Ground Fault Relay Test diagnostic

Verify N-G Fault Indicator on GFR is not lit; if lit, install bonding jumper at facility service entrance
Move control switch to Run position
Press TEST switch on ground fault relay
Verify control panel warning message displayed and Fault Indicator (>I) lit on GFR
Reset the control panel fault (also resets ground fault relay)

Megger and PI Test diagnostic

⚠ Medium-voltage (601 to 15,000 volts) windings must be dry before the generator is operated.

Tools: Megger or Insulation Resistance Meter, Wheatstone bridge or digital ohmmeter, Grounding Cluster

Perform the Generator Set Grounding Procedure.
Disconnect plug J10 from the voltage regulator output module and the AC control leads (marked 4, 5, 6, 7, 8).
If RTD option installed, ground all six RTD temperature leads (18 leads total).
Perform the Winding Resistance Test for the desired windings.
Perform the Insulation Resistance (Megger) Test and PI Test for the desired windings.
Megger test: apply voltage for up to one minute.
PI test: apply voltage for ten minutes; record resistance at one minute and ten minutes.
PI is the ten-minute reading divided by the one-minute reading; ratio of two or greater is good.

Testing the Float Switch Assembly diagnostic

Tools: Ohmmeter, Feeler gauge

Remove the fuel pump control cover, disconnect the wiring jack and unscrew the assembly from the top of the day tank.
With an ohmmeter, test for electrical continuity between each pair of colored leads while holding the assembly vertical; all readings should be zero.
Lift each float, in turn, to 1/8 inch (3 mm) below the C-clip stop above it and test for continuity; all readings should be infinity.
Use pipe thread sealant when replacing the assembly.

Testing the PMG diagnostic

⚠ HIGH VOLTAGE. Touching uninsulated high voltage parts inside the control and power output boxes will result in severe personal injury or death.

Tools: Wheatstone bridge or digital ohmmeter, Voltmeter, Elbow length insulating gloves

Disconnect plug J10 from the voltage regulator output stage module.
Start the engine at the set and let the speed stabilize.
Measure voltage across lead pairs J10-1 & J10-4, J10-4 & J10-5, and J10-5 & J10-1.
Voltage should be at least 150 VAC for 50 Hz sets and at least 180 VAC for 60 Hz sets, approximately the same for each set of leads.
If voltages are low or uneven, check all leads and connections between A37 and the PMG and repair as necessary.
Stop the set and measure electrical resistance across lead pairs J10-1 & J10-4, J10-4 & J10-5, and J10-5 & J10-1 with a Wheatstone bridge or digital ohmmeter.

Current Transformer (CT) Installation installation

⚠ Improper installation of CT's will cause a 335 Reverse Power shutdown error (non-parallel units only).

Orient the CT dot toward the generator (conventional current flowing into the dot); dot also indicates pin 1 of the CT.
CT21 - U load leads (A phase); CT22 - V load leads (B phase); CT23 - W load leads (C phase).
Route the appropriate leads through each CT: 6-lead gensets route generator output leads; 12-lead gensets route load wires.
For 12 lead (reconnectable) gensets, connect CT secondary wire marked 1 to pin 1; secondary wire marked 2/3 to pin 2 for high voltage or pin 3 for low voltage.
For 6 lead (non-reconnectable) gensets, connect lead from CT terminal #1 to metering circuitry and lead from CT 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.

Voltage reconnection

Voltage	Phase	Connection	Notes
110 V - 120 V L-N	1	Single phase, 2-wire	PTC module jumper locations
190 V - 240 V L-L	3	Three phase	Use PTC module 0300-5382-01; 50/60 Hz
200 V - 240 V L-L	1	Single phase, 3-wire	PTC module jumper locations
380 V - 600 V L-L	3	Three phase	Use 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 engine is in the Cummins/Onan DFGE?

The Cummins/Onan DFGE is powered by the Cummins/Onan VTA28-G7 engine.

What fuel does the Cummins/Onan DFGE use?

The Cummins/Onan DFGE runs on Diesel.

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

The Cummins/Onan VTA28-G7 engine in the Cummins/Onan DFGE has an oil capacity of 84.0 liters.

How much coolant does the Cummins/Onan DFGE hold?

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

What size battery does the Cummins/Onan DFGE need?

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

What oil filter fits the Cummins/Onan DFGE?

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

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

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

Troubleshooting

Fault codes

Code	Meaning	Cause	Remedy
1131	Battle 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.
1416	Fail 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.
1123	Shutdown 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

Symptom	Remedy
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 DFGE troubleshooting guide (12 entries) →

Repair guides

Step-by-step procedures compiled from the Cummins/Onan service manual for this model.

