Specifications
| Fuel | Diesel (ASTM No. 2) |
|---|---|
| Frequency | 60.0 Hz |
| Standby power | 80 kW |
| Standby kVA | 100 |
| Controller | Detector 12 (optional), Detector 7 (standard) |
| Oil capacity | 16.0 L |
| Voltage options | 12 V |
| Phase | 1 or 3 |
| Power factor | 0.8 |
| Battery group | 24 |
| Battery cranking | 800 CCA |
| Battery voltage | 24 V |
| Battery quantity | 2 |
| Coolant capacity | 25 L |
Engine
| Oil capacity | 16.0 L |
|---|---|
| Coolant capacity | 25.0 L |
| Displacement | 5.9 L |
| Aspiration | Turbocharged |
| Rated speed | 1500 rpm |
Same engine, other brands
1 brandThe Cummins/Onan 6BT5.9G2 in this set also powers 1 generator set sold under 1 other brand. Service parts and maintenance intervals for the engine are shared; enclosure, alternator, controller and ratings are not.
| Brand | Models |
|---|---|
| AKSA | ACD 125 |
Maintenance & consumables
for the Cummins/Onan 6BT5.9G2| Item | Spec | Capacity | Part # | Interval | |
|---|---|---|---|---|---|
| Air filter | Normal duty air filter. | — | |||
| Fuel filter | Oil and fuel filter fitted, water separator. | — | |||
| Oil filter | Oil and fuel filter fitted, water separator. | — | |||
| Battery | 460 amps minimum at ambient temperature of 32°F (0°C) | ×1 | — | ||
| Belt | N/A | — | |||
| Coolant | Coolant capacity (engine and radiator) | 24.6 l | — | ||
| Oil | Lubrication system oil capacity | 16.4 l | — | ||
| Spark plug | N/A | — |
Service intervals
4| 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) | |
| Valve lash | Adjust | 1000 hr | Footnote 5: Contact an authorized service center for service. | |
| Alternator bearings (sealed) | Inspect | 4000 hr | Inspect all sealed bearings every 4000 to 4500 hours (10000 hr/2 years) | |
| Alternator bearings (sealed) | Replace | 30000 hr | Replace all sealed bearings every 30000 hr/5 years (or if necessary after 10000 hr/2 years) |
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
33| Type | Item | Value | Unit | Condition |
|---|---|---|---|---|
| Other | Amperage | 222.1 | A | rated |
| Other | Automatic stop delay after normal power source returns | about 15 minutes | minutes | |
| Other | Coolant level below radiator cap opening | about two inches (50 mm) | mm | cold engine |
| Other | Exercise period | at least once a week for a minimum of 30 minutes with load | minutes | |
| Other | Kilowatts | 80 | kW | rated |
| Other | Power Factor | 1.0 | rated | |
| Other | Power rating reference conditions | altitude 300 feet (92 m), ambient temperature 81 F (27 C) | ||
| Pressure | Engine oil pressure | 25 to 45 | psi | engine at operating temperature |
| Pressure | Low oil pressure shutdown | 14 psi (97 kPA) | psi | |
| Pressure | Maximum allowable exhaust back pressure | 41 | inches H2O | |
| Pressure | Normal engine oil pressure range | 25 to 40 psi (172 to 275 kPa) | psi | |
| Pressure | Oil Pressure | 55-93 | load bank test | |
| Pressure | Pre-low oil pressure alarm | 20 psi (137 kPA) or less | psi | |
| Resistance | Battery specific gravity (recharge threshold) | recharge if below 1.260 | specific gravity | |
| Speed | Cycle cranking (optional) | three 15-second cranking cycles with two 15-second rest periods | seconds | |
| Speed | Frequency | 60 | Hz | rated |
| Speed | Overcrank cranking limit | 75 | seconds | |
| Speed | Overspeed shutdown (50 Hz units) | 1850 +50 | r/min | |
| Speed | Overspeed shutdown (60 Hz units) | 2100 ±90 | r/min | |
| Speed | Starter disconnect speed | 450 to 570 | RPM | |
| Temperature | Coolant Temperature | 94-194 | °F | load bank test |
| Temperature | Engine coolant maintained minimum per NFPA 110 (with coolant heaters) | 90 F (32 C) | F | |
| Temperature | Engine coolant temperature (heat exchanger, adjust raw water flow) | 165 to 195 | °F | viewing water temperature gauge |
| Temperature | Engine water temperature | 165 to 195 | °F | depending on load and ambient temperature |
| Temperature | High engine temperature shutdown | above 222 F (106 C) | F | |
| Temperature | Low engine temperature (LET) alarm | 70 F (21 C) or lower | F | |
| Temperature | Pre-high engine temperature alarm | approximately 215 F (102 C) | F | |
| Voltage | DC Voltage | 13.7-14.3 | V | load bank test |
| Voltage | DC voltmeter reading | 24 to 28 | volts | set running |
| Voltage | Generator AC voltage regulation from no load to full load | plus or minus two percent | % | |
| Voltage | Random voltage variation for constant loads | plus or minus one percent | % | |
| Voltage | Voltage | 208 | V | rated |
| Voltage | Voltage adjusting rheostat range | approximately plus or minus five percent adjustment of the rated output voltage | % |
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 | water/antifreeze mixture | 21.0 litres | Capacity with standard radiator 5.5 gallons (21 litres) for 37 DGBA, 35 DGBB, 40 DGBC, 50 DGCA, 60 DGCB; 6.5 gallons (25 litres) for 80 DGDA, 100 DGDB. Do not use antifreeze with anti-leak additives. | ||
| Engine oil | SAE 5W synthetic | API class CC/CD; sulphated ash content does not exceed 1.85 percent; pour point 9 F (5 C) below lowest expected temperature; viscosity 10,000 mPa s max at -31 F (-35 C) and 4.1 mm2/s min at 212 F (100 C) | below -23°C | For ambient temperature consistently below -10 F (-23 C) with no provision to keep engine warm; do not use petroleum base 5W grade oil | |
| Engine oil | SAE 10W30 / SAE 15W40 / SAE 20W40 (spec table) | -25°C to 35°C | 11.0 litres | Specifications table: Oil Capacity with Filters 11.5 quarts (11 litres) for 37 DGBA, 35 DGBB, 40 DGBC, 50 DGCA, 60 DGCB; 17.3 quarts (16 litres) for 80 DGDA, 100 DGDB. Oil type -13 F to 95 F (-25 C to 35 C) SAE 10W30; 14 F (-10 C) and above SAE 15W40; 32 F (0 C) and above SAE 20W40 | |
| Engine oil | SAE 10W-30 | API Class CC/CD (max sulphated ash 1.85 percent) | -23°C to -10°C | -10 F (-23 C) to 14 F (-10 C) | |
| Engine oil | SAE 15W-40 | API Class CC/CD (max sulphated ash 1.85 percent) | above -10°C | 14 F (-10 C) and above | |
| Engine oil | SAE 20W-40 | API Class CC/CD (max sulphated ash 1.85 percent) | above 0°C | 32 F (0 C) and above | |
| Fuel | ASTM No. 2 Diesel | ASTM No. 2 | Cummins engines on DG series sets normally use ASTM No. 2 Diesel; will operate on alternate diesel fuels within engine manual specifications. Never use galvanized or copper fuel lines, fittings or tanks. | ||
| Fuel | No. 2 diesel fuel | Engine will also operate on No. 1 fuel or other similar fuels; consult engine manufacturer for specific requirements |
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
12| Code | Name | Meaning | Severity | Action |
|---|---|---|---|---|
| FAULT 1 | FAULT 1 (red) lamp | Indicates an undedicated fault. May be field programmed as a shutdown or non-shutdown, and as a timed or non-timed fault (normally set for timed shutdown). | Shutdown | Determined when the set installation is designed. |
| FAULT 2 | FAULT 2 (red) lamp | Indicates same features as Fault 1 (normally set for timed shutdown). | Shutdown | Determined when the set installation is designed. |
| HI ENG TEMP | HI ENG TEMP (red) lamp | Indicates engine has shut down because of critically high engine temperature (above 222 F/106 C) or low coolant level. | Shutdown | Allow engine to cool; check coolant level and replenish; check for cooling airflow obstructions; check fan belt; reset control and restart. |
| LO FUEL | LO FUEL (yellow) lamp | Indicates fuel supply is marginally low. | Warning | Check fuel supply and replenish as required. |
| LO OIL PRES | LO OIL PRES (red) lamp | Indicates engine has shut down because of critically low oil pressure (below 14 psi/97 kPa). | Shutdown | Check oil level, lines and filters; replenish oil if low; reset control and restart; contact an authorized service center if oil pressure is not in the range of 25 to 40 psi (172 to 275 kPa). |
| LOW ENG TEMP | LOW ENG TEMP (yellow) lamp | Lights if engine temperature is marginally low for starting (70 F/21 C or lower); may indicate an inoperative coolant heater. | Warning | Check coolant heater power supply, fuse and heater cord; check coolant level and replenish. |
| OVERCRANK | OVERCRANK (red) lamp | Indicates engine has failed to start during the cranking period. | Shutdown | Check for empty fuel tank, fuel leaks or plugged fuel lines; check for dirty fuel or air filter and replace if necessary; reset control and restart. |
| OVERSPEED | OVERSPEED (red) lamp | Indicates engine has shut down because of excessive speed. | Shutdown | Contact an authorized service center for service. |
| PRE HI ENG TEMP | PRE HI ENG TEMP (yellow) lamp | Indicates engine temperature is marginally high (approximately 215 F/102 C) and engine continues to operate. | Warning | Reduce load if possible; check air inlets and outlets and remove obstructions to airflow. |
| PRE LO OIL PRES | PRE LO OIL PRES (yellow) lamp | Indicates engine oil pressure is marginally low (20 psi/137 kPa or less) and engine continues to operate. | Warning | Find and correct the cause as soon as possible. |
| RUN | RUN (green) lamp | Comes on when starter circuit opens after set starting. | Info | |
| SWITCH OFF | SWITCH OFF (flashing red) lamp | Indicates generator set is not in automatic start mode. | Warning | Move the Run/Stop/Remote switch to the Remote position for automatic starting. |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Procedures
7Vibration Isolators Installation and Adjustment Procedure installation
- Place the vibration isolators on the genset support structure.
- Shim or grout isolators so all bases are within 0.25 inch (6 mm) elevation of each other on a flat surface.
- Loosen the side snubber lock nuts so the top plate is free to move vertically and horizontally.
- Place the genset onto the isolators, aligning the skid mounting with the threaded isolator hole.
- Adjust isolators with the leveling bolt through the skid (locking nut threaded up toward bolt head) to level the set.
- Set nominal clearance between top plate and isolator base of 0.25 inch (6 mm) or greater.
- Adjust leveling bolts until set is level and sufficient clearance remains, then lock with the lock nut.
- Snubber nuts may remain loose to provide better isolation between genset and support structure.
Air Cleaner Element Replacement maintenance
⚠ Filters should be handled with care to prevent damage. If the filter does become damaged, install recommended replacement part.
- Remove the air cleaner cover.
- Remove thumb screw and gasket washer, then remove the element from air cleaner.
- Wipe out the interior of the air cleaner housing and cover with a clean, damp cloth.
- Install new element and secure with gasket washer and thumb screw.
- Put on the air cleaner cover and secure.
Engine Oil Change maintenance
⚠ Crankcase pressure can blow out hot oil and cause serious burns. Do NOT check oil while the generator set is operating.
Tools: Oil drain pan
- Bring the engine up to operating temperature and then shut if off.
- Open the drain valve and collect the engine oil in a pan. When the crankcase is drained close the drain valve.
