The Cummins/Onan C33 D5 is a 3.3 L naturally aspirated engine. It powers generator sets from Cummins/Onan.
Also known as: Cummins C33 D5
| Displacement | 3.3 L |
|---|---|
| Aspiration | naturally aspirated |
How to read your Cummins/Onan engine serial & model number →
| Code | Meaning | Cause | Remedy |
|---|---|---|---|
| 81 u | Generator set output frequency cannot be maintained. | ||
| 59 | High AC voltage shutdown (Output voltage on any phase exceeds pre-set values). | ||
| 27 | Low AC voltage shutdown (Voltage on any phase has dropped below a preset value). | ||
| 96 | Lamp: Shutdown | Indicates that the engine oil temperature is above normal and has reached the shutdown trip point. | |
| 202 | Lamp: Warning | Indicates engine is operating near cooling system capacity (monitor condition). Increase in load or higher ambient temperature may cause High Coolant Temp (1) shutdown. | Review code 1 correction list for other possible causes. |
| Symptom | Cause | Remedy |
|---|---|---|
| Output voltage on any phase exceeds pre-set values. | Values adjustable from 105-125% of nominal voltage, with time delay adjustable from 1-10 seconds. Default value is 110% for 5 seconds. | |
| Voltage on any phase has dropped below a preset value. | Adjustable over a range of 50-95% of voltage, time delay 2-20 seconds. Default value is 90% for 5 seconds. | |
| Low oil pressure or high coolant temperature | The control (with graphical display) will light a yellow Warning lamp or a red Shutdown lamp and display a message on the graphical display. A control without the graphical display indicates a shutdown condition by intermittent flashing of the status indicator. | |
| Unexpected start-up or failure to crank | Remote input | Verify that the remote input is not causing the symptom or isolate the control from these inputs before troubleshooting the control. |
| Equipment damage due to wrong calibration file | Do not swap Baseboards from another genset model and only use the calibration file shown on the nameplate. | |
| Features not available for troubleshooting base board | Confirm that the feature is installed and enabled prior to trouble-shooting the base board for symptoms related to a feature. | |
| Shutdown condition | Make sure that parameter adjustments and time delays, related to the fault condition, have been appropriately set for the application. It may be necessary to write the initial capture file to the device or update the calibration file. | |
| Shutdown or unexpected start-up | Press the button to switch to the Off mode. Turnoff or remove AC power from the battery charger. Remove the negative (–) battery cable from the generator set starting battery. | |
| L not start in remote mode, but starts in manual mode. | The remote start switch or configurable wiring is faulty. | Reset the control. Attempt to start, and check for ground at TB1-11. If ground level is not present, isolate to the remote switch or configurable wiring. Repair as necessary. If ground is present, go to next step. |
| The menu display Auto button, harness or the Base board is bad. | Check for continuity between P11-16 (AUTO) to P11-8 (GND). If no continuity when pressing the menu display Auto button, isolate to front membrane panel or wiring harness. If there is continuity, the Base board is bad. | |
| Increase in load or higher ambient temperature may cause High Coolant Temp (1) shutdown. | Review code 1 correction list for other possible causes. |
Fault codes and symptom→remedy steps extracted from this engine’s service/owner documentation; verify against the official manual before servicing.
Compiled from service & troubleshooting documentation across every generator set that uses the Cummins/Onan C33 D5.