Parts

108

Part #	Description	Qty	System
0300-4623-18	DFGB (600V)	1	Current transformer	Amazon eBay $205.65
0300-4623-34	DFGB BR (0-480V)	1	Current transformer	Amazon eBay
122-0702	Head, Oil Filter	1	Oil filter	Amazon eBay
122-0777	Filter, Lube Oil	1	Oil filter	Amazon eBay
128-0108	Insulation, Hose – Bulk (Order By The Foot – 12 Feet Required)	-	Hose	Amazon eBay
130-1193	Gasket, Outlet Adapter	1	Gasket	Amazon eBay
130-3839-01	Guard, Belt − Right Side	1	Belt	Amazon eBay
130-3839-02	Guard, Belt − Left Side	1	Belt	Amazon eBay
130-3840	Guard, Belt − Top	1	Belt	Amazon eBay
130-3841	Guard, Belt − Bottom	1	Belt	Amazon eBay
130-3842	Guard, Belt − Front	1	Belt	Amazon eBay
130-3843	Guard, Belt − Right Side	1	Belt	Amazon eBay
130-3844	Guard, Belt − Bottom Back	1	Belt	Amazon eBay
130-3845	Guard, Belt − Top Back	1	Belt	Amazon eBay
130-3846	Guard, Belt − Left Side	1	Belt	Amazon eBay
130-3874	Base, 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 Above	1	Hose	Amazon eBay
130-3875	Tube, Outlet	1	Hose	Amazon eBay
130-4354	Radiator (Includes Cap, Sight Gauge And Overflow Hose) (Also Includes Cover Plates, Gaskets, Screws And Lock Washers For All Water Outlets)	1	Gasket	Amazon eBay
130-4552	Cover, Coolant Heater	2	Fluid	Amazon eBay
130-4576	Tube	1	Hose	Amazon eBay
130-4577	Tube	1	Hose	Amazon eBay
130-4581	Tube	1	Hose	Amazon eBay
140-2301	Cleaner, Air (Includes Replacement Elements) 140−2465	2	Air filter	Amazon eBay
140-3288-02	Cleaner, Air	2	Air filter	Amazon eBay
140-3349-02	Bracket, Air Cleaner	1	Air filter	Amazon eBay
151-0411	Pickup, Magnetic	1	Sensor	Amazon eBay KuduParts $208.00 FridayParts $218.33 SinoCMP $279.00
193-0432	Sender, Oil Temperature (S2 Engine Block, E4 Oil Pan)	2	Sensor	Amazon eBay
193-0444	Sender, Oil Pressure (S1)	1	Sensor	Amazon eBay
193-0468	Sender, Low Coolant Level (S7)	1	Sensor	Amazon eBay
193-0481	Sender Assembly - Low Coolant Level	1	Sensor	Amazon eBay
193-0529-01	Sender, Oil Temperature	1	Sensor	Amazon eBay
309-0269	Sender, Temperature-Lo Engine	1	Sensor	Amazon eBay $239.00
309-0649	Thermostat (Includes Connector Socket) (S11)	1	Thermostat	Amazon eBay $144.99
323-1445	* Seal, Cable (Used With Station 17)	2	Seal	Amazon eBay
330-0141-04	Gasket, Cover	1	Gasket	Amazon eBay
330-0142	Box, Terminal (Includes Cover and Gasket − Ref No. 19 and 20)	1	Gasket	Amazon eBay
333-0407-05	Heater, Oil (300 Watt, 480 Volt)	1	Fluid	Amazon eBay
416-0680	Cable, Battery (10")	3	Hose	Amazon eBay
501-0537-22	Hose, Oil (86”)	1	Hose	Amazon eBay
501-0537-23	Hose, Oil (22”)	1	Hose	Amazon eBay
501-0744-01	Hose, Coolant	1	Hose	Amazon eBay
501-0744-05	Hose, Coolant	2	Hose	Amazon eBay
502-0313	Elbow, Hose − 90° (1/8” Pipe to 1/4” Hose)	1	Hose	Amazon eBay
502-0395	Connector, Hose	1	Hose	Amazon eBay
502-0971	Connector, Hose	2	Hose	Amazon eBay
502-1337	Adapter, Coolant Heater	1	Fluid	Amazon eBay
502-1530	Union, Hose (1”) − Nylon	2	Hose	Amazon eBay
502-1531	Connector, Hose	2	Hose	Amazon eBay
503-0189	Clamp, Hose	1	Hose	Amazon eBay
503-0249	Hose − Bulk (Order by the Foot − 3 Feet Required)	1	Hose	Amazon eBay
503-0569	Hose (3−1/2” ID) Bulk (Order By The Foot − 2 Feet Required)	1	Hose	Amazon eBay
503-0685	Clamp, Hose	1	Hose	Amazon eBay $15.00
503-0856	Hose, Radiator − Lower (3−1/2” ID x 5−1/2”)	2	Hose	Amazon eBay $42.58
503-1418	Hose − Bulk (1/4” ID) (Order By The Foot − 18 Feet Required)	1	Hose	Amazon eBay
503-1620	Hose – Bulk (3/8" ID) (Order by the Foot)	-	Hose	Amazon eBay
503-1634	Hose, Silicon Rubber	1	Hose	Amazon eBay
503-1634-01	Hose, Rubber (3/4” ID x 4”)	4	Hose	Amazon eBay
503-1728	Hose (3” ID x 5–1/2”)	1	Hose	Amazon eBay
503-1779	Hose − Bulk (1” ID) (Order By The Foot − 1 Foot Required)	-	Hose	Amazon eBay
503-1870-07	Clamp, Hose	2	Hose	Amazon eBay
503-1870-11	Clamp, Hose	2	Hose	Amazon eBay
503-1870-12	Clamp, Hose	2	Hose	Amazon eBay
503-1870-14	Clamp, Hose	2	Hose	Amazon eBay
503-1872-01	Clamp, Hose	4	Hose	Amazon eBay
503-1872-05	Clamp, Hose	2	Hose	Amazon eBay
503-1872-07	Clamp, Hose	6	Hose	Amazon eBay
503-2157-01	Clamp, Hose	8	Hose	Amazon eBay
503-2276	Elbow, Hose	2	Hose	Amazon eBay
503-2350-04	Hose, Coolant (1” x 5‘)	1	Hose	Amazon eBay
503-2350-05	Hose, Coolant (1” x 8‘)	2	Hose	Amazon eBay
505-0759	Adapter − Pipe to Hose (1” x 1”)	1	Hose	Amazon eBay
508-0292	Washer, Sealing - Copper	1	Seal	Amazon eBay
511-0105	Belt−V	1	Belt	Amazon eBay
518-0548-20	Clamp, Hose	1	Hose	Amazon eBay
518-0548-24	Clamp, Hose	2	Hose	Amazon eBay
960-0504	PCC Control Service Manual	*	Service manual	Amazon eBay
960-0507	Detector Control Service Manual	**	Service manual	Amazon eBay $49.00
960-0630C	PCC2100 PowerCommand Control	1	Controller	Amazon eBay
FF202	Fuel, Spin-On	2	Fuel filter	Amazon eBay $34.99 NAPA $43.99
FS1216	Fuel/Water Sep Spin-On	2	Fuel filter	Amazon eBay $49.99 NAPA $65.16 FridayParts $48.99
098-7954	Label, Information − Element Replacement	2	Service part / kit	Amazon eBay
102-1335	Plug, Oil Drain	1	Service part / kit	Amazon eBay
130-1430	Exchanger, Heat	2	Service part / kit	Amazon eBay
130-1515	Tank, Water	1	Service part / kit	Amazon eBay
130-4582	Bracket, Mounting	1	Service part / kit	Amazon eBay
130-5666-02	Tube, Water Heater	1	Service part / kit	Amazon eBay
130-5852-02	Tube, Water Heater	1	Service part / kit	Amazon eBay
140-1260	Fitting, Safety Filter	2	Service part / kit	Amazon eBay $116.27 NAPA $10.13
140-1260-01	Fitting, Safety Filter	1	Service part / kit	Amazon eBay
193-0128	Gauge, Fuel Pressure (0-200 Lbs)	1	Service part / kit	Amazon eBay
307-2621-02	Relay, Start Solenoid (K4)	1	Service part / kit	Amazon eBay
307-2859	Relay, Power - 24VDC (K11)	1	Service part / kit	Amazon eBay $199.95
323-1491	* Pin, Contact (Used With Inline G)	3	Service part / kit	Amazon eBay
323-1492	* Socket, Contact (Used In Stations 18, 19)	4	Service part / kit	Amazon eBay
323-1718	* Pin, Contact (Used In Station 17)	2	Service part / kit	Amazon eBay
332-2634	Clamp, Hose	1	Service part / kit	Amazon eBay
333-0639-01	Heater, Coolant (4990 Watt)	1	Service part / kit	Amazon eBay
333-0639-02	Heater, Coolant (6420 Watt)	1	Service part / kit	Amazon eBay
416-0446	Cable, Battery - Jumper	1	Service part / kit	Amazon eBay
504-0171	Valve, Shutoff	1	Service part / kit	Amazon eBay
505-0100	Nipple, Pipe - Close (1/2”)	1	Service part / kit	Amazon eBay $9.34
505-1071	Coupling, Flexible (For 2" Pipe)	2	Service part / kit	Amazon eBay
505-1072	Valve, Water	2	Service part / kit	Amazon eBay
518-0548-42	Clamp, Retainer 4 Prior To December 1996 Production (Mounted On Top And Side Of Control Box Wrapper)	20	Service part / kit	Amazon eBay
870-0257	Nut, 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 Regulator	1	Service part / kit	Amazon eBay
898-1254-25	Sleeving – Heater Leads (59”)	1	Service part / kit	Amazon eBay
M-CK4911685P	Cylinder Kit		Service part / kit	Amazon eBay
MCB4911685	Piston Kit		Service part / kit	Amazon eBay

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

Fuel consumption

Rating	Load	L/h	gal/h
Standby		167.5	44.2
Standby	100%	167.5	44.2

Available documents

Spec sheet — 0080258 (Cummins/Onan)Operator's manual — 960-0169 Cummins DFGB DFGE Operator's Manual (6-2005) (Cummins/Onan)Parts manual — 960-0295 Cummins DFGB DFGE Parts Manual (1-2010) (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 — 960-0619D 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)

This page was generated from the 7 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.

Cummins/Onan DFGE Generator Set

Service parts for the DFGE

Air intake

Oil system

Belts

Specifications

Engine

Filters for the Cummins/Onan VTA28-G7

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