Specifications
Ratings spec sheet not in our library yet — see the documents below.
Filters & service parts
model family| Item | Spec | Capacity | Part # | Interval | |
|---|---|---|---|---|---|
| Air filter | — | ||||
| Fuel filter | — | 4 hr | |||
| Oil filter | — | 250 hr | |||
| Battery | Two 12V Group 8D batteries | — | 5060 hr | ||
| Belt | — | 3 hr | |||
| Coolant | — | ||||
| Coolant filter | — | 5060 hr | |||
| Oil | Refer to Cummins engine Operation and Maintenance Manual | 36.0 L | — | 50 hr | |
| Spark plug | — |
Compiled from this model's family documentation — may include parts for closely-related variants. Confirm the exact part for your serial number.
Service intervals
2| Item | Action | Hours | Months | Notes |
|---|---|---|---|---|
| crankcase oil | Change | 50 hr | First service — Drain and replace the crankcase oil after the first 50 hours of operation on new generator sets (break-in) | |
| Rupture basin leak detect switch | Test | 12 mo | Check once a year; in some areas weekly inspections may be required by safety code regulations |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Service specifications
60| Type | Item | Value | Unit | Condition |
|---|---|---|---|---|
| Clearance | Air cleaner nozzle distance from element | at least 1 (25) | inch (mm) | |
| Clearance | Angular alignment maximum T.I.R. | 0.001 | inch per inch of radius (center of shaft to indicator axis) | measuring deflection to bolt heads |
| Clearance | Float switch assembly float lift clearance below C-clip stop | 1/8 | inch (3 mm) | use a feeler gauge |
| Clearance | Generator-to-engine angular alignment (T.I.R.) | .001 in. per inch of radius (center of shaft to indicator axis), maximum | in | 750 kW gensets and larger |
| Gap | MPU sensor to flywheel ring gear tooth | back it out one quarter turn | turn | sensor threaded in until it just touches gear tooth |
| Other | AVR Droop setting | 5 | % at full load, 0 PF | |
| Other | AVR voltage regulation (load regulation) | approximately ±0.5 | % RMS | |
| Other | Air cleaner element cleaning air pressure | 30 (207) | psi (kPa) | low pressure compressed air through element from clean side |
| Other | Angular alignment maximum T.I.R. | .001 inches per inch of radius | in/in | center of shaft to indicator axis |
| Other | Battery electrolyte specific gravity | 1.260 | at 80°F | |
| Other | Battery specific gravity (high ambient, above 95F/35C) | 1.225 | recommended to reduce electrolyte loss | |
| Other | Battery specific gravity (recharge threshold) | below 1.260 | ||
| Other | Battery specific gravity, fully charged | approximately 1.260 | specific gravity | at 80 F (27 C) |
| Other | Fuel lift height limit | 6 | feet | (1.8 meters) between fuel lift pump and bottom of dip tube |
| Other | GOV GAIN default value for paralleling applications | 70 | % | |
| Other | Low oil pressure / high engine temperature fault time delay after starter disconnect | about 10 | seconds | |
| Other | Maximum cranking voltage drop | 2 | volts | difference between battery and starter terminals while cranking |
| Other | Over/Under Frequency Sensor Module - Over Hz Set, 50 Hz nominal | 55 | Hz | reset 53 Hz |
| Other | Over/Under Frequency Sensor Module - Over Hz Set, 60 Hz nominal | 65 | Hz | reset 63 Hz |
| Other | Over/Under Frequency Sensor Module - Under Hz Set, 50 Hz nominal | 45 | Hz | reset 47 Hz |
| Other | Over/Under Frequency Sensor Module - Under Hz Set, 60 Hz nominal | 55 | Hz | reset 57 Hz |
| Other | Over/Under Voltage Sensor Module time delay | typically 25 percent, approximately 2.5 | seconds | |
| Other | Overcrank cranking limit | 75 | seconds | three 15-second cranking cycles with two 15-second rest periods |
| Other | Overcrank cranking limit (standard control) | 75 | seconds | |
| Other | Overcrank cycling option | three 15-second cranking cycles with two 15-second rest periods | 12-lamp control | |
| Other | REG VHZ (underfrequency roll-off) adjustable range | 1 through 50; normal range 7 through 21 | ||
| Other | Start delay adjustment range | 0 to 300 | seconds | |
| Other | Stop delay adjustment range | 0 to 600 | seconds | |
| Other | Under Frequency Roll Off (UFRO) knee point, 50 Hz units | 48 to 49 | Hz | |