- Fill the crankcase to the full mark on the dipstick. Allow for oil filters when drained or if changed.
- Start the engine and check for oil leaks.
- Shut off the engine and wait 15 minutes before checking the oil level. Add oil if required.
Filling the Cooling System (Standard Radiator and Heat Exchanger Sets) maintenance
⚠ Contact with hot coolant can result in serious burns. Do not bleed hot, pressurized coolant from a closed cooling system.
- Remove the cooling system pressure cap and fill the system with water or a water/antifreeze mixture.
- When the engine is first started, remove the pressure cap and monitor the coolant level.
- As trapped air is expelled from the system, the coolant level will drop and additional coolant should be added.
- Replace the pressure cap when the coolant level is stable.
Flushing and Cleaning the Cooling System maintenance
⚠ Excessive air pressure while starting the water flow could split the radiator core. Apply air pressure gradually to avoid damage.
Tools: Flushing gun nozzle
- Chemical Cleaning: use a good cooling system cleaner such as sodium bisulphate or oxalic acid and follow the supplier instructions. Neutralize and flush with clean water.
- Flushing: open the upper and lower radiator hose connections and install the radiator cap.
- Attach a flushing gun nozzle to the lower radiator hose connection and let the water run until the radiator is full.
- Gradually apply air pressure to avoid damaging the core. Shut off the air and allow the radiator to refill. Repeat until water coming from the radiator is clean.
- To flush the engine block, first remove the thermostat. Attach the flushing gun to the upper radiator hose and fill the block with water.
- Restrict the lower radiator hose opening until the block is filled. Apply air pressure and force water from the lower opening. Repeat until water is clean.
- Replace the thermostat and all hoses and refill cooling system.
Generator Check list maintenance
- Check coolant level and record freeze protection: -35
- Visual inspection of radiator
- Visual inspection of radiator hoses
- Check condition of coolant hoses
- Check condition of fuel hoses
- Check condition of engine belts
- Batteries and QTY: 1, GROUP31P, BATTERY IS GOOD
- Battery install date if applicable: (No)
- Genset has battery charger: (No)
- Genset has coolant heater: (Yes)
- Check engine oil level
- Engine oil filters last changed date and HRS: 728HRS, 8/4/25
- Inspect exhaust system for cracks / leaks
- Check rain cap for proper operation
- Generator end is 12 lead reconnectable (Yes)
Oil Filter Change maintenance
Tools: Filter wrench
- Clean around the filter head.
- Using a filter wrench, remove the oil filter.
- Fill the filter with clean oil as recommended in Table 5-2.
- Apply a light film of lubricating oil to the gasket sealing surface before installing the filter.
- Install the filter until hand tight then turn an additional 1/2 turn.
- Start engine to verify that filter is tight and does not leak.
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Common questions
What size generator is the Cummins/Onan 80 DGDA?
The Cummins/Onan 80 DGDA is rated 80 kW standby (100.0 kVA).
What engine does the Cummins/Onan 80 DGDA use?
The Cummins/Onan 80 DGDA is powered by the Cummins/Onan 6BT5.9G2 engine.
What fuel does the Cummins/Onan 80 DGDA use?
The Cummins/Onan 80 DGDA runs on Diesel (ASTM No. 2).
What is the oil capacity of the Cummins/Onan 80 DGDA?
The Cummins/Onan 6BT5.9G2 engine in the Cummins/Onan 80 DGDA has an oil capacity of 16.0 liters.
What is the cooling system capacity of the Cummins/Onan 80 DGDA?
The Cummins/Onan 80 DGDA cooling system holds 25 liters (6.6 US gallons) for the radiator system including the engine, per the manufacturer specification sheet.
What voltages is the Cummins/Onan 80 DGDA available in?
The Cummins/Onan 80 DGDA is offered in 12 V, 1 or 3-phase.
How many cold cranking amps does the Cummins/Onan 80 DGDA require?
The Cummins/Onan 80 DGDA uses 2 batteryies, 24 V each, 800 CCA, group 24, per the manufacturer specification sheet.
Troubleshooting
6Symptoms & remedies
| Symptom | Cause | Remedy |
|---|---|---|
| PRE HI ENGINE TEMP lamp lights. Engine continues to operate. | Indicates engine has begun to overheat and engine temperature has risen to approximately 215F (102C). | A. Reduce load if possible by turning off non-critical loads. b. Check air inlets and outlets and remove any obstructions to airflow. If engine can be stopped, follow procedure in step 3. |
| HI ENG TEMP lamp lights. Engine shuts down. | 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 if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check for a slipping fan belt and tighten if loose. d. Reset control and restart after locating and correcting problem. Contact an authorized service center for service if none of the above. | |
| PRE LO OIL PRES lamp lights. Engine continues to operate. | Indicates engine has overheated (engine temperature has risen above 222F/106C) or coolant level is low (sets with coolant level sensor). | A. Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check for a slipping fan belt and tighten if loose. d. Reset control and restart after locating and correcting problem. Contact an authorized service center for service if none of the above. |
| LO OIL PRES lamp lights. Engine shuts down. | Indicates engine oil pressure has dropped to 20 psi (138 kPa). | If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then follow step 5 procedure. If engine can be stopped, follow procedures in step 5. |
| LO OIL PRES lamp lights. | Indicates engine oil pressure has dropped to 14 psi (97 kPa). | Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Reset control and restart. Contact an authorized service center if oil pressure is not in the range of 25 to 40 psi (172 to 275 kPa). |
| OVERCRANK lamp lights and engine stops cranking. | 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 (see Maintenance section). c. Check for dirty or plugged air filter and replace if necessary (see Maintenance section). d. Reset the control and restart after correcting the problem. Contact an authorized service center for service if none of the above. |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing. Full Cummins/Onan 80 DGDA troubleshooting guide (14 entries) →
Parts
15| Part # | Description | Qty | System | |
|---|---|---|---|---|
| 982-0200 | Air Filter | 6 | Air filter | Amazon eBay |
| GM12667 | Sealing ring | 1 | Seal | Amazon eBay |
| 965-0520 | Cooling Fan | 37 | Service part / kit | Amazon eBay |
| GM12641 | Safety/locking agent | 1 | Service part / kit | Amazon eBay |
| GM12657 | Dipstick | 1 | Service part / kit | Amazon eBay |
| GM12676 | Cylinder liner | 1 | Service part / kit | Amazon eBay |
| GM12678 | Screw plug | 1 | Service part / kit | Amazon eBay |
| GM12697 | Torx-head bolt | 1 | Service part / kit | Amazon eBay |
| GM12921 | Hexagon bolt | 1 | Service part / kit | Amazon eBay |
| GM12924 | Rear end cover | 1 | Service part / kit | Amazon eBay |
| GM12936 | Wrapped bearing bush | 1 | Service part / kit | Amazon eBay |
| GM12937 | Wrapped bearing bush | 1 | Service part / kit | Amazon eBay |
| GM12954 | Dipstick | 1 | Service part / kit | Amazon eBay |
| GM12970 | Compression spring | 1 | Service part / kit | Amazon eBay |
| GM13175 | Pipe clamp | 1 | Service part / kit | Amazon eBay |
Service, wear & replacement parts referenced for this model and its engine — confirm the exact part for your serial number. See the full parts catalog to search and cross-reference.
Available documents
Operator's manual — 960-0143 Cummins DGBA DGCA DGDA Operator's Manual (8-2015) (Cummins/Onan)Reference — Cummins-80DGDA-SN-K990018824-Load-Test-Report-and-Inspection-Checklist (Cummins/Onan)Reference — cummins-dgda-sn-k000176362-load-test-and-inspection-report-1776194845 (Cummins/Onan)Parts manual — 0960-0211 I8 201410 (Cummins/Onan)Service manual — 960-0610 Onan DGBB thru DGFB Installation Manual (10-1995) (Cummins/Onan)
This page was generated from the 5 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.