Name: Cummins/Onan DQAE Generator Set
Brand: Cummins/Onan

Service parts for the DQAE

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

Oil system

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 3100, PowerCommand 3100, PowerCommand 3100 (PCC 3100), PowerCommand 3100 (PCC), PowerCommand PCC 3100
Oil capacity	36.7 L
Phase	3
Battery group	8D
Battery cranking	900 CCA
Battery voltage	12 V
Battery quantity	2
Coolant capacity	40 L

Engine

Cummins/Onan QSM11

Oil capacity	36.7 L
Coolant capacity	40.0 L
Displacement	10.8 L
Aspiration	Turbocharged and Charge-Air Cooled
Rated speed	1470 rpm

Maintenance & consumables

for the Cummins/Onan QSM11

Item	Spec	Capacity	Part #	Interval
Air filter	K&N RU-3220		—	1500 hr
Fuel filter	Cummins Filtration FS1000		—	600 hr
Oil filter			3397929	600 hr	Amazon eBay
Battery			—	6000 hr
Belt			—	6000 hr
Coolant	Use coolant solution per Cummins engine Operation and Maintenance Manual		—	500 hr
Coolant filter	Cummins Filtration WF2075		—	1500 hr
Oil		36.7	—	6000 hr
Spark plug			—	1500 hr