| Other | Under Frequency Roll Off (UFRO) knee point, 60 Hz units | 58 to 59 | Hz | |
| Other | Under-frequency roll-off threshold (UFRO) | typically 59 Hz for 60 Hz applications and 49 Hz for 50 Hz applications | Hz | AVR UFRO pot preset |
| Pressure | Engine oil pressure - K19 normal | 50-70 | psi (345-482 kPa) | run mode |
| Pressure | Engine oil pressure - K38 normal | 45-65 | psi (310-448 kPa) | run mode |
| Pressure | Engine oil pressure - K50 normal | 50-70 | psi (345-482 kPa) | run mode |
| Pressure | Engine oil pressure - L10/M11 normal | 30-50 | psi (207-345 kPa) | run mode |
| Pressure | Engine oil pressure - NTA 855 normal | 35-50 | psi (241-345 kPa) | run mode |
| Pressure | Engine oil pressure - V28 normal | 50-90 | psi (345-620 kPa) | run mode |
| Pressure | Engine oil pressure shutdown limit - L10/M11 | 20 | psi (138 kPa) | run mode value |
| Pressure | Engine oil pressure shutdown limit - L10/M11 | 8 | psi (55 kPa) | idle mode value |
| Pressure | Engine oil pressure warning limit - L10/M11 | 12 | psi (83 kPa) | idle mode value |
| Pressure | Engine oil pressure warning limit - L10/M11 | 25 | psi (172 kPa) | run mode value |
| Pressure | K19 engine idle oil pressure | 20 | psi (138 kPa) | idle |
| Pressure | K19 engine normal oil pressure | 50-70 | psi (345-482 kPa) | normal run |
| Pressure | K19 oil pressure shutdown/warning limits | shutdown 35 psi (241 kPa) run; warning 40 psi (276 kPa) run; shutdown 10 psi (69 kPa) idle; warning 15 psi (103 kPa) idle | psi (kPa) | |
| Pressure | K38 engine idle oil pressure | 20 | psi (138 kPa) | idle |
| Pressure | K38 engine normal oil pressure | 45-65 | psi (310-448 kPa) | normal run |
| Pressure | K38 oil pressure shutdown/warning limits | shutdown 35 psi (241 kPa) run; warning 40 psi (276 kPa) run; shutdown 10 psi (69 kPa) idle; warning 15 psi (103 kPa) idle | psi (kPa) | |
| Pressure | K50 engine idle oil pressure | 20 | psi (138 kPa) | idle |
| Pressure | K50 engine normal oil pressure | 50-70 | psi (345-482 kPa) | normal run |
| Pressure | K50 oil pressure shutdown/warning limits | shutdown 35 psi (241 kPa) run; warning 40 psi (276 kPa) run; shutdown 10 psi (69 kPa) idle; warning 15 psi (103 kPa) idle | psi (kPa) | |
| Pressure | L10/M11 engine idle oil pressure | 15 | psi (103 kPa) | idle |
| Pressure | L10/M11 engine normal oil pressure | 30-50 | psi (207-345 kPa) | normal run |
| Pressure | L10/M11 oil pressure shutdown limit | 20 | psi (138 kPa) | run mode value |
| Pressure | L10/M11 oil pressure shutdown limit | 8 | psi (55 kPa) | idle mode value |
| Pressure | L10/M11 oil pressure warning limit | 12 | psi (83 kPa) | idle mode value |
| Pressure | L10/M11 oil pressure warning limit | 25 | psi (172 kPa) | run mode value |
| Pressure | Low oil pressure service limit while cranking | 10 | psi | service lubricating system if below |
| Pressure | Low oil pressure shutdown | 14 | psi (97 kPa) | |
| Pressure | Low oil pressure shutdown | below 14 | psi (97 kPa) | time delayed ~10 seconds following starter disconnect |
| Pressure | Low oil pressure shutdown threshold | 14 | psi | less than this value shuts down |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Recommended fluids
| Fluid | Grade | Standard | Ambient | Capacity | Notes |
|---|---|---|---|---|---|
| Coolant | soft water / E.G. / DCA mixture | Cooling system to be filled with soft water/E.G./DCA mixture (on-site review checklist). | |||
| Coolant | water/antifreeze mixture (permanent type antifreeze) | Clean, low mineral content water free of chloride, sulphate or acid | Mix water and antifreeze per supplier recommendation for lowest expected ambient temperature; do not use antifreeze containing anti-leak additives | ||
| Engine oil | SAE 5W synthetic | API class CC/CD; sulphated ash content not exceeding 1.85 percent; pour point 9°F (5°C) below lowest expected temperature; viscosity 10,000 mPa.s maximum at -31°F (-35°C) and 4.1 mm2/s minimum at 212°F (100°C) | above -25°C | Recommended when ambient temperature is consistently below -13°F (-25°C) and there is no provision to keep the engine warm; do not use petroleum base 5W grade oil | |
| Engine oil | multigrade / multiviscosity | API Class CC/CD; maximum sulphated ash content 1.85 percent | -25°C to 35°C | Specifications section lists ambient ranges -13°F to 95°F (-25°C to 35°C), 14°F (-10°C) and above, and 32°F (0°C) and above; single grade oil not recommended; do not mix oils of another classification or brand | |
| Fuel | Diesel | Day tank fuel transfer pump maintains reservoir of diesel fuel in the day tank. | |||
| Fuel | No. 2 diesel | Engine will also operate on No. 1 fuel or other similar fuels if they meet certain specifications | |||
| Grease | Lithium based grease | Mobilux No. 2 or Shell Alvania R3 | 2.74 oz (81 ml) | Generator end bearing. Temperature range -22F to +248F (-30C to +120C). Grease should be equally divided between the bearing, bearing cap cavity, and bearing cartridge cavity. | |
| Grease | Lithium based grease, Mobilux No. 2 or Shell Alvania R3 | -30°C to 120°C | 2.74 oz (81 ml) | End bearing lubricant; grease equally divided between bearing, bearing cap cavity and bearing cartridge cavity. |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Fault codes
61| Code | Name | Meaning | Severity | Action |
|---|---|---|---|---|
| 101 | IDLE MODE | Indicates that the engine is operating in idle mode. Grounding the engine idle input causes generator build-up to be inhibited and the engine to be governed at 800 RPM. | Warning | Remove ground from engine idle input to return to normal speed and voltage. |
| 102 | EMERGENCY STOP | Indicates local or remote Emergency Stop. | Shutdown | Turn the switch clockwise and allow it to pop out (local only); move the Run/Off/Auto switch to Off; press the Reset switch; select Run or Auto as required. Can be reset only at the PCC front panel. |
| 200 | LOW OIL PRESSURE | Indicates engine oil pressure has dropped to an unacceptable level. | Warning | If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then follow 201-SHUTDOWN procedure. Access the Oil Pressure menu prior to clearing the fault. |
| 201 | LOW OIL PRESSURE | Indicates engine oil pressure has dropped below the shutdown trip point. | Shutdown | Check oil level, lines and filters; replenish if low; reset control and restart. |
| 204 | OIL PRES SENDER | Indicates that the control has sensed that the engine oil pressure sender is out of its working range. | Warning | Check that the engine oil pressure sender is properly connected. |
| 210 | LOW COOLANT TEMP | Warning occurs when engine coolant temperature is 70°F (21°C) or lower. | Warning | Indicates engine coolant heater is not operating or is not circulating coolant. Check coolant heater power supply, low coolant level, and heater element current draw. |
| 211 | HIGH COOLANT TEMP | Indicates the engine coolant temperature is getting close to the recommended maximum temperature limit: 215° F (102° C) − standby or 207° F (97° C) − primary. | Warning | Reduce load if possible; check air inlets and outlets and remove obstructions to airflow. |
| 212 | HIGH COOLANT TEMP | Indicates engine has overheated (coolant temperature has risen above the shutdown trip point: 215 F (102 C) - standby or 207 F (97 C) - primary). | Shutdown | Check for obstructions to cooling airflow; check fan belt; check coolant mixture; check blower fan and circulation pumps; reset control and restart. |
| 213 | COOLANT SENDER | Resistance of the coolant temperature sender is out of range. | Warning | Check the resistance of the sender; should be 500 to 2k ohms. |
| 214 | LOW COOLANT LVL | Indicates engine coolant level has fallen below the trip point. | Warning | Check coolant level in radiator and coolant recovery bottle; replenish if low; look for leaks. |
| 215 | LOW COOLANT LVL | Indicates engine coolant level has fallen below the trip point. | Shutdown | Allow engine to cool; check coolant level and leakage points; reset control and restart. |
| 220 | MAG PICKUP | Mag pickup speed indication is not being sensed or does not match generator set output frequency. | Shutdown | Restart and check RPM; check PCC model setting; inspect and test MPU. |
| 221 | FAIL TO CRANK | Possible fault with control or starting system. | Shutdown | Check fuse F3 on the Engine Interface board; check battery cable connections; recharge or replace the battery. |