| Type | Item | Value | Unit | Condition |
|---|---|---|---|---|
| Resistance | Coolant heater coil resistance | 10 to 60 | ohms | closed heater |
| Resistance | Injection pump actuator resistance | 2.3 | ohms | |
| Resistance | Main rotor resistance | 0.415 | Ohms | within 10% of value |
| Resistance | Main rotor resistance | 0.437 | Ohms | within 10% of value |
| Resistance | Main rotor resistance | 0.465 | Ohms | within 10% of value |
| Resistance | Main rotor resistance | 0.545 | Ohms | within 10% of value |
| Resistance | Main rotor resistance | 0.551 | Ohms | within 10% of value |
| Resistance | Main rotor resistance | 0.657 | Ohms | within 10% of value |
| Resistance | Main rotor resistance | 0.67 | Ohms | within 10% of value |
| Resistance | Main rotor resistance | 0.708 | Ohms | within 10% of value |
| Resistance | Main rotor resistance | 0.857 | Ohms | within 10% of value |
| Resistance | Main rotor resistance | 0.89 | Ohms | within 10% of value |
| Resistance | Main rotor resistance | 0.983 | Ohms | within 10% of value |
| Resistance | Main rotor resistance | 0.99 | Ohms | within 10% of value |
| Resistance | Main stator winding resistance | 0.3 | Ohms | |
| Resistance | Main stator winding resistance | 0.353 | Ohms | |
| Resistance | Main stator winding resistance | 0.51 | Ohms | |
| Resistance | Main stator winding resistance | 0.625 | Ohms | |
| Resistance | Main stator winding resistance | 0.95 | Ohms | |
| Resistance | Main stator winding resistance | 1.33 | Ohms | |
| Resistance | Main stator winding resistance | 1.908 | Ohms | |
| Resistance | Stator insulation resistance | 1.0 | Meg-Ohm | minimum to Earth (Ground) |
| Torque | AVR cover to NDE bracket | 5 | Nm | |
| Torque | AVR to NDE bracket | 5 | Nm | |
| Torque | Axial air inlet cover to NDE bracket | 5 | Nm | |
| Torque | Clamping spacer to rectifier hub | 2.8/3.6 | Nm | |
| Torque | Coupling disc to flywheel | 51 | Nm | |
| Torque | Coupling disc to shaft | 75 | Nm | |
| Torque | DE Adaptor to Flywheel housing | 51 | Nm | |
| Torque | DE Adaptor to frame blocks | 26 | Nm | |
| Torque | DE Air outlet cover | 6.5 | Nm | |
| Torque | Diode fitting | 2.8/3.6 | Nm | |
| Torque | Diode fitting torque | 36 to 42 | in-lbs (4 to 4.8 Nm) | |
| Torque | EBG Housing cover to housing | 6.5 | Nm | |
| Torque | EBG Rtr to shaft | 50 | Nm | |
| Torque | EBG Str Hsg to NDE bracket | 10 | Nm | |
| Torque | EBG Str to EBG Str Hsg | 10 | Nm | |
| Torque | Earth lead to NDE bracket | 6 | Nm | |
| Torque | Excitor stator to NDE bracket | 10 | Nm | |
| Torque | Fan to fan hub 290 and 344 | 5 | Nm | |
| Torque | Main rotor terminals | 24 | in-lbs (2.7 Nm) | |
| Torque | NDE bracket to Frame blocks | 26 | Nm | |
| Torque | Pigtail terminals | 24 | in-lbs (2.7 Nm) | |
| Torque | Radial Inlet cover to Nde bracket | 5 | Nm | |
| Torque | Rectifier hub to excitor rotor | 2.8/3.6 | Nm | |
| Torque | Rotor leads to Clamping spacer | 2.8/3.6 | Nm | |
| Torque | Small Terminal box to NDE bracket | 5 | Nm | |
| Torque | Stator Lead to terminal studs | 6.5 | Nm | |
| Torque | Surge suppresser terminals | 24 | in-lbs (2.7 Nm) | |
| Torque | Terminal block to NDE bracket | 5 | Nm | |
| Torque | Terminal box lid to terminal box | 5 | Nm | |
| Torque | Varistor to rectifier hub | 2.8/3.6 | Nm | |
| Voltage | MPU output while cranking | 3.5 to 15 | VAC | while cranking |
| Voltage | Oil pressure sender output | 0.5 | VDC | at 0 psi |
| Voltage | Oil pressure sender output | 4.5 | VDC | at 100 psi |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| Fluid | Grade | Standard | Ambient | Capacity | Notes |
|---|---|---|---|---|---|
| Fuel | Number 2 diesel fuel | Direct injection |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| Code | Name | Meaning | Severity | Action |
|---|---|---|---|---|
| 1 | HIGH COOLANT TEMP | Engine has overheated; coolant temperature has risen above shutdown trip point. | Shutdown | Allow engine to cool. Check coolant level, airflow obstructions, fan belt, blower and circulation pumps. Reset and restart. |