Service intervals

Item	Action	Hours	Months	Notes
Charge Air Piping	Check	8 hr		Daily or after 8 Hours; tighten hose clamps to 74 inch-lbs (8 N-m) if necessary
Coolant Level	Check	8 hr		Daily or after 8 Hours
Fuel Level	Check	8 hr		Daily or after 8 Hours
Genset	Inspect	8 hr		Daily or after 8 Hours; check for oil, fuel, cooling and exhaust system leaks; check exhaust system audibly and visually with set running
Oil Level	Check	8 hr		Daily or after 8 Hours
Air Cleaner	Check	50 hr		Weekly or after 50 Hours; clean if required; perform more often in dusty conditions
Air cleaner	Clean	50 hr		Weekly or after 50 Hours; clean if required. Perform more often in dusty conditions.
Battery Charging System	Check	100 hr	1 mo	Weekly or after 50 Hours
Coolant heater(s)	Check	50 hr		Weekly or after 50 Hours
Crankcase Oil	Drain	50 hr		First service — Break-in: drain and replace crankcase oil after the first 50 hours of operation on new generator sets
Exhaust Condensate Trap	Drain	50 hr		Weekly or after 50 Hours
Fuel Filter(s)	Drain	100 hr	1 mo	Weekly or after 50 Hours; drain 1 cup or more of fuel to remove water and sediment; refer to Cummins engine Operation and Maintenance Manual
Fuel Tank (Water and Sediment)	Drain	50 hr		Weekly or after 50 Hours; drain 1 cup or more of fuel to remove water and sediment
Starting Batteries	Check	100 hr	1 mo	Weekly or after 50 Hours
Anti-freeze and DCA Concentration	Check	250 hr	6 mo	Monthly or after 100 Hours; refer to Cummins engine Operation and Maintenance Manual
Drive belt tension	Check	100 hr	1 mo	Monthly or after 100 Hours; visually check belt for wear or slippage, replace if hard or brittle.
Fuel tank water and sediment	Drain	100 hr	1 mo	Monthly or after 100 Hours; drain 1 cup or more of fuel to remove water and sediment.
Radiator Hoses for Wear & Cracks	Check	100 hr		Monthly or after 100 Hours
Battery electrolyte level	Check	200 hr		Check at least every 200 hours of operation; fill cells to bottom of filler neck.
Coolant Filter	Change	250 hr	6 mo	6 Months or after 250 Hours; refer to Cummins engine Operation and Maintenance Manual
Crankcase Breather	Clean	250 hr	6 mo	6 Months or after 250 Hours; refer to Cummins engine Operation and Maintenance Manual
Air cleaner element	Change	500 hr		Yearly or after 500 Hours; perform more often in dusty conditions.
Cooling system	Clean	500 hr	12 mo	Yearly or after 500 Hours; refer to Cummins engine Operation and Maintenance Manual
Crankcase oil and filter	Change	500 hr	12 mo	Yearly or after 500 Hours. Prime power: change every 6 months or 250 hours. Standby: change oil every 12 months or 250 hours, whichever comes first.
Fuel Filters	Change	500 hr		Yearly or after 500 Hours; refer to Cummins engine Operation and Maintenance Manual
Radiator hoses	Check	500 hr		Yearly or after 500 Hours; check for wear and cracks.
Rupture basin leak detect switch	Test	500 hr	12 mo	Yearly or after 500 Hours; check leak detect switch in sub-base fuel tank of optional enclosure, once a year or as required 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	Exhaust pipe clearance from combustible wall/partition	12	inches (305 mm)
Clearance	Float switch lift below C-clip stop	1/8 inch (3 mm)	inch (mm)	use a feeler gauge
Clearance	Fuel line clearance from electrical wiring	1/2	inch (12.7 mm)	minimum
Clearance	Fuel line clearance from hot exhaust parts	2	inch (51 mm)	minimum
Clearance	MPU sensor to flywheel gear tooth	back it out one quarter turn	turn	after sensor just touches gear tooth
Clearance	Minimum fuel level above fuel pump inlet for critical start	6	inches (150 mm)	recommended
Clearance	Vibration isolator top plate to base clearance	0.25	inch (6 mm)	nominal or greater
Other	Battery specific gravity (charge if below)	1.215		corrected
Other	Battery specific gravity (fully charged, corrected)	1.260		corrected to 80 F (27 C)
Other	Exhaust Outlet Size	5	in. NPT
Other	GOV RAMP adjustable range	0 through 10	seconds
Other	Ground Fault Relay current setting	5 to 1200	amperes
Other	Ground Fault Relay time delay setting	0 to 1	second
Other	Overcurrent warning	110% of rated for 60 seconds		generator output current
Other	Overload warning	105% of standby (or 115% of prime) rating		three-phase power output
Other	REG VHZ underfrequency roll-off adjustable range	1 through 50 (normal range 7 through 21)
Other	Short circuit shutdown	175% of rated		generator output current
Other	Voltage/frequency adjustment range (ADJUST menu)	+/- 5%	%
Pressure	Air cleaner cleaning air pressure	30	psi	cleaning element
Pressure	Air cleaner cleaning compressed air	30	psi (207 kPa)	max, clean side, nozzle at least 1 inch (25 mm) away
Pressure	Idle oil pressure	15	psi (104 kPa)	idle
Pressure	Idle oil pressure limit (unlabeled third value as printed)	8	psi	idle
Pressure	Idle oil pressure shutdown limit	12	psi	idle
Pressure	Idle oil pressure shutdown limit	8	psi (55 kPa)	idle
Pressure	Idle oil pressure warning limit	12	psi (83 kPa)	idle
Pressure	Idle oil pressure warning limit	15	psi	idle
Pressure	Max fuel inlet restriction	4	in. Hg (13.5 kPa)
Pressure	Max fuel return restriction	2.5	in. Hg (8.5 kPa)
Pressure	Max. Fuel Inlet Pressure	10	PSI (69 kPa)
Pressure	Max. Fuel Inlet Restriction	4	in. Hg. (13.5 kPa)
Pressure	Max. Fuel Return Restriction	2.5	in. Hg. (8.5 kPa)
Pressure	Maximum allowable exhaust back pressure	41	in. H20
Pressure	Maximum fuel inlet restriction	4	in. Hg.
Pressure	Maximum fuel return restriction	2.5	in. Hg.
Pressure	Normal oil pressure	207-345	kPa	normal operation
Pressure	Normal oil pressure	30-50	psi (207-345 kPa)
Pressure	Normal oil pressure shutdown limit	20	psi (138 kPa)
Pressure	Normal oil pressure warning limit	25	psi (172 kPa)
Pressure	Oil pressure shutdown limit	20	psi	normal operation
Pressure	Oil pressure warning limit	25	psi	normal operation
Pressure	Radiator cleaning compressed air/water	35	psi (242 kPa)	maximum
Pressure	Radiator cleaning water/air pressure (maximum)	35	psi	cleaning radiator
Resistance	Battery charge threshold	1.215	specific gravity	charge battery if reading below this
Resistance	Coolant temperature sender	500 to 2k	ohms
Resistance	Fully charged battery corrected specific gravity	1.260	specific gravity	corrected; add four gravity points (0.004) per 10°F above 80° F (27° C)
Resistance	Governor gain potentiometer R1 (between C-01-21 and C-01-49)	1.4k	ohms	plug C-01 removed from CM570 module
Resistance	PMG stator resistance	2	ohms
Resistance	PMG stator resistance	6	ohms
Resistance	PT primary	1K-2.5K	ohms
Resistance	PT secondary	140-225	ohms
Resistance	PT/CT module 3-ohm resistors (J8-15 to 14, J8-22 to 23, J8-7 to 8)	3	ohms
Resistance	Winding resistance (Exciter stator 0.096; Exciter rotor 1.25; Main rotor winding 11 N/A; Main stator winding 12 0.0076; winding 17 N/A; winding 07 0.0104)	0.096 / 1.25 / N/A / 0.0076 / N/A / 0.0104	ohms	approximate, at 68 F (20 C) +10%
Resistance	Winding resistance (Exciter stator 0.096; Exciter rotor 1.4; Main rotor winding 11 N/A; Main stator winding 12 0.0056; winding 17 N/A; winding 07 0.008)	0.096 / 1.4 / N/A / 0.0056 / N/A / 0.008	ohms	approximate, at 68 F (20 C) +10%
Resistance	Winding resistance (Exciter stator 0.096; Exciter rotor 1.64; Main rotor winding 11 N/A; Main stator winding 12 0.0044; winding 17 N/A; winding 07 0.006)	0.096 / 1.64 / N/A / 0.0044 / N/A / 0.006	ohms	approximate, at 68 F (20 C) +10%
Resistance	Winding resistance (Exciter stator 0.096; Exciter rotor 1.75; Main rotor winding 11 N/A; Main stator winding 12 0.0036; winding 17 N/A; winding 07 0.0044)	0.096 / 1.75 / N/A / 0.0036 / N/A / 0.0044	ohms	approximate, at 68 F (20 C) +10%
Resistance	Winding resistance (Exciter stator 0.136; Exciter rotor 0.91; Main rotor winding 11 0.0085; Main stator winding 12 N/A; winding 17 0.0115; winding 07 N/A)	0.136 / 0.91 / 0.0085 / N/A / 0.0115 / N/A	ohms	approximate, at 68 F (20 C) +10%
Resistance	Winding resistance (Exciter stator 0.136; Exciter rotor 1.04; Main rotor winding 11 0.007; Main stator winding 12 N/A; winding 17 0.01; winding 07 N/A)	0.136 / 1.04 / 0.007 / N/A / 0.01 / N/A	ohms	approximate, at 68 F (20 C) +10%
Resistance	Winding resistance (Exciter stator 0.136; Exciter rotor 1.17; Main rotor winding 11 0.0055; Main stator winding 12 N/A; winding 17 0.0075; winding 07 N/A)	0.136 / 1.17 / 0.0055 / N/A / 0.0075 / N/A	ohms	approximate, at 68 F (20 C) +10%
Resistance	Winding resistance (Exciter stator 0.136; Exciter rotor 1.35; Main rotor winding 11 0.005; Main stator winding 12 N/A; winding 17 0.0052; winding 07 N/A)	0.136 / 1.35 / 0.005 / N/A / 0.0052 / N/A	ohms	approximate, at 68 F (20 C) +10%
Resistance	Winding resistance (Exciter stator 0.158; Exciter rotor 1.44; Main rotor winding 11 0.0037; Main stator winding 12 0.0148; winding 17 N/A; winding 07 0.011)	0.158 / 1.44 / 0.0037 / 0.0148 / N/A / 0.011	ohms	approximate, at 68 F (20 C) +10%