| 222 | OVERCRANK | Possible fuel system problem. | Shutdown | Check for empty fuel tank, leaks, plugged fuel lines; replace dirty fuel or air filter; reset and restart. |
| 223 | OVERSPEED | Indicates engine has exceeded normal operating speed. (115% ±1% of nominal). | Shutdown | Check mechanical fuel linkage and governor module/digital board duty cycle. |
| 224 | FAIL TO SYNCHRONIZE | Generator set has not synchronized to the system bus within the allowable time frame. | Warning | Check governor system stability; adjust governing and synchronizer parameters; check fuel system. |
| 226 | FAIL TO CLOSE | Paralleling breaker has been given a signal to close, but has not closed properly. | Shutdown | Verify breaker charging mechanism; check close signal; verify auxiliary contact signals. |
| 230 | LOW DC VOLTAGE | Indicates battery voltage is below 10 VDC. | Warning | Recharge or replace the battery; check the battery charger fuse. Clean and tighten battery cable connections. Check engine DC alternator; replace if normal charging voltage is not obtained. Check float level if applicable. |
| 231 | HIGH DC VOLTAGE | Indicates battery voltage exceeds 32 VDC. | Warning | Lower battery charger float level if applicable; check engine DC alternator. |
| 232 | WEAK BATTERY | Indicates battery voltage drops below 60% of nominal for two seconds, during starting. | Warning | See LOW DC VOLTAGE 230. |
| 240 | LOW FUEL−DAY | Indicates day tank fuel supply is running low. | Warning | Check fuel supply and replenish as required. |
| 241 | LOW FUEL | Low fuel signal received. | Warning | Check fuel supply and replenish; check for short to ground in external wiring. |
| 250 | EEPROM ERROR | PCC memory error; data corruption of critical operating parameters. | Shutdown | Perform the initial start setup procedure; if the set shuts down on the same EEPROM ERROR message, replace the digital board (A32). |
| 251 | EEPROM ERROR | PCC memory error; data corruption of noncritical operating parameters. | Warning | Perform the adjustment procedures; if the same message occurs, perform calibration procedures; if the message persists, replace the digital board (A32). |
| 252 | EEPROM ERROR | PCC memory error; data corruption of noncritical operating parameters. | Warning | Verify values/choices selected and repeat the save operation; if the same message occurs, replace the digital board (A32). |
| 260 | CUSTOMER FAULT 1 | When this customer defined input is closed to ground, the corresponding fault message is displayed. Programmable to initiate a shutdown or a warning. | Warning | Isolate source of false signal; repair external wiring or replace A34. |
| 261 | GROUND FAULT | When a customer defined input is closed to ground, the corresponding fault message is displayed. Default message; editable for customer site requirements. | Warning | Isolate source of false signal; repair external wiring or replace A34. |
| 262 | RUPTURE BASIN | When a customer defined input is closed to ground, the corresponding fault message is displayed. Default message; editable for customer site requirements. | Warning | Isolate source of false signal; repair external wiring or replace A34. |
| 263 | HIGH GEN TEMP | When a customer defined input is closed to ground, the corresponding fault message is displayed. Default message; editable for customer site requirements. | Warning | Isolate source of false signal; repair external wiring or replace A34. |
| 270 | PHASE ROTATION | The phase relationship between the generator set and the system bus is not matched. | Shutdown | Verify genset phase rotation matches bus; verify control wiring to bus PT module. |
| 272 | FIRST START | PowerCommand control is not receiving a proper signal from the system master first start sensor. | Warning | Verify Master First Start Sensor and interconnection wiring. |
| 301 | HIGH AC VOLTAGE | One or more phase voltages exceeded 130% of nominal, or exceeded 110% of nominal for 10 seconds. | Shutdown | Set display to GEN, VOLTS, L-N; determine if the output voltage the control sees is low or high; isolate PCC/alternator/excitation circuit. |
| 303 | LOW AC VOLTAGE | One or more phase voltages dropped below 85% of nominal for 10 seconds. | Shutdown | Check PMG/field wiring, rotating rectifier, load and connectors. |
| 313 | UNDER FREQUENCY | Indicates that engine speed has dropped below 90% of nominal for 10 seconds. Five seconds before shutdown, a Load Dump signal is initiated. | Shutdown | Check fuel supply, intake air supply and load. |
| 320 | OVERCURRENT | Indicates that generator output current has exceeded 110% of rated for 60 seconds. | Warning | Check load and load lead connections. |
| 321 | OVERCURRENT | Indicates that generator output current has exceeded 110% of rated, and that a PCC time/current calculation has initiated an overcurrent shutdown. | Shutdown | Check load and load lead connections. |
| 322 | SHORT CIRCUIT | Indicates that generator output current has exceeded 175% of rated. | Shutdown | Check load and load lead connections. |
| 330 | OVERLOAD | Three-phase power output exceeds 105% of standby (or 115% of prime) rating. | Warning | Check load and load lead connections. |
| 335 | REVERSE POWER | Power is flowing into the generator set rather than out from the unit. | Shutdown | Verify CT connections, load sharing lines, and generator set frequency/voltage. |
| 337 | LOSS OF EXCITATION | Alternator excitation system is improperly adjusted or has failed. | Shutdown | Check output voltage calibration, load sharing lines, and leading power factor loads. |
| FAULT 1 | Fault 1 (Red) | Undedicated customer-defined fault; may be programmed as timed or non-timed shutdown or fault light only. | Shutdown | Service as required by the customer-supplied fault indicating switches. |
| FAULT 2 | Fault 2 (Red) | Undedicated customer-defined fault, same features as Fault 1. | Shutdown | Service as required by the customer-supplied fault indicating switches. |
| GF | Ground Fault Alarm (Optional) | Ground fault relay monitors neutral to ground connection and line to neutral, activating a fault alarm when the connection is broken or a ground fault is sensed. | Warning | Clear fault condition by pushing the Run/Stop (Reset)/Remote switch to Reset (auto reset link set at factory). |
| HET | High Engine Temperature (Red) | Engine shut down because of excessively high engine coolant temperature (greater than 230 deg F). | Shutdown | Check coolant level and leaks; service cooling system; reset engine control. |
| HI ENG TEMP | High Engine Temperature | Engine shut down due to critically high coolant temperature (above 215F/102C). | Shutdown | |
| LET | Low Engine Temperature (Yellow) | Engine temperature is less than 70 deg F and the engine might not start. | Warning | Plug in, repair or install engine coolant and oil heaters. |
| LO FUEL | Low Fuel | Fuel supply is marginally low, if equipped (Detector-12). | Warning | |
| LO OIL PRES | Low Oil Pressure | Engine shut down due to critically low oil pressure (below 14 psi/97 kPa). | Shutdown | |
| LOP | Low Oil Pressure (Red) | Engine shut down because of excessively low engine oil pressure (less than 14 psi). | Shutdown | Check oil level and oil leaks; service lubricating system; reset engine control. |
| LOW ENG TEMP | Low Engine Temperature | Engine water jacket temperature is 70F/21C or lower; indicates possible inoperative coolant heater (Detector-12). | Warning | |
| LOW FUEL | Low Fuel (Yellow) | Fuel level in the supply tank has dropped below the reserve necessary to run the set at full load for the prescribed number of hours. | Warning | Fill the main fuel supply tank with the appropriate grade of fuel. |
| OC | Overcrank (Red) | Engine shut down because it did not start during the timed cranking period (approximately 75 seconds, including two rest periods). | Shutdown | Service the set as necessary; reset engine control. |
| OS | Overspeed (Red) | Engine shut down because of overspeed. | Shutdown | Adjust the Electronic Overspeed Module; check governor for binding; reset engine control. |
| OVERCRANK | Overcrank | Starter locked out because of excessive cranking time (limited to 75 seconds). | Shutdown | |
| OVERSPEED | Overspeed | Engine shut down because of excessive speed. | Shutdown | |
| PRE HI ENG TEMP | Pre-High Engine Temperature | Coolant temperature is marginally high (205F/97C or higher). | Warning | Attend to when generator set is shut down. |