| 12 | HIGH AC VOLTAGE | One or more phase voltages exceeded 130% of nominal for 0 second, or exceeded high AC voltage threshold for time delay. | Shutdown | Check fault simulation, block load removal, threshold setting, Base board or generator, voltage sense connections. |
| 121 | Speed Signal Lost - Shutdown | Shutdown | ||
| 13 | LOW AC VOLTAGE | One or more phase voltages dropped below low AC voltage threshold for time delay. | Shutdown | Check fault simulation, threshold, overload, output connections, excitation inputs, rotating rectifier diodes, connector or Base board. |
| 1311 | CUST_FAULT #1 - Warning | Warning | ||
| 1312 | CUST_FAULT #2 - Warning | Warning | ||
| 1317 | CUST_FAULT #3 - Warning | Warning | ||
| 135/141 | Oil Pressure Sensor OOR - Warning | Warning | ||
| 14 | OVER FREQUENCY | Frequency is 10% above base frequency for approximately 10 seconds. | Shutdown | Check threshold, fuel or air delivery, governor, connector or Base board. |
| 143 | Pre-Low Oil Pressure - Warning | Warning | ||
| 1438 | Fail to Crank - Shutdown | Shutdown | ||
| 1442 | Weak Battery - Warning | Warning | ||
| 1446 | High AC Voltage - Shutdown | Shutdown | ||
| 1447 | Low AC Voltage - Shutdown | Shutdown | ||
| 1448 | Under Frequency - Shutdown | Shutdown | ||
| 1449 | Over Frequency - Shutdown | Shutdown | ||
| 145 | Coolant Sensor OOR - Warning | Warning | ||
| 146 | Pre-High Coolant Temp - Warning | Warning | ||
| 1471 | High AC Current - Warning | Warning | ||
| 1472 | High AC Current - Shutdown | Shutdown | ||
| 15 | UNDER FREQUENCY | Engine speed dropped below 90% of nominal for approximately 10 seconds. | Shutdown | Check fuel supply, intake air supply, load, threshold, governor, connector or Base board. |
| 151 | High Coolant Temp - Shutdown | Shutdown | ||
| 1944 | Annunciator Error - Warning | Warning | ||
| 2 | LOW OIL PRESSURE | Engine oil pressure has dropped below shutdown trip point. | Shutdown | Check oil level, lines and filters; replenish if low; reset and restart; check oil switch. |
| 202 | PRE-HIGH COOL TMP | Engine is operating near cooling system capacity. | Warning | Review code 1 correction list. |
| 203 | LOW COOLANT TEMP | Engine coolant temperature is 70F (21C) or lower. | Warning | Check coolant heater power, low coolant level, heater element; check current draw. |
| 204,205 | CONFIGURABLE INPUT #1,#2 | Optional configurable input warning. | Warning | Disconnect signal lead from TB1 and reset control; check CUST_IN1 TB1-14 and CUST_IN2 TB1-12. |
| 212 | COOL SENSOR OOR | Coolant temperature sensor output is out of range (high or low). | Warning | Check sender, connectors and wires. |
| 213 | LOW BATTERY | Battery voltage supply to control is approaching a low level. | Warning | Check battery charger fuse; recharge or replace battery; clean connections; check wiring/calibration, engine DC alternator, float level. |
| 214 | HIGH BATTERY | Battery voltage supply to control is approaching a high level. | Warning | Check float level on battery charger; check battery wiring/calibration. |
| 215 | PRE-LOW OIL PRESSURE | Engine oil pressure dropped below warning trip point. | Warning | Follow code 2 procedure. |
| 216 | HIGH AC CURRENT | One or more phase currents exceeded high AC warning threshold for time delay. | Warning | Check load and load lead connections. |
| 217 | OIL PRESS SENSOR OOR | Engine oil pressure sensor output is out of range (high or low). | Warning | Check sender, connectors and wires. |
| 218 | BATTLE SHORT ACTIVE | Control is in Battle Short mode; bypasses several fault shutdowns for emergency operation. | Warning | |
| 219 | CHARGER FAILURE | Battery charging alternator has not reached acceptable voltage range within selected period (default 120 seconds). | Warning | Refer to engine service manual if fault occurs; check wiring if not failed. |
| 220 | FAIL TO SHUTDOWN | Genset continues to run after shutdown command; Battle Short feature enabled. | Warning | |
| 221 | WEAK BATTERY | During cranking, battery voltage is at or below weak battery warning trip point for time >= weak battery set time. | Warning | See code 213 for corrective action. |
| 222,223,224 | ANNUNCIATOR FAULT 1,2,3 | Optional configurable annunciator fault. | Warning | |
| 225 | ANNUNCIATOