Cummins/Onan Ford Engine Model Engine Engine

• There is no remote circuit signal (12 VDC at auxiliary relay board A28-TB1-6) because the remote circuit is not functioning properly.
  Fix: Apply 12 VDC to A28-TB1-6. If the engine cranks, find and repair the fault in the remote control circuit. See Section 7 for remote connections.
• There is no remote circuit signal (12 VDC at auxiliary relay board A28-TB1-6) because fuse F3 on the ECM has blown. a
  Fix: A. Replace the fuse with one of the same type and amp rating (15 A).<br>b. If fuse F3 blows again, find and repair the fault in the remote control circuit, such as a loose wire that may be shorting to ground or a shorted relay coil or other component. See Section 7 for remote connections.
• The starter disconnects normally but neither the panel nor the remote Run indicator lamps light
  Cause: AC (K10) starter disconnect circuit is not working
• The Run-Stop-Remote switch is at Stop. (The Switch-Off light will be flashing.)
  Fix: Push the Run-Stop-Remote switch to Remote.
• The magnetic speed pick-up is defective or requires adjustment. 9
  Fix: Refer to Magnetic Speed Pickup Unit Adjustment in Section 6.
• The grounding strap between the control box and the battery negative (−) terminal or the ground wire between the control and engine ground is loose, damaged or missing
  Fix: Check for continuity (zero ohms) between the grounding stud on the bottom of the control box and the battery negative (−) terminal. If there is no continuity or the grounding strap is loose or damaged, repair as necessary.
• The engine runs until fault shutdown.
  Fix: 1. The OVERSPEED lamp comes on and the engine shuts down. a. Reset the ECM by pushing the Run-Stop-Remote switch to Stop and the Reset switch to Reset and restart the set, monitoring engine speed. b. Adjust the governor for Type A fuel system/check operation of Type B integrated governor (see Section 6). c. Type A: If the governor cannot be adjusted to prevent shutdown due to overspeed, check for binding in the linkage. Repair and adjust the linkage as necessary. d. Type A and B: If the set still shuts down due to overspeed, re-install the magnetic speed pick-up unit to make sure the clearance with the flywheel gear teeth is correct (see Section 6). Replace the speed-pickup unit if output voltage at cranking speed is less than 1.5 VAC. (Intermittent open on magnetic speed pick-up lead can also cause an overspeed condition.) e. Replace the governor controller board (Type A) or integrated governor assembly (Type B) if the set still shuts down due to overspeed. 2a. The OVERSPEED lamp comes on and the engine shuts down within 1 to 5 seconds (no over-speed condition detected). (V6 Spec A & B, V10 Spec A−C) a. Remove K5-30 lead from K5. Start genset. If set shuts down and overspeed light is on, replace ECM (A11). b. Remove K5-30 lead from K5 and check lead continuity to ground. If ground present, replace ignition module. c. Connect K5-30. Remove lead K5-87 and check lead continuity to ground. If ground present, replace K5 relay. d. Remove K5-87 lead from K5 and start genset. If set shuts down and OVERSPEED lamp comes on, replace ECM (A11). e. Check Ford engine harness oil pressure lead for proper ground to intake manifold. Must be grounded to prevent false ignition module fault. 2b. The OVERSPEED lamp comes on and the engine shuts down within 1 to 5 seconds (no over-speed condition detected). (V6 Spec C) f. Remove connector from J2 of the ECM (A11) board and check pin J2-6 continuity to ground. If ground present, replace ignition module. g. Check Ford engine harness oil pressure lead for proper ground to intake manifold. Must be grounded to prevent false ignition module fault.
• The engine ignition system is malfunctioning. 7
  Fix: Refer to wiring diagrams in Section 7. V6 Engine: a. Check for battery VDC at coil while cranking. (Red wire with green stripe.) b. Spec C − Check Ford engine harness ground lead connection. c. Spec C − Check 10 amp fuse located on Ford engine harness power block. d. Check crank position sensor (315 to 385 ohms). e. Check ignition coil (0.5 to 1.3 ohms). f. Replace ignition module if above items are OK. V10 Engine: a. Check for battery VDC at ignitor coil while cranking. (Red wire with green stripe.) b. Spec D − Check three fuses located on Ford engine harness power block. c. Spec D − Check B+ power connection of Ford engine harness power lead (starter motor stud − B1). d. Check crank position sensor (315 to 385 ohms). e. Check cam position sensor (315 to 385 ohms). f. Check ignition coil primary (0.5 to 1.3 ohms). g. Replace ignition module if above items are OK.
• The engine does not crank in RUN mode
  Cause: The Emergency Stop switch has been used.; A Fault Shutdown is being indicated by one of the red lights on the control panel.; Cranking voltage is too low to crank the engine.
  Fix: Pull the Emergency Switch button. To reset the engine con-; Service the set as necessary. To reset the engine control, push the Run-Stop-Remote switch to Stop and the Reset switch to Reset. Then push the Run-Stop-Remote switch to Run to start the genset.; a. Clean and tighten or replace the positive (+) and negative (−) battery cable connectors and cables at the battery and the set.; b. Recharge or replace the battery. Specific gravity for a fully charged battery is approximately 1.260 at 80° F (27° C).; c. If the set is in standby service, install a battery charger.; d. Replace the engine-driven battery charging alternator if normal battery charging voltage (12 to 14 VDC) is not obtained.
• The engine cranks but does not start.
  Fix: 10. Incorrect main fuel valve adjustment. Refer to Gaseous Fuel Adjustment (Type A or B) in Section 6. 11. Incorrect secondary regulator adjustment. Refer to Initial Secondary Regulator Adjustment in Section 6.
• The Emergency Stop switch has been used. (The switch button is lit.)
  Fix: Pull the Emergency Switch button. To reset the engine control, push the Run-Stop-Remote switch to Stop and the Reset switch to Reset. Then push the Run-Stop-Remote switch to Remote.
• Same as Steps 3 through 11 in the RUN mode.
  Fix: See steps 3 through 11 in table Engine Does Not Crank In Run Mode.
• Incorrect secondary regulator adjustment. 11
  Fix: Refer to Initial Secondary Regulator Adjustment in Section 6.
• Incorrect main fuel valve adjustment. 10
  Fix: Refer to Gaseous Fuel Adjustment (Type A or B) in Section 6.
• Cranking voltage is too low to reach required cranking speed. 6
  Fix: A. While cranking the engine, measure voltage directly across the battery terminals and then immediately across the starter motor terminal and the grounding bolt on the block. Cable, terminal or relay contact resistance is too high if the difference is more than 2 volts. Service as necessary. b. Recharge or replace the battery. Specific gravity for a fully charged battery is approximately 1.260 at 80° F (27° C). c. Replace the engine-driven battery charging alternator if normal battery charging voltage is not between 12 and 14 volts.

Compiled from service & troubleshooting documentation across every generator set that uses the Cummins/Onan Ford Engine Model.