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		Use a coolant solution as recommended in the Cummins engine Operation and Maintenance Manual		40.0 L	Balanced coolant mixture of water, antifreeze and coolant additives; drain and replace every year or after 500 hours; 10.5 Gal (40 L) printed; gensets shipped with coolant added
Engine oil		Refer to the Cummins engine Operation and Maintenance Manual for lubricating oil classification and recommendations/specifications		36.7 L	Gensets are shipped with oil added; check oil level before initial start; 9.7 Gal (36.7 L) printed
Fuel	ASTM No. 2 diesel fuel				Cummins engines normally use ASTM No. 2 diesel fuel. They will also operate on alternate diesel fuels within specifications shown in Cummins engine Operation and Maintenance Manual.
Fuel	Diesel fuel				Do not use zinc coated or copper fuel lines with diesel fuel. Fuel connection at engine should be made with an approved flexible line.
Grease	Lithium based grease, Mobilux No. 2 or Shell Alvania R3		-30°C to 120°C	2.74 oz. (81 ml)	Generator end bearing lubricant; -22F to +248F (-30C to +120C). 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

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	No corrective action required. When ground is removed from the input, the set returns to normal speed and voltage; oil pressure warning and shutdown trip points are reset automatically.
102	EMERGENCY STOP	Local or remote Emergency Stop.	Shutdown	Reset only at PCC front panel: pull button out, switch to Off, press Reset.
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 then follow 201 Low Oil Pressure procedure. If engine can be stopped, follow 201 procedure. To check oil pressure, access 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 and restart. Contact service center.
204	OIL PRES SENDER	Indicates that the engine oil pressure sender is not functioning correctly.	Warning	Check that the engine oil pressure sender is properly connected. Contact an authorized service center.
210	LOW COOLANT TEMP	Warning occurs when engine coolant temperature is 70 F (21 C) or lower. Below 40F (4C) ambient the warning may occur even though coolant heaters are operating.	Warning	Indicates engine coolant heater is not operating or is not circulating coolant. Check coolant heater power supply (blown fuse or disconnected heater cord), check for low coolant level and replenish, look for coolant leakage points and repair. Contact an authorized service center if none of the above.
211	HIGH COOLANT TEMP	Indicates engine has begun to overheat and coolant temperature has risen to an unacceptable level: (215 F − standby / 207 F − primary).	Warning	Reduce load if possible; check air inlets/outlets and remove obstructions.
212	HIGH COOLANT TEMP	Indicates engine has overheated (coolant temperature above shutdown trip point: 223 F − standby / 215 F − primary) or the coolant level is low.	Shutdown	Allow to cool; check coolant level, airflow, fan belt. Reset and restart. Contact service center if unresolved.
213	ENG COOLANT SENDER	Indicates that the resistance of the coolant temperature sender is out of range.	Warning	Contact an authorized service center.
214	LOW COOLANT LVL	Indicates engine coolant level has fallen below the trip point. (Shutdown will not occur if generator set is in Idle mode − low coolant warning only.)	Warning	Allow to cool; check and replenish coolant; repair leaks; reset and restart.
215	LOW COOLANT LVL	Indicates engine coolant level has fallen below the trip point. (Shutdown will not occur if generator set is in Idle mode − low coolant warning only.)	Shutdown	Allow to cool; check and replenish coolant; repair leaks; reset and restart.
220	MAG PICKUP	Mag pickup speed indication not sensed or does not match genset output frequency.	Shutdown	Restart and check RPM on the digital display. Contact an authorized service center.
221	FAIL TO CRANK	Possible fault with control or starting system.	Shutdown	Check fuse F3 on the Engine Interface board; clean and tighten battery cable connections; recharge or replace the battery.
222	OVERCRANK	Possible fuel system problem.	Shutdown	Check fuel tank, leaks, plugged fuel lines; replace dirty fuel or air filters. Reset and restart.
223	OVERSPEED	Indicates engine has exceeded normal operating speed (115% +/-1% of nominal).	Shutdown	Refer to engine service manual to troubleshoot fuel system; use InSite service tool to troubleshoot CM570 module.
230	LOW DC VOLTAGE	Indicates battery voltage is below 24 VDC.	Warning	Check the battery charger fuse. Discharged or defective battery: recharge or replace. Check for poor battery cable connections; clean terminals and tighten all connections. Contact an authorized service center if none of the above.
231	HIGH DC VOLTAGE	Indicates battery voltage exceeds 32 VDC.	Warning	Contact an authorized service center.
232	WEAK BATTERY	Indicates battery voltage drops below 60% of nominal for two seconds, during starting.	Warning	See Warning message 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 the genset 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 same error, perform calibration procedures; if same error, replace digital board (A32).
252	EEPROM ERROR	PCC memory error; data corruption of noncritical operating parameters.	Warning	Verify values or choices selected and repeat the save operation; if same error, replace digital board (A32).
260	CUSTOMER FAULT 1	When this customer defined input is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. (Default message; editable for customer site requirements.)	Warning	These fault functions can be programmed to initiate a shutdown or a warning. Contact an authorized service center.
261	GROUND FAULT	When this customer defined input is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. (Default message; editable for customer site requirements.)	Warning	These fault functions can be programmed to initiate a shutdown or a warning. Contact an authorized service center.
262	CM570/ENGINE	Indicates that the engine control module (CM570) is not properly operating.	Warning	Contact an authorized service center.
263	CM570/ENGINE	Indicates that the engine control module (CM570) is not properly operating.	Shutdown	Contact an authorized service center.
301	HIGH AC VOLTAGE	One or more phase voltages exceeded 130% of nominal, or 110% of nominal for 10 seconds.	Shutdown	Determine if output voltage the control sees is low or high; isolate regulator module A37, A31, A32, A36, A34, or A33.
303	LOW AC VOLTAGE	One or more phase voltages dropped below 85% of nominal for 10 seconds.	Shutdown	Contact an authorized service center.
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	Load Dump signal initiated five seconds before shutdown. Contact an authorized service center.
320	OVERCURRENT	Indicates that generator output current has exceeded 110% of rated for 60 seconds.	Warning	Contact an authorized service center.
321	OVERCURRENT	Output current exceeded 110% of rated; PCC time/current calculation initiated shutdown.	Shutdown	Contact an authorized service center.
322	SHORT CIRCUIT	Indicates that generator output current has exceeded 175% of rated.	Shutdown	Contact an authorized service center.
330	OVERLOAD	Three-phase output exceeds 105% of standby (or 115% of prime) rating.	Warning	Load Dump activated after 5 seconds; OVERLOAD warning after 60 seconds. Contact an authorized service center.
335	REVERSE POWER	Indicates improper CT or PT phasing. (Non-parallel units only.)	Shutdown	Contact an authorized service center.

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

Procedures

Adjust Start and Stop Delays adjustment

Press the button next to the word ADJUST in the Main Menu. The VOLTAGE submenu will appear.
Press the button next to the '>>' to move through the VOLTAGE and FREQUENCY submenus to the START DELAY submenu.
Use the buttons next to the '⇑' and '⇓' symbols to set the start delay. The start delay adjustment range is 0 to 300 seconds.
From the START DELAY submenu, press the button next to the '>>' to move to the STOP DELAY submenu.
Use the buttons next to the '⇑' and '⇓' symbols to set the stop delay. The stop delay adjustment range is 0 to 600 seconds.
From the STOP DELAY submenu, press the button next to the '>>' to move to the SAVE/EXIT submenu. Select SAVE to save your changes.
At the CHANGES SAVED submenu, select EXIT to return to the Main menu.

Adjusting Start/Stop Delays (PCC Adjust Menu) adjustment

Press button next to ADJUST in Main Menu to display VOLTAGE submenu
Press button next to >> to move through FREQUENCY submenu to STOP DELAY submenu
Use buttons next to arrows to set start delay, range 0 to 300 seconds
Use buttons next to arrows to set stop delay, range 0 to 600 seconds
Press >> to move to SAVE/EXIT submenu and select SAVE to retain changes, then EXIT

Axial Alignment Procedure (Aligning Generator with Engine) adjustment

Tools: Dial indicator holding device with magnetic base or clamp

Fasten a dial indicator holding device to skid base, engine block, or generator shell.
Position the indicator sensor point on the generator shaft hub.
Bar the engine over in a clockwise rotation through a couple of rotations.
Record indicator readings in eight equally spaced points around the shaft diameter.
To correct out-of-tolerance T.I.R., remove drive disc capscrews and mark discs and flywheel.
Rotate engine or generator so drive disc holes are repositioned 180 degrees from original location.
Reinstall capscrews and retorque; recheck alignment.
If T.I.R. is unchanged, rotate discs 30, 60, or 90 degrees from original location.

Converting Day Tank Controller from 120 VAC to 240 VAC adjustment

Remove jumpers between TB1-5/TB1-6 and TB1-7/TB1-8; connect two jumpers between TB1-6 and TB1-7
Move selector switch S103 on control PCB to down position for 240 VAC
If equipped with transformer, remove jumpers between H1/H3 and H2/H4 and connect two jumpers between H2 and H3

Converting Day Tank Controller from 240 VAC to 120 VAC adjustment

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

Voltage and Frequency Adjustment adjustment

⚠ Improper calibration or adjustment of the PowerCommand control can cause equipment malfunction or damage. Calibration and adjustment must be performed by technically qualified personnel only.

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

With the genset OFF, attach a calibrated frequency/voltmeter to the AC output from L1 to L2.
Select ADJUST from the Main Menu to display the VOLTAGE adjust menu.
Start the genset and allow it to reach normal operating speed.
Adjust VOLTAGE so that the calibrated voltmeter reads the desired voltage.
Select the Frequency adjust menu and verify/adjust frequency to the desired value.
Select EXIT if no adjustment was made; if an adjustment was made, SAVE then EXIT.

Generator/PCC Control Isolation Procedure diagnostic

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

⚠ This test involves unregulated excitation; make sure all loads are disconnected and all faults cleared.

Tools: True RMS meter, Jumper leads

Throw the line circuit breaker OFF and shut down the set.
Remove plug 10 from connector 10 of the voltage regulator output module (A37).
Prepare to measure output voltage across generator terminals while the set is running.
Connect jumpers from a 12 volt battery to X (Field +) 10-6 red and XX (Field -) 10-3 brown.
Check polarity again; opposed polarity makes this test inconclusive.
Start the set and connect the battery negative (-) to the XX lead.
Rated or higher balanced voltage indicates generator circuitry is probably okay.
If unbalanced, troubleshoot main stator first; if uniformly low, troubleshoot exciter and field circuits first.

