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

Service parts for the DGCC

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

Belts

1 required

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

Specifications

Fuel	diesel
Frequency	60.0 Hz
Controller	PCC, PowerCommand PCC 3100
Oil capacity	11.0 L
Voltage options	600 V
Battery group	4D
Battery cranking	1080 CCA
Battery voltage	12 V
Battery quantity	1
Coolant capacity	22 L

Engine

Cummins/Onan 4BTA3.9

Oil capacity	11.0 L
Coolant capacity	22.0 L
Displacement	3.9 L
Aspiration	Turbocharged
Rated speed	1800 rpm

Filters for the Cummins/Onan 4BTA3.9

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	P558616	Lube Filter, Spin-On Full Flow	CUMMINS 3290712, CUMMINS 3890709, NAPA 1602, BALDWIN BT427	KuduParts $11.00 FridayParts $13.20
Oil filter	P558615	Lube Filter, Spin-On Full Flow	CUMMINS 10521, CUMMINS 3865405, NAPA 1607, NAPA 61607	buy
Fuel filter	P550440	Fuel Filter, Spin-On Secondary	CUMMINS 3831063, CUMMINS 3890707, NAPA 3358, BALDWIN BF788	FridayParts $356.80
Fuel filter	P553004	Fuel Filter, Spin-On	CUMMINS 3903640, CUMMINS 53C0045, NAPA 3358, RENAULT VI 0000150564	FridayParts $18.20
Fuel / water separator	P551329	Fuel Filter, Water Separator Spin-On Twist&Drain	CUMMINS 11E170210, CUMMINS 3890063, NAPA 3357, BALDWIN BF1280	FridayParts $151.00
Fuel / water separator	P550248	Fuel Filter, Water Separator Spin-On Twist&Drain	CUMMINS 1492827, CUMMINS 3286503, NAPA 3472, BALDWIN BF1226	FridayParts $229.00

Maintenance & consumables

for the Cummins/Onan 4BTA3.9

Item	Spec	Capacity	Part #	Interval
Belt	Belt, V-Grooved		328876800		eBay

Service intervals

Item	Action	Hours	Months	Notes
Coolant Heater	Check	8 hr		Verify hot coolant is being discharged from the outlet hose.
Coolant Level	Check	8 hr
Exhaust Condensate Trap	Drain	8 hr
Fuel Filter(s)	Drain	8 hr		Drain 1 cup or more of fuel to remove water and sediment. Refer to engine operation and maintenance manual for procedure.
Fuel Level	Check	8 hr
Fuel Tanks (water and sediment)	Drain	8 hr		Drain 1 cup or more of fuel to remove water and sediment.
Inspect Genset	Check	8 hr		Check for oil, fuel, cooling and exhaust system leaks. Check exhaust system audibly and visually with set running and repair any leaks immediately.
Oil Level	Check	8 hr		Keep oil level near the dipstick high mark without overfilling.
Air Cleaner	Clean	50 hr		Clean if required. Perform more often in dusty conditions.
Battery Charging System	Check	50 hr
Charge Air Piping	Check	50 hr
Crankcase Oil	Drain	50 hr		First service — Break-in: drain and replace the crankcase oil after the first 50 hours of operation on new generator sets.
Starting Batteries	Check	50 hr
Anti-freeze and DCA Concentration	Check	250 hr	3 mo	Refer to engine operation and maintenance manual.
Crankcase Oil and Filter	Change	250 hr	3 mo	If genset is used for prime power applications, change oil and filter every 3 months or 250 hours. If used for standby applications, change oil every 12 months or 250 hours, whichever comes first.
Drive Belt Tension	Check	250 hr	3 mo	Visually check belt for evidence of wear or slippage. Replace if hard or brittle. Refer to engine operation and maintenance manual.
Fuel Filters	Change	250 hr	3 mo	Refer to engine operation and maintenance manual.
Governor Adjustment	Check	250 hr	3 mo
Radiator Hoses for Wear & Cracks	Check	250 hr	3 mo
Air Cleaner Element	Change	500 hr		Perform more often in dusty conditions. Replace yearly or sooner if service indicator button pops up.
Coolant Filter	Change	500 hr	6 mo	Refer to engine operation and maintenance manual.
Cooling System	Clean	500 hr	6 mo	Refer to engine operation and maintenance manual.
Crankcase Breather	Clean	500 hr	6 mo	Refer to engine operation and maintenance manual.
Valve Lash	Adjust	1000 hr		After 1000 hours. Contact an authorized service center for service.

