The Electronically Regulated is a generator-set controller. It is used on generator sets from Cummins/Onan, including the BGE and NH.
| Code | Meaning |
|---|---|
| loss | Loss of coolant |
| Symptom | Cause | Remedy |
|---|---|---|
| Black Exhaust Smoke | Lean fuel mixture due to: a. incorrectly adjusted fuel mixture screws. b. incorrect float level. c. dirt in carburetor. d. vacuum leak. | 3a. Adjust carburetor main and idle adjustment screws. 1b. Adjust carburetor float level. 1c. Disassemble carburetor and clean all internal passages. 1 Replace fuel filter. 4d. Repair vacuum leak. |
| Black smoke exits the tailpipe. | Service the air cleaner. | |
| Blue Exhaust Smoke | 1. Incorrect float level in carburetor. | Adjust carburetor float level. Replace carburetor float |
| CRANKS BUT WON'T START | 1. Fuel below genset pickup level in tank. 2. Fuel supply shutoff valve closed. | 1. Add fuel. 2. Fully open fuel supply valve. 3. Remove spark plugs and clean. 4. Add oil if necessary. |
| CRANKS BUT WON’T START | 1. Fuel below genset pick-up level 2. Fuel supply shutoff valve closed. 3. Carbon deposits on spark plugs. 4. Blown fuel pump/in tank. | 1. Add fuel. 2. Fully open fuel supply valve. 3. Remove spark plugs and clean. 4. Replace fuse with same type and rating. If problem persists, see Onan service center. |
| CRANKS SLOWLY | 1. Low battery. 2. Bad battery connection. 3. Oil is too heavy. 4. Load connected. | 1. Check battery electrolyte level. 2. Clean and tighten all battery and cable connections. 3. Replace with lighter oil. 4. Remove load. |
| Carburetor icing | 8.Carburetor icing.2 | In cold weather, place air preheater in winter position. |
| Carburetor icing. | Place air preheater in winter position. | |
| Contaminated fuel supply | 2.Contaminated fuel.2 | Drain and replace fuel. |
| Contaminated fuel. | Drain fuel tank and refill with fresh fuel. | |
| Dirty air cleaner. | Replace air cleaner. | |
| Disconnecting Set from RV Systems | 1. First disconnect the negative (-) battery cable from the baitery and then disconnect the battery cables from the genset. 2. Disconnect the remote control wiring harness connector at the genset. 3. Disconnect the generator output wiring and conduit from the power distribution panel or box on the vehicle. Tag all wires to make reconnections easier. 4. Disconnect the exhaust tailpipe from the outlet of the muffler and then remove the muffler. See EXHAUST SYSTEM under Engine Subsystems. 5. Disconnect the fuel line from the genset. Follow the applicable instructions depending on the fuel. | |
| Dizziness | IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired. | |
| EXHAUSTING BLACK SMOKE | 1. Rich fuel mixture. 2. Dirty air filter. 3. Choke stuck. | 1. Turn main fuel adjustment in 1/8 turn (location of adjustment is shown in Figure 3-1). 2. Replace air filter. 3. Contact an Onan service center. |
| Eng Cranks But Will Not Start (Genset) | -01 Check: - Spark plugs - Ignition coil - Ignition module -02 Perform checks in step 01 | |
| Engine Backfires | Faulty ignition due to: a. worn or fouled spark plugs. **b. worn breaker points. **c. incorrect ignition timing. d. faulty ignition coil, e. faulty plug wires. **f. faulty condenser. **g. faulty ignition module (electronic ignition) | A. Replace spark plugs. b. Replace breaker points. c. Set breaker point gap. d. Test coil and replace if necessary. e. Test spark plug wires and f. Replace condenser. g. See Testing Ignition Module. |
| Engine Hunts or Surges | 1. Sticking or binding governor linkage. 2. Incorrect governor adjustment 3. Faulty governor spring. 4. Incorrect fuel mixture due to: a. incorrectly adjusted fuel mixture screws, b. incorrect float level, or c. dirt in carburetor. 5. Governor mechanism worn excessively. *6. Carburetor icing. | 1. Clean and lubricate governor linkage. 2. Adjust governor speed and sensitivity. 3. Replace governor spring. 4a. Adjust carburetor main and idle adjustment screws. 4c. Disassemble carburetor and clean all internal passages. |
| Engine Lacks Power | Faulty ignition due to: **a. incorrect ignition timing. b. incorrect spark plug gap. **c. faulty condenser. | A. Adjust breaker point gap. b. Reset spark plug gap. c. Replace condenser. |
| Engine Misfires | Faulty ignition due to: a. worn or fouled spark plugs. **b. worn breaker points. **c. incorrect ignition timing. d. faulty ignition coil, e. faulty plug wires. **f. faulty condenser. **g. faulty ignition module (electronic ignition); Lean fuel mixture due to: a. incorrectly adjusted fuel mixture screws. **b. incorrect float level. c. dirt in carburetor. d. vacuum leak.; Contaminated fuel; Carburetor icing *Gasoline sets only. | A. Replace spark plugs. b. Replace breaker points. c. Set breaker point gap. d. Test coil and replace if necessary. e. Test spark plug wires and f. Replace condenser. g. See Testing Ignition Module.; 2a. Adjust carburetor main and idle adjustment screws. b. Adjust carburetor float level. c. Disassemble carburetor and clean all internal passages. d. Locate leak and correct as required.; 3. Drain fuel tank and refill with fresh fuel. 4. In cold weather, place air preheater in winter position. |
| Engine Overfueling (Genset) | -01 Check: - Spark plugs - Fuel pressure at carburetor - Vacuum pull−off - Electric choke heater -02 Perform checks in step 01 - Check: - Governor adjustments - Carburetor adjustments -03 Perform checks in step 02 - Check: - Ignition coil - Ignition module | |
| Engine Overheats | Mechanical damage to engine *Gasoline sets only. | See Engine Block Assembly section. |
| Engine Unstable (Hunts) (Genset) | -01 Check: - Fuel supply - Fuel Lines for leakage - Loose wire connection -02 Perform checks in step 01 - Check: - Governor linkage for binding - Governor adjustments - Carburetor adjustments | |
| Engine Will Not Crank (Genset) | -01 Check: - Low battery voltage - Terminal connection−loose or dirty - Battery cable size - Starter drive engagement -02 Perform checks in step 01 - Check: - Remote control - Connections on PCB control board - Start solenoid - Starter | |
| Engine does not crank or start after several tries or stops running. | See Troubleshooting if the engine does not crank or start after several tries or stops running. | |
| Engine surges | 1. Sticking or binding (mechanical) governor linkage. 2. Incorrect (mechanical) governor adjustment. 3. Faulty (mechanical) governor spring. 4. Incorrect fuel mixture due to: a. incorrectly adjusted fuel mixture screws.1 b. incorrect float level.1. 2 c. dirt in carburetor d. ignition misfires 5. Intermittent electrical connections. 6. Governor mechanism worn excessively. 7. Fuel supply problem caused by: a. Faulty fuel pump.2 b. Contaminated fuel supply.2 c. Vapor locking.2 d. Plugged fuel filter | 1. Clean governor linkage (remove dirt or ice buildup). Check that linkage does not touch other parts. 2. Adjust governor speed and sensitivity. 3. Replace governor spring. 4a. Adjust carburetor main and idle adjustment screws.1 4b. Adjust carburetor float level.1 4c. Disassemble carburetor and clean all internal passages.1 4d. Check connections, see Ignition section. 5. Check battery and ignition connections. 6. See Engine Block Assembly section.. 7a. Check fuel pump and replace if defective. 7b. Drain and refill fuel supply 7c. Check for cause of overheating 7d. Replace fuel filter. |
| Exhaust system for leaks is examined | Stop the set and have the exhaust system repaired immediately | |
| FAILS TO CRANK | 1. Low battery. 2. Bad battery connection. 3. Blown fuse. | 1. Check battery electrolyte level. 2. Clean and tighten all battery and cable connections. 3. Replace fuse on control box. See specifications for proper fuse rating. |
| Faulty (mechanical) governor spring | 3.Faulty (mechanical) governor spring. | Replace governor spring. |
| Faulty ignition due to incorrect spark plug gap. | Reset spark plug gap. | |
| Faulty ignition due to: a. worn or fouled spark plugs. | Misfires | Replace spark plugs. |
| Faulty ignition due to: b. faulty ignition coil. | Misfires | Test coil and replace if necessary. |
| Faulty ignition due to: c. faulty plug wires. | Misfires | Test spark plug wires and replace if faulty. |
| Fuel leaks are found | Stop the set immediately, close off the fuel supply and have the leak(s) repaired | |
| Fuel supply problem caused by: a.Faulty fuel pump. | Check fuel pump and replace if defective. | |
| Fuel supply problem caused by: b.Contaminated fuel supply. | Drain and refill fuel supply | |
| Fuel supply problem caused by: c. Vapor locking. | Check for cause of overheating | |
| Fuel supply problem caused by: d.Plugged fuel filter. | Replace fuel filter. | |
| Generator set is excessively noisy | Have it inspected and repaired immediately by an authorized Onan service center | |
| Generator set runs louder than usual, compartment has holes to the interior, or exhaust system has leaks | Do not operate the generator set and have the exhaust system repaired as soon as possible. See your Onan service center. | |
| Governor mechanism worn excessively | 6.Governor mechanism worn excessively. | See Engine Block Assembly section. |
| High Oil Consumption | 1. Oil viscosity too light or oil is diluted. 2. Crankcase breather valve is dirty or defective. 3. Oil leaks. | 1. Drain oil and refill with correct viscosity oil. 2. Clean crankcase breather and replace if defective. 3. Locate source of leak and repair as required. |
| High Oil Consumption (Note: New engines sometimes have high oil consumption during break-In) | 1. Oil viscosity too light or oil is diluted. 2. Crankcase breather valve is dirty or faulty. 3. Oil leaks. 4. Excessive engine wear. 5. Light loading. | |
| High/Low AC Output (Genset) | -01 Check: - Broken or loose wires - Voltage regulator - Transformer regulator - Engine speed - Voltage ad | |
| If the genset fails to start | See the Troubleshooting Guide in the Operator’s Manual | |
| Inability to Think Coherently | IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired. | |
| Incorrect (mechanical) governor adjustment | 2.Incorrect (mechanical) governor adjustment. | Adjust governor speed and sensitivity. |
| Incorrect fuel mixture | 4a. Adjust carburetor main and idle adjustment screws. | Adjust carburetor main and idle adjustment screws.1 |
| Intermittent electrical connections | 5.Intermittent electrical connections. | Check battery and ignition connections. |
| Lean fuel mixture | A.incorrectly adjusted fuel mixture screws. | Adjust carburetor main and idle adjustment screws.1 |
| Lean fuel mixture due to: a. incorrectly adjusted main and idle adjustment screws. | Adjust carburetor main and idle adjustment screws. | |
| Lean fuel mixture due to: b. incorrect float level. | Adjust carburetor float level. | |
| Lean fuel mixture due to: c. dirt in carburetor. | Disassemble carburetor and clean all internal passages. Replace fuel filter. | |
| Lean fuel mixture due to: d. vacuum leak. | Locate leak and correct as required. | |
| Lean fuel mixture due to: e. altitude setting. | Reset altitude adjust knob on carburetor. | |
| Low Bat (Fig. 3) lights and/or the remote battery meter (Fig. 4) indicates low voltage. | A. Clean and tighten the positive (+) and negative (- ) battery cable connections at the battery and the genset. b. Recharge the battery. Refer to the battery manufacturer’s recommendations. | |
| Low Bat LED (red) MAY flash ON | If it stays on during operation, see BATTERY CARE under Periodic Maintenance. | |
| Low Oil Pressure | 1. Oil viscosity too light or oil is diluted. 2. Low oil level. 3. Low oil pressure switch defective. 4. Faulty oil bypass valve. | 1. Drain oil and refill with correct viscosity oil. 2. Add oil as required. 3. Replace oil pressure switch (see Engine Block Assembly section). 4. Inspect oil bypass valve and clean or replace as required (see Engine Block Assembly section.). |
| Make sure there is ample fresh air when operating the genset in a confined area. | Ensure adequate ventilation when operating the genset in a confined space. | |
| Muscular Twitching | IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not operate until it has been inspected and repaired. |
Fault codes and symptom→remedy steps extracted from this controller’s service/owner documentation; verify against the official manual before servicing. Aggregated from the service documentation of generator sets built on this controller.