Ground Fault Alarm Relay Test diagnostic

Verify that the N-G Fault Indicator on the GFR is not lit. If lit, it indicates that the bonding jumper circuit (neutral to ground) is open. If genset does not require bonding jumper, a bonding jumper
Move the control switch to the Run position.
Press the TEST switch on the ground fault relay.
Verify that the control panel warning message is displayed and the Fault Indicator (>I) on the GFR is lit.
Reset the control panel fault (this will also reset the ground fault relay).

Rupture Basin Leak Detect Switch Test diagnostic

Remove the pipe fitting/switch assembly from the rupture basin tank.
Move the O/Manual/Auto switch to the MANUAL position.
Activate leak detect switch (move float upward).
Check control display for Rupture Basin fault message.
If no indication of fault, repair defective circuit.
Apply thread sealant to pipe fitting and install switch assembly.

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 between each pair of colored leads while holding the assembly vertical.
Replace the assembly if any switch is open (all 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 the assembly if any switch does not open (all readings should be infinity).
Use pipe thread sealant when replacing the assembly.

Testing the Ground Fault Relay diagnostic

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

Testing the PMG diagnostic

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

Tools: Wheatstone bridge or digital ohmmeter, Voltmeter

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.
Voltages should be approximately the same for each set of leads.
Stop the set and measure resistance across the same lead pairs.
Refer to Table 6-3 for resistance values and Generator Reassembly for frame size.

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

Phase	Connection	Leads	Notes
	3-pole ATS system grounding	generator neutral to ATS, not bonded to ground at generator
	4-pole ATS system grounding	grounding electrode conductor and bonding jumper connect generator neutral to ground
	Alarm Relay K14 contacts	TB1 (jumper wire required for K14 relay option)	3-pole double-throw, same ratings as run relays; energized by any genset warning or shutdown
	B+ Input (RUN signal)	Blue (A37 J7)	Voltage regulator output module A37 J7 wiring connections (control)
	CT21 (+) In	White (A36 J9)	PT/CT Board (A36) J9 wiring connections
	CT21 (common) In	Gray (A36 J9)	PT/CT Board (A36) J9 wiring connections
	CT22 (+) In	Grn/Ylw (A36 J9)	PT/CT Board (A36) J9 wiring connections
	CT22 (common) In	Black (A36 J9)	PT/CT Board (A36) J9 wiring connections
	CT23 (+) In	Purple (A36 J9)	PT/CT Board (A36) J9 wiring connections
	CT23 (common) In	Blue (A36 J9)	PT/CT Board (A36) J9 wiring connections
	Current Transformers CT21/CT22/CT23	U (A phase)/V (B phase)/W (C phase) load leads	dot on CT must face toward generator; dual secondaries, wire 1 to pin 1, wire 2/3 to pin 2 (high voltage gensets) or pin 3 (low voltage gensets)
	Gen. Common In	Brown (A36 J9)	PT/CT Board (A36) J9 wiring connections to AC harness
	Ground Input	Purple (A37 J7)	Voltage regulator output module A37 J7 wiring connections (control)
	Phase A PMG power	Green (A37 J10)	Voltage regulator output module A37 J10 wiring connections (power)
	Phase B PMG power	Yellow (A37 J10)	Voltage regulator output module A37 J10 wiring connections (power)
	Phase C PMG power	Orange (A37 J10)	Voltage regulator output module A37 J10 wiring connections (power)
	Regulator Drive (+) Input	Gray (A37 J7)	Voltage regulator output module A37 J7 wiring connections (control)
	Regulator Drive (-) Input	White (A37 J7)	Voltage regulator output module A37 J7 wiring connections (control)
	Run Relay K11/K12/K13 contacts	TB1	3-pole double-throw, rated 10A at 28VDC or 120VAC 80%PF, 6A at 240VAC 80%PF, 3A at 480/600VAC 80%PF; energized when genset receives start signal
	Start in	Grn/Yel (A37 J7)	Voltage regulator output module A37 J7 wiring connections (control)
	Start solenoid	Black (A37 J7)	Voltage regulator output module A37 J7 wiring connections (control)
	X (Field +) Output	Red (A37 J10)	Voltage regulator output module A37 J10 wiring connections (power); X = red wire of connector 10-6
	XX (Field -) Output	Brown (A37 J10)	Voltage regulator output module A37 J10 wiring connections (power); XX = brown wire of connector 10-3
A	CT1 - U load leads	CT1	Route the appropriate leads through each CT; dot must face toward the generator
A	Gen. A In	Yellow (A36 J9)	PT/CT Board (A36) J9 wiring connections to AC harness
B	CT2 - V load leads	CT2	Route the appropriate leads through each CT; dot must face toward the generator
B	Gen. B In	Orange (A36 J9)	PT/CT Board (A36) J9 wiring connections to AC harness
C	CT3 - W load leads	CT3	Route the appropriate leads through each CT; dot must face toward the generator
C	Gen. C In	Red (A36 J9)	PT/CT Board (A36) J9 wiring connections to AC harness

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 DQAE?

The Cummins/Onan DQAE is powered by the Cummins/Onan QSM11 engine.

What fuel does the Cummins/Onan DQAE use?

The Cummins/Onan DQAE runs on diesel.

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

The Cummins/Onan QSM11 engine in the Cummins/Onan DQAE has an oil capacity of 36.7 liters.

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

The Cummins/Onan DQAE uses oil filter part number 3397929.

Troubleshooting

Fault codes

Code	Meaning	Cause	Remedy
HIGH COOLANT TEMP 212	Shutdown lamp lights. MESSAGE: HIGH COOLANT TEMP 212 − SHUTDOWN	Indicates engine has overheated (coolant temperature has risen above the shutdown trip point: 223° F (106° C) − standby or 215° F (102° C) − prime.)	Allow engine to cool down completely before proceeding with the following checks: a. Check for obstructions to cooling airflow and correct as necessary. b. Check fan belt and repair or tighten if necessary. c. Check coolant mixture. d. Check blower fan and circulation pumps on remote radiator installations. e. Reset control and restart after locating and correcting problem.
COOLANT SENDER 213	Warning lamp lights. MESSAGE: COOLANT SENDER 213 − WARNING		Indicates that the resistance of the coolant temperature sender is out of range. Check the resistance of the sender. Resistance should be 500 to 2k ohms.
LOW COOLANT LVL 214	Shutdown lamp lights. MESSAGE: LOW COOLANT LVL 214 − WARNING or LOW COOLANT LVL 215 − SHUTDOWN		Indicates engine coolant level has fallen below the trip point. Allow engine to cool down completely before proceeding. a. Check coolant level in both radiator and coolant recovery bottle and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Reset control and restart after locating and correcting problem. LOW COOLANT LVL Shutdown will not occur if genset is in Idle mode (low coolant warning only).
MAG PICKUP 220	Shutdown lamp lights. MESSAGE: MAG PICKUP 220 − SHUTDOWN		Indicates mag pickup speed indication is not being sensed or does not match generator set output frequency. a. Restart and check RPM on the digital display.
FAIL TO CRANK 221	Shutdown lamp lights. Engine stops cranking. MESSAGE: FAIL TO CRANK 221 − SHUTDOWN		Indicates possible fault with control or starting system. Check for the following conditions: a. Check fuse F3 on the Engine Interface board. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Discharged or defective battery. Recharge or replace the battery.
OVERCRANK 222	Shutdown lamp lights. Engine runs and then shuts down. MESSAGE: OVERCRANK 222 − SHUTDOWN		Indicates possible fuel system problem. a. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. b. Check for dirty fuel filter and replace if necessary. c. Check for dirty or plugged air filter and replace if necessary. d. Reset the control and restart after correcting the problem.

Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing. Full Cummins/Onan DQAE troubleshooting guide (74 entries) →

Parts

Part #	Description	Qty	System
12000180	Fuel inlet to pump	1	Pump	Amazon
12000183	Fuel filter	1	Fuel filter	Amazon eBay
12000185	Power steering pump mounting location	1	Pump	Amazon
12000186	Oil pressure and temperature sensor	1	Oil pressure and temperature sensor	Amazon
12000187	Engine position sensor	1	Engine position sensor	Amazon
13200052	Slow Idle Feature		Slow idle feature	Amazon
13200060	Engine Speed Control Switch		Engine speed control switch	Amazon
13200087	Oil Pressure Gauge		Oil pressure gauge	Amazon
15600049	Fuel Shutoff Valve		Fuel shutoff valve	Amazon
19400715	OEM Interface 21-Pin Harness Connector		Hose	Amazon
19400718	OEM Interface 24-Pin Harness Connector		Hose	Amazon
2871254	Starter 12V		Starter	Amazon eBay
2874862	Alternator 12V		Alternator	Amazon eBay
2874863	Alternator 24V	As needed	Alternator	Amazon eBay FridayParts $200.27
3037425	Belt		Belt	Amazon eBay $22.85
3103916	Starter 24V		Starter	Amazon eBay $393.22 FridayParts $298.65
3200069	STOP CHECK!		Stop check	Amazon
33200082	Engine Stop Button		Engine stop button	Amazon
3375049	Oil Filter Wrench	1	Oil filter	Amazon eBay
3376326	Pulley Pusher		Pulley pusher	Amazon eBay
3376807	Engine coolant and fuel filter wrench	1	Fuel filter	Amazon eBay
3377401	Pulley Pusher Adapter, 5/16 X 24 X 2 capscrews		Pulley pusher adapter	Amazon eBay
3397929	Oil filter wrench	1	Oil filter	Amazon eBay
38200567	Idle Adjustment Switch		Idle adjustment switch	Amazon
3823494	Sealant		Fluid	Amazon eBay
39200434	Governed rpm		Rpm governor	Amazon
43200085	Voltmeter		Voltmeter	Amazon
43200086	Tachometer w/Hour Meter		Tachometer	Amazon
49c00185	Data Link		Data link	Amazon
A40-TB1-8	JUMPER WIRE		Belt	Amazon eBay
FS1000	Fuel Filter	1	Fuel filter	Amazon $60.99 eBay $101.98 KuduParts $95.00
LF9001	Lube Filter	1	Oil filter	Amazon eBay $78.82 KuduParts $17.00
LFg9001	Valvoline® Premium Blue®		Oil filter	Amazon
RU3220	Air Cleaner	1	Air filter	Amazon eBay $79.95
V70509	Lube Oil	4 Gal.	Fluid	Amazon eBay
WF2072	Coolant Filter	1	Coolant filter	Amazon $41.15 eBay $20.95
05200182	Flywheel ring gear sensor	1	Service part / kit	Amazon
12000184	Rail pressure	1	Service part / kit	Amazon
12000188	Freon compressor mounting location.	1	Service part / kit	Amazon
19400716	Hard-Coupled		Service part / kit	Amazon
19400734	Intermediate Speed Control		Service part / kit	Amazon
19800802	Multiple Unit Synchronization		Service part / kit	Amazon
3305070	Heater, 240V	1	Service part / kit	Amazon eBay
3315033	Heater, 120V	1	Service part / kit	Amazon eBay
3885910	Red Paint, Spray can	3	Service part / kit	Amazon eBay
492000038	Operation and Maintenance Nanual		Service part / kit	Amazon
49800897	Intermediate Speed Control		Service part / kit	Amazon
49801587	Electronic Fan Clutch		Service part / kit	Amazon
8210G4-12VDC	1" 12V solenoid	As needed	Service part / kit	Amazon eBay
8210G4-24VDC	1" 24V solenoid	As needed	Service part / kit	Amazon eBay
98200038	Engine Steam Cleaning		Service part / kit	Amazon
A40-TB1-1	B+		Service part / kit	Amazon eBay
A40-TB1-11	(COMMON ALARM)		Service part / kit	Amazon eBay
A40-TB1-12	(B-)		Service part / kit	Amazon eBay
A40-TB1-30	COMMON ALARM		Service part / kit	Amazon eBay
A40-TB1-31	(COMMON ALARM)		Service part / kit	Amazon eBay
C2800	Fleetguard® refractometer	1	Service part / kit	Amazon eBay
CC2800	Fleetguard® refractometer		Service part / kit	Amazon eBay
D036			Service part / kit	Amazon eBay
D041			Service part / kit	Amazon eBay
F154			Service part / kit	Amazon eBay
F159			Service part / kit	Amazon eBay
H479			Service part / kit	Amazon eBay
H487			Service part / kit	Amazon eBay
H488			Service part / kit	Amazon eBay
H530			Service part / kit	Amazon eBay
H556			Service part / kit	Amazon eBay
H557			Service part / kit	Amazon eBay
K882			Service part / kit	Amazon eBay $260.95
LE9o01	Cummins Engine Company, Inc.		Service part / kit	Amazon

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%	65.5	17.3

Available documents

Operator's manual — 960-0172 Cummins DQAD DQAE DQAF Operator's Manual (2-2004) (Cummins/Onan)Owner's manual — 960-0159 Cummins DQAD DQAE DQAF Operator's Manual (7-2010) (Cummins/Onan)Parts manual — 960-0217 Cummins DQAD DQAE DQAF Parts Manual (5-2001) (Cummins/Onan)Service manual — 960-0516B Cummins DQAD DQAE DQAF Service Manual (2-2004) (Cummins/Onan)Service manual — 960-0624 Cummins DGAD DGAE DGAF Installation Manual (5-2001) (Cummins/Onan)Service manual — 960-0632B Cummins DQAD DQAE DQAF Installation Manual (2-2004) (Cummins/Onan)