| PRE LO OIL PRES | Pre-Low Oil Pressure | Engine oil pressure is marginally low (20 psi/138 kPa or less). | Warning | Attend to when generator set is shut down. |
| PRE-HET | Pre High Engine Temperature (Yellow) | Engine coolant temperature is abnormally high (greater than 220 deg F). | Warning | Shut down if possible or disconnect non-critical loads; service cooling system. |
| PRE-LOP | Pre Low Oil Pressure (Yellow) | Engine oil pressure is abnormally low (less than 20 psi). | Warning | Shut down if possible or disconnect non-critical loads; service lubricating system. |
| RUN | Run (Green) | Green lamp comes on when both primary and secondary starter circuits open after unit starts. | Info | |
| SWITCH OFF | Switch-off (Flashing Red) | The Run/Stop/Remote switch is in the Stop position, preventing remote automatic operation. | Info | Push the Run-Stop-Remote switch to Remote. |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Procedures
12Aligning Generator with Engine (Angular Alignment) adjustment
⚠ Accidental starting of the generator set during this procedure presents the hazard of severe personal injury or death.
Tools: Dial indicator, Shims
- Disconnect the negative (-) battery cable(s) before beginning.
- Fasten a dial indicator to the generator shaft or cooling fan with the sensing point on the capscrew head or flat surface of the drive disc at the bolt circle diameter.
- Bar the engine over in a clockwise rotation as viewed from engine flywheel; do not allow it to roll back on compression.
- Determine the total indicator reading (T.I.R.) as the sum of the maximum positive and negative dial indicator readings over one revolution.
- Measure the distance from the center of the generator shaft to the indicator measuring point.
- Measure the distance from the generator side of the flex discs to the center of the generator mounting bolt.
- Compare the distances; multiply this ratio times one half the T.I.R. to approximate the amount of shims to remove or add.
Angular Alignment Procedure adjustment
⚠ Accidental starting of the generator set during this procedure presents the hazard of severe personal injury or death. Make sure to disconnect the negative (-) battery cable(s) before beginning.
Tools: Dial indicator, Wooden shims
- Disconnect the negative (-) battery cable(s) before beginning.
- Fasten a dial indicator to the generator shaft or cooling fan with sensing point on capscrew head or flat surface of drive disc at bolt circle diameter.
- Bar the engine over in a clockwise rotation as viewed from engine flywheel; do not allow it to roll back on compression.
- Record maximum positive and negative dial indicator readings as the engine completes one revolution.
- T.I.R. equals the sum of the maximum positive and negative readings.
- Maximum T.I.R. should not be more than .001 inch for each inch of radius.
- Remove equal shims from under both generator mounting feet to lower the generator.
Angular Alignment Procedure (Generator to Engine) adjustment
⚠ Accidental starting during this procedure presents the hazard of severe personal injury or death.
⚠ Do not bar engine over by prying on fan blade.
Tools: dial indicator
- Disconnect the negative (-) battery cable(s) before beginning.
- Fasten a dial indicator to the generator shaft or cooling fan with sensing point resting on the drive disc capscrew head/flat surface at the bolt circle diameter.
- Bar the engine over in a clockwise rotation as viewed from the engine flywheel; do not allow it to roll back on compression at the end of travel of each reading.
- Record the total indicator reading (T.I.R.) as the sum of the maximum positive and negative dial indicator readings over one engine revolution.
- Compare the measured T.I.R. to the maximum allowed (.001 in. per inch of radius from center of shaft to indicator axis); add or remove shims under the generator mounting feet to correct.
Axial Alignment Procedure (Generator to Engine) adjustment
Tools: dial indicator
- Fasten a dial indicator holding device to the skid base, engine block, or generator shell with the sensor point resting on the generator shaft hub.
- Bar the engine over in a clockwise rotation through a couple of rotations, recording indicator readings at eight equally spaced points around the shaft diameter to obtain axial T.I.R.
- Reduce the measured T.I.R. runout by one half if excessive vibration remains after angular alignment.
Gain Adjustment adjustment
- Close the main line circuit breaker and apply approximately 1/4 of the rated load.
- Make sure the engine speed is constant.
- Turn the GAIN potentiometer clockwise slowly until the engine speed is not constant.
- Slowly turn the potentiometer counterclockwise until a constant speed is achieved, then an additional 1/2 division.
Governed Speed Adjustment adjustment
- For 60 Hz full load, set engine no-load governed speed to 60.0 Hz (1800 RPM) isochronous, 61.8 Hz (1854 RPM) for 3% droop, or 63.0 Hz (1890 RPM) for 5% droop.
- For 50 Hz full load, set engine no-load governed speed to 50.0 Hz (1500 RPM) isochronous, 51.5 Hz (1545 RPM) for 3% droop, or 52.5 Hz (1575 RPM) for 5% droop.
- Use the SPEED ADJUST potentiometer on the engine instrument panel for fine speed adjustments of less than ±100 RPM.
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.
Preliminary Governor Adjustments adjustment
- Idle Speed potentiometer: turn screw counterclockwise 20 turns then clockwise 10 turns to set mid position.
- Run Speed potentiometer: turn screw counterclockwise 20 turns then clockwise 10 turns to set mid position.
- Gain potentiometer: turn the screw fully counterclockwise.
- Droop potentiometer: turn fully counterclockwise for isochronous operation; approximately 40 for 3 percent droop; approximately 80 for 5 percent droop.
UFRO Adjustments adjustment
⚠ Use an insulated handle screw driver to prevent electrical shock.
Tools: Insulated handle screwdriver, Frequency meter or tachometer
- Make a note of the no-load frequency.
- Determine roll-off frequency by turning the governor speed pot until the LED lights; if okay go to step 5.
- Adjust the governor speed pot to the proper roll-off frequency.
- Turn the UFRO pot until LED goes off, then slowly turn it back until the LED just goes on.
- Adjust the governor speed pot back to the initial frequency setting.
Voltage and Voltage Stability Adjustments adjustment
⚠ Touching uninsulated high voltage parts inside the control and power output boxes can result in severe personal injury or death.
Tools: Insulated handle screwdriver, AC voltmeter
- Use the control panel mounted voltage trimmer, if provided, for small voltage adjustments.
- Measure generator output voltage while running without load at nominal frequency.
- If trimmer is insufficient, lock it at midpoint.
- Turn the VOLTS pot fully counterclockwise and the STABILITY pot to its midpoint.
- If the red LED lights, refer to Jumper Reconnections and UFRO Adjustments.
- Turn the VOLTS pot clockwise until rated voltage is obtained.
- If voltage becomes unstable with a large load, turn the STABILITY pot clockwise until stable.
- Check and readjust the VOLTS pot each time the STABILITY pot is readjusted.
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Voltage reconnection
| Voltage | Phase | Connection | Leads | Notes |
|---|---|---|---|---|
| 12 lead generator sets | Load wires are routed through the CTs | Reconnectable gensets (12 leads) have dual secondary CTs (3 pins); CT wire 2/3 to pin 2 (high voltage) or pin 3 (low voltage). | ||
| 6 lead generator sets | Generator output leads are routed through the CTs | Non-reconnectable gensets (6 leads) have single secondary CTs (2 pins). | ||
| Cummins PowerCommand generic AC Reconnect Wiring Diagram 625-2755 (Rev. D) and 625-3100 (Rev. F) | Applies to models DFAA, DFAB, DFAC, DFBF, DFCB, DFCC, DFEB, DFEC, DFFB, DFGA, DFGB, DFJA, DFJB, DFJC, DFJD, DFLB, DFLC, DFLD, DFMB (625-2755) and models DFAA-DFMB plus DFCE, DFED, DQAA, DQAB, DQBA, DQBB (625-3100). | |||
| A (U) | CT21 | U load leads (A phase) | CT dot must face the generator; CT terminal 1 connects to metering circuit, terminal 2/3 to ground. | |
| B (V) | CT22 | V load leads (B phase) | CT dot must face the generator; terminal 1 to metering circuit, terminal 2/3 to ground. | |
| C (W) | CT23 | W load leads (C phase) | CT dot must face the generator; terminal 1 to metering circuit, terminal 2/3 to ground. |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Troubleshooting
6Fault codes
| Code | Meaning | Remedy |
|---|---|---|
| FAULT 1 or FAULT 2 | The FAULT 1 or FAULT 2 fault lamp lights. Engine shuts down immediately, or engine continues to run. | A. Fault lamp on. Correct fault and reset control. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Discharged or defective battery. Recharge or replace the battery. |
Symptoms & remedies
| Symptom | Cause | Remedy |
|---|---|---|
| Green RUN lamp lights following engine loads and cannot be shut down | A. Reduce load if possible by turning off non-critical loads. b. Check air inlets and outlets and remove any obstructions to airflow. c. Open doors or windows in generator area to increase ventilation. Allow engine to cool down completely before proceeding with the following checks: a. Check coolant level and replenish if low. Look for possible coolant leakage points and repair b. Check for obstructions to cooling airflow and correct as necessary. c. Check for a slipping fan belt and tighten if required. d. Reset control and restart after locating and correcting problem. Contact your Dealer or Distributor if none of the above. | |
| OVERCRANK lamp lights and engine cannot be started | A. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. d. Refer to Step 5. | |
| Engine runs and then shuts down, OVERSPEED lamp lights | A. Check for low coolant level and replenish if required. Look for possible coolant leakage points and repair as required. b. Contact your Dealer or Distributor if none of the above. | |
| Engine shutdown and Hi Engine Temp fault lamp lights | Submerged sensor in the top portion of the radiator with coolant level below sensor level | |
| Overcrank fault | Place Run/Stop/Remote switch in STOP position, depress Reset switch momentarily, wait two minutes for starter motor to cool and repeat starting procedure |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing.
Repair guides
5- Flushing and Cleaning the Cooling System
- Gain Adjustment
- Governed Speed Adjustment
- Oil and Filter Change
- Preliminary Governor Adjustments
Step-by-step procedures compiled from the Cummins/Onan service manual for this model.
Parts
2| Part # | Description | Qty | System | |
|---|---|---|---|---|
| 960-0504 | PCC Control Service Manual | * | Service manual | Amazon eBay |
| 960-0507 | Detector Control Service Manual | ** | Service manual | Amazon eBay $49.00 |
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.
Available documents
Spec sheet — Cummins-installation-manual-DFAA-DFAB-DFAC-DFBC-DFBF-DFBD-DFBE-DFBF-DFCB-DFCC-DFCE-DFEB-DFEC-DFED-DFFA-DFFB-DFGA-DFGB-DFGC-DFJA-DFJB-DFJC-DFJD-DFLA-DFLB-DFLC-DFLD-DFLE-DFMB-DQAA-DQAB-DQBA-DQBB (Cummins/Onan)Operator's manual — 960-0140 Cummins DFLA DFLx KTA51 KTA5x Operator's Manual (9-1989) (Cummins/Onan)Parts manual — 0932-0112 Onan Post-Sale Literature Index (07-1998) (Cummins/Onan)Service manual — 960-0504 Onan DFxx series Generator Control Service Manual 04-1993 (Cummins/Onan)Service manual — 960-0507C Cummins DFAA thru DFMB DQAA Service Manual (2-2004) (Cummins/Onan)Service manual — 960-0619D Cummins DFA DFB DFC DFE DFF DFG DFJ DFL DFM DQA DQB Installation (6-2003) (Cummins/Onan)Service manual — Cummins-3100-PowerCommand-DFAA-DFAB-DFAC-DFBC-DFBD-DFBE-DFBF-DFCB-DFCC-DFCE-DFEB-DFEC-DFED-DFFA-DFFB-DFGA-DFGB-DFGC-DFJA-DFJB-DFJC-DFJD-DFLA-DFLB-DFLC-DFLD-DFLE-DFMB-DQAA-DQAB-DQBB (Cummins/Onan)Service manual — DFxx Generator Set Service Manual PCC3100 (Cummins/Onan)Service manual — Detector Control Generator Set Service Manual (Cummins/Onan)
This page was generated from the 9 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.