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 lift below C-clip stop	1/8	inch (3 mm)
Clearance	Overspeed switch magnet-to-fly arm air gap (minimum)	0.005	inches (0.13 mm)
Other	Battery electrolyte corrected specific gravity (fully charged)	1.260		electrolyte temperature corrected
Other	Battery recharge threshold specific gravity	1.215
Other	Battery specific gravity temperature correction	four gravity points (0.004) for every ten degrees above 80 F (27 C)
Other	Battery specific gravity, fully charged	approximately 1.260	at 80°F (27°C)
Other	Cycle crank crank and rest time	7 to 20	seconds
Other	Cycle crank number of cycles	3, 4, or 5
Other	ECM fuse F1 (starter solenoid circuit)	20	amps
Other	ECM fuse F2 (fuel solenoid circuit)	20	amps
Other	ECM fuse F3 (continuous B+ to remote circuits)	15	amps
Other	ECM fuse F4 (ECM circuits)	5	amps
Other	ECM fuse F5 (engine gauge circuits)	5	amps
Other	Frequency adjustment range	±5%	%	genset running
Other	Fuse A31-F1 (control B+)	5	Amp	Engine Interface board
Other	Fuse A31-F3 (auxiliary B+)	5	Amp	Engine Interface board; panel lights, run and start relays
Other	Fuse A38-F1 (Network B+)	10	Amp	Governor Output Module
Other	Fuse A38-F2 (Switched B+)	10	Amp	Governor Output Module
Other	Fuse A38-F3 (Governor B+)	10	Amp	Governor Output Module
Other	Fuse TB-Bat F1 (Customer B+)	20	Amp	Engine Harness Assembly
Other	GOV RAMP adjustment range	0 through 10	seconds
Other	Governor droop adjustment range	within 5	percent of nominal frequency (3 Hz for 60Hz sets, 2.5 Hz for 50Hz sets)
Other	Low oil pressure / high engine temperature fault time delay	about 10	seconds	following starter disconnect and inhibited during cranking
Other	Overcrank limit (Sentinel)	60	seconds
Other	Overcrank option limit (Detector)	75	seconds
Other	REG VHZ adjustment range	1 through 50 (normal range 7 through 21)
Other	Setup/calibration menu access code	574
Other	Standard cycle cranking (Detector)	three 15-second cranking cycles with two 15-second rest periods
Other	Start delay adjustment range	0 to 300	seconds	remote starting in Auto mode
Other	Stop delay adjustment range	0 to 600	seconds	remote stopping in Auto mode
Other	Voltage adjustment range	±5%	%	genset running
Pressure	Engine oil pressure (normal)	30 to 65	psi (207 to 449 kPa)	at normal operating temperature
Pressure	Engine oil pressure range (low oil pressure troubleshooting)	25 to 65	psi (172 to 449 kPa)
Pressure	Fuel shutoff valve rating (TB1-8 and TB1-5)	not more than 0.5	amps	120 or 240 VAC
Pressure	Idle oil pressure	10 - 30	psi (69 - 207 kPa)	idle
Pressure	Idle oil pressure	10-30	psi (69-207 kPa)	idle
Pressure	Idle oil pressure (normal)	10-30	psi (69-207 kPa)	Engine model 6C, idle
Pressure	Idle oil pressure shutdown limit	8	psi (55 kPa)	idle
Pressure	Idle oil pressure warning limit	12	psi (83 kPa)	idle
Pressure	Low Oil Pressure shutdown threshold	14	psi (97 kPa)
Pressure	Low oil pressure shutdown limit	14	psi (97 kPa)
Pressure	Normal oil pressure	40 - 70	psi (276 - 483 kPa)	normal operating speed
Pressure	Oil pressure shutdown limit	15	psi (103 kPa)	normal operating speed
Pressure	Oil pressure warning limit	20	psi (138 kPa)	normal operating speed
Pressure	Pre-Low Oil Pressure warning threshold (Detector control)	20	psi (138 kPa)
Pressure	Pre-low oil pressure alarm	20	psi (137 kPa)
Pressure	Radiator cleaning maximum air/water pressure	35	psi (242 kPa)
Resistance	A31 J1-2 to J4-10 / J1-1 to J4-11 continuity	270	ohms
Resistance	Coolant temperature sender (H2O 1 / H2O 2) resistance	700 to 1800	ohms	6 to 230 deg F
Resistance	Coolant temperature sender resistance	500 to 2k	ohms
Resistance	Exciter rotor winding insulation resistance (minimum)	1	megohm
Resistance	Exciter stator winding insulation resistance (minimum)	1	megohm
Resistance	Exciter stator/rotor winding insulation resistance	greater than 1	megohm	Replace if less than 1 megohm
Resistance	Exhaust temperature sender resistance	100 to 376	ohms	32 to 1471 deg F
Resistance	Main rotor winding insulation resistance (minimum)	1	megohm
Resistance	Main stator winding insulation resistance (minimum)	1	megohm
Resistance	Oil temperature sender resistance	700 to 1800	ohms	6 to 230 deg F
Resistance	PMG winding resistance	approximately 4.4	ohms	across lead pairs P2-P3, P3-P4 and P4-P2
Resistance	PMG winding resistance (P2-P3, P3-P4, P4-P2)	4.4	ohms
Resistance	PMG winding resistance (each of P2-P3, P3-P4, P4-P2)	approximately 4.4	ohms

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	Notes
Coolant		soft water/E.G./DCA mixture	Installation review checklist item: cooling system must be filled with soft water/E.G./DCA mixture.
Coolant	50/50 mix of water and antifreeze	Balanced coolant mixture of water, antifreeze and coolant additives	Drain and replace the mixture every 6 months or after 500 hours of operation. Do not add cold coolant to a hot engine; allow engine to cool below 120 F (50 C) before adding coolant.
Engine oil		Refer to the Cummins engine Operation and Maintenance Manual for lubricating oil classification/recommendations/specifications	Gensets are shipped with oil added.
Fuel	diesel		Do not use zinc coated or copper fuel lines with diesel fuel.

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; generator build-up is inhibited and engine governed at 800 RPM.	Warning	Remove ground from the engine idle input to return to normal speed and voltage.
102	EMERGENCY STOP	Indicates local or remote Emergency Stop.	Shutdown	Pull the button out; move the Run/Off/Auto switch to Off; press the Reset switch; select Run or Auto as required. Can only be reset at the PCC front panel.
200	LOW OIL PRESSURE	Indicates engine oil pressure has dropped to an unacceptable level.	Warning	If powering critical loads, wait until next shutdown period and follow 201-SHUTDOWN procedure; check oil pressure via menu prior to clearing 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. Oil pressure limits in Table 4-3.
204	OIL PRESS SENDER	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, indicating the engine coolant heater is not operating or is not circulating coolant.	Warning	Indicates engine coolant heater is not operating or is not circulating coolant; check coolant heater power supply/fuse, low coolant level, and open heater element.
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) prime.	Warning	Reduce load if possible; check air inlets/outlets; follow 212-SHUTDOWN procedure if engine can be stopped.
212	HIGH COOLANT TEMP	Indicates engine has overheated (coolant temperature above the shutdown trip point: 223°F (106°C) standby or 215°F (102°C) prime).	Shutdown	Allow engine to cool; check for obstructions to cooling airflow, check fan belt, check coolant mixture, check blower fan and circulation pumps; reset control and restart after correcting problem.
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; look for leakage; reset control and restart.
215	LOW COOLANT LVL	Indicates engine coolant level has fallen below the trip point. LOW COOLANT LVL Shutdown will not occur if genset is in Idle mode (low coolant warning only).	Shutdown	Check coolant level in radiator and recovery bottle and replenish if low; check defective coolant bottle hose or radiator cap; reset control and restart after correcting problem. Will not occur in Idle mode.
220	MAG PICKUP	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; isolate per troubleshooting table 4-18.
221	FAIL TO CRANK	Possible fault with control or starting system; engine will not crank.	Shutdown	Check fuse F3 on the Engine Interface board; clean battery cable connections; recharge or replace battery.
222	OVERCRANK	Possible fuel system problem; engine stops cranking.	Shutdown	Check for empty fuel tank, fuel leaks, or plugged fuel lines; check/replace dirty fuel filter and air filter; reset and restart.
223	OVERSPEED	Indicates engine has exceeded normal operating speed (115% ±1% of nominal).	Shutdown	Inspect the mechanical fuel linkage and repair or replace; check the EFC for binding or damage; monitor the PCC duty cycle display and replace A32 or A38 as indicated.
224	FAIL TO SYNCHRONIZE	The generator set has not synchronized to the system bus within the allowable time frame.		Check governor system stability and adjust governing/synchronizer parameters; check for fuel system problems causing engine instability; widen synchronizing window and reduce acceptance time delay.
226	FAIL TO CLOSE	Indicates that the paralleling breaker has been given a signal to close, but has not closed properly.		Verify charging mechanism of paralleling breaker; check the close signal to the breaker; verify auxiliary contact signals from the breaker to the control are operational.
230	LOW DC VOLTAGE	Indicates battery voltage is below 10 VDC.	Warning	Recharge or replace battery; clean/tighten connections; check engine DC alternator; check battery charger float level.
231	HIGH DC VOLTAGE	Indicates battery voltage exceeds 32 VDC.	Warning	Check voltage float level on battery charger if applicable (lower float level); check engine DC alternator and 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	Recharge or replace the battery; see 230 LOW DC VOLTAGE.
240	LOW FUEL-DAY	Indicates day tank fuel supply is running low.	Warning	Check fuel supply and replenish as required.
241	LOW FUEL	Indicates fuel supply is running low.	Warning	Check fuel supply and replenish as required.
250	EEPROM ERROR	PCC memory error; data corruption of critical operating parameters.	Shutdown	Perform the initial start setup procedure; if shutdown repeats, replace the digital board (A32).
251	EEPROM ERROR	PCC memory error; data corruption of noncritical operating parameters.	Warning	Perform the adjustment procedures and save; if the same EEPROM ERROR occurs, perform the calibration procedures; if it still occurs, 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 EEPROM ERROR message occurs, replace the digital board (A32).
260	CUSTOMER FAULT 1	Customer defined input closed to ground; the nature of the fault is an optional customer selection which can be programmed to initiate a shutdown or a warning. Default message is editable.	Warning	Isolate the source of the false signal; disconnect the signal lead near the control and reset; if the message drops out there is a short to ground in the external wiring; if it remains replace A34. Customer fault messages are editable.
261	GROUND FAULT	Customer defined input closed to ground; the nature of the fault is an optional customer selection. Default message is editable.	Warning	Isolate the source of the false signal; check the corresponding customer interface board LED; disconnect the signal lead and reset the control; replace A34 or A32 as indicated.
262	RUPTURE BASIN / DAY TANK	Customer defined input closed to ground; the nature of the fault is an optional customer selection. Default message is editable.	Warning	Isolate the source of the false signal; check the corresponding customer interface board LED; disconnect the signal lead and reset the control; replace A34 or A32 as indicated.
263	HIGH GEN TEMP	Customer defined input closed to ground; the nature of the fault is an optional customer selection. Default message is editable.	Warning	Isolate the source of the false signal; check the corresponding customer interface board LED; disconnect the signal lead and reset the control; replace A34 or A32 as indicated.
270	PHASE ROTATION	The phase relationship between the generator set and the system bus is not matched.	Shutdown	Using a phase rotation checker, verify that the generator set phase rotation matches the system bus; verify control wiring to the bus PT module is properly connected.
272	FIRST START	The PowerCommand control is not receiving a proper signal from the system master first start sensor.	Warning	Control reverts to fallback mode; verify the Master First Start Sensor is functioning and that the voltage pulse is present at the PowerCommand control (terminal TB1-50); check interconnection wiring.
301	HIGH AC VOLTAGE	One or more phase voltages has exceeded 130% of nominal, or has exceeded 110% of nominal for 10 seconds.	Shutdown	Set the display to GEN VOLTS L-N and observe; determine if the output voltage the control sees is low or high; isolate to the PCC, alternator, PT/CT module (A36), customer interface board (A34), analog board (A33) or digital board (A32).
303	LOW AC VOLTAGE	One or more of the phase voltages has dropped below 85% of nominal for 10 seconds.	Shutdown	Check and repair the PMG or field wiring; check rotating rectifier diodes; check the load and correct any overload; check connectors J8 and J9 on A36, J3 and J5 on A34, and J7 on A37; isolate to A33, A32, A37 or A31.
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; isolate governor output module (A38), A32 or A31.
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	Indicates that power is flowing into the generator set rather than out from the unit.	Shutdown	Verify connection of generator set CT's; verify proper connection of load sharing lines; verify correct frequency and voltage on all sets.
337	LOSS OF EXCITATION	Indicates that the alternator excitation system is improperly adjusted or has failed.	Shutdown	Check output voltage with calibrated meter and adjust; check load sharing lines; see Section 6 Servicing the Generator.

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

Procedures

Convert Day Tank Controller 240 VAC to 120 VAC adjustment

Remove the two jumpers between terminals TB1-6 and TB1-7.
Connect one jumper between TB1-5 and TB1-6 and the other between TB1-7 and TB1-8.
Move selector switch S103 on the control PCB to the up position for 120V.
If equipped with a transformer, remove jumpers between H2 and H3 and connect one between H1 and H3 and the other between H2 and H4.

Day Tank Controller Conversion 240 VAC to 120 VAC adjustment

Remove the two jumpers between terminals TB1-6 and TB1-7 and connect one between TB1-5 and TB1-6 and the other between TB1-7 and TB1-8.
Move selector switch S103 on the control PCB to the up position for 120V.
On the control transformer, remove the two jumpers between terminals H2 and H3 and connect one between H1 and H3 and the other between H2 and H4.

Governor Adjustments (Type A Electric Governor) adjustment

Set selector switch S1 to OFF, S2 to appropriate model position.
Set pots initially: Gain 20%, I 20%, D 30%, Droop 0%.
Start set, adjust Speed pot for required frequency (60Hz=1800RPM or 50Hz=1500RPM) at operating temperature.
Disconnect load, turn Gain pot to 100% or until unstable, then back off until stable.
Adjust D and I pots similarly; readjust Speed if necessary.
Push throttle to minimum speed, release and observe overshoot (2-5 Hz acceptable); adjust I pot to reduce overshoot or hunting.

Initial Start Setup adjustment

⚠ Selecting this menu resets all operating parameters to default values; perform only by technically qualified personnel.

Press RESET, MENU and PHASE SELECT simultaneously to invoke the Initial Start Setup menu.
Toggle the Standby/Prime option.
Select the correct generator set model, frequency and kW rating.
Select the correct nominal line-to-line output voltage.
Select DELTA or WYE.
Select SAVE to save changes; MAIN MENU is then displayed.

Operating PowerCommand in Droop Mode adjustment

Set the no load speed and voltage at the desired level (bus must be de-energized or disconnect Bus PT module).
Apply 100% load and adjust KW load sharing gain for desired full load frequency; adjust KVAR load sharing gain for desired full load voltage.
Repeat the process for other generator sets in the system.
Test the system with all available load and verify approximately equal load sharing at no load and maximum load.

Torque Tester / Current Transformer Installation Check adjustment

Verify the dot on the CT faces toward the generator.
Verify CT21 is on U load leads, CT22 on V load leads, CT23 on W load leads.
Verify the correct CT secondary terminal (pin 2 high voltage / pin 3 low voltage) is used.
Check CT/PT wiring if a 335 Reverse Power shutdown occurs.

Servicing the PMG diagnostic

⚠ Touching uninsulated high voltage parts can result in severe personal injury or death.

Tools: Wheatstone bridge, digital ohmmeter

Disconnect leads P2, P3, P4 from voltage regulator.
Start engine and let speed stabilize.
Measure voltage across lead pairs P2-P3, P3-P4, P4-P2; should be at least 150 VAC (50Hz) or 180 VAC (60Hz).
Stop set and measure resistance across same lead pairs; each winding approximately 4.4 ohms.
Torque PMG rotor center bolt to 40 ft-lbs (54 Nm) when reassembling; stator leads must be at 12 o'clock.

Servicing the PMG - Testing diagnostic

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

Tools: Wheatstone bridge or digital ohmmeter

Disconnect leads P2, P3 and P4 from the voltage regulator.
Start the engine at the set and let the speed stabilize.
Measure voltage across lead pairs P2-P3, P3-P4 and P4-P2 (at least 150 VAC for 50 Hz, at least 180 VAC for 60 Hz).
If voltages are low or uneven, check all leads and connections before disassembling the PMG.
Stop the set and measure electrical resistance across P2-P3, P3-P4 and P4-P2 (approximately 4.4 ohms each winding).

Test 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 continuity between each pair of colored leads while holding the assembly vertical; replace assembly if any switch is open (readings should be zero).
Lift each float in turn to 1/8 inch (3 mm) below the C-clip stop and test for continuity; replace assembly if any switch does not open (readings should be infinity).
Use pipe thread sealant when replacing the assembly.

Testing Exciter Stator Winding diagnostic

Tools: Wheatstone bridge, digital ohmmeter

Measure winding resistance with Wheatstone bridge or digital ohmmeter between the two stator leads X and XX.
Replace stator if resistance not as specified in Table 7-1.
Disconnect leads from terminals X and XX; measure insulation resistance between either lead and stator laminations with ohmmeter.
Replace stator if insulation resistance less than 1 megohm.

Testing the Exciter Rotor diagnostic

Tools: Wheatstone bridge, ohmmeter

Disconnect six rotor winding leads from rectifier terminal posts.
Measure resistance across each pair of rotor windings (U-V, V-W, W-U) with Wheatstone bridge.
Replace whole rotor shaft assembly if resistance not per Table 7-1.
Measure insulation resistance between any rotor winding lead/terminal and rotor laminations; replace if less than 1 megohm.

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 continuity (switch closed) between each pair of colored leads while holding the assembly vertical; replace if any switch is open.
Lift each float in turn to 1/8 inch (3 mm) below the C-clip stop above it and test for continuity; replace if any switch does not open.
Use pipe thread sealant when replacing the assembly.

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
		Fault relay K8/K9 (Dry Contact Module)	K8=Over Crank, Low Oil Pressure, High Engine Temperature, Low Coolant Level, Low Fuel Level; K9=Low Fuel Level, Rupture Basin	Contact ratings: 40A max carry/break N.O. 12V coil, 30A N.C. 12V coil, 20A N.O./10A N.C. 24V coil
		TB3 (ECM alternative RUN/STOP/REMOTE connection)	TB3-1=REMOTE, TB3-2=RUN, TB3-3=STOP	Provides alternative direct connection to ECM for troubleshooting or customer connection

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

Which engine powers the Cummins/Onan DGCC?

The Cummins/Onan DGCC is powered by the Cummins/Onan 4BTA3.9 engine.

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

The Cummins/Onan DGCC runs on diesel.

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

The Cummins/Onan 4BTA3.9 engine in the Cummins/Onan DGCC has an oil capacity of 11.0 liters.

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

The Cummins/Onan DGCC cooling system holds 22 liters (5.8 US gallons) for the radiator system including the engine, per the manufacturer specification sheet.

What voltages is the Cummins/Onan DGCC available in?

The Cummins/Onan DGCC is offered in 600 V.

What size battery does the Cummins/Onan DGCC need?

The Cummins/Onan DGCC uses 1 battery, 12 V each, 1080 CCA, group 4D, per the manufacturer specification sheet.

Repair guides

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

Parts

Part #	Description	Qty	System
328876800	Belt, V-Grooved	1	Belt	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	100%	11.0	2.9

Available documents

Operator's manual — 960-0107 Cummins DGBB DGCB DGDB DGFA Operator's Manual (7-2009) (Cummins/Onan)Parts manual — 0932-0112 Onan Post-Sale Literature Index (07-1998) (Cummins/Onan)Parts manual — 0960-0210 I8 201512 (Cummins/Onan)Service manual — 900-0524B Onan DGxx Power Command Control 3100 Series Paralleling Gensets Operation & Service manual (01-2002) (Cummins/Onan)Service manual — 960-0510B Onan DGBB thru DGFC Series Service Manual (10-1998) (Cummins/Onan)Service manual — 960-0511B Cummins DGBB DGC DGD DGF Series Service Manual (10-2001) (Cummins/Onan)Service manual — 960-0618D Cummins DGBB DGCA DGEA DGFA Series Installation Manual (10-2001) (Cummins/Onan)Service manual — DG Generator Set Service Manual PCC 3100 (Cummins/Onan)

This page was generated from the 8 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.

Cummins/Onan DGCC Generator Set

Service parts for the DGCC

Belts

Specifications

Engine

Filters for the Cummins/Onan 4BTA3.9

Maintenance & consumables

Service intervals

Service specifications

Recommended fluids

Fault codes

Procedures

Voltage reconnection

Common questions

Repair guides

Parts

Fuel consumption

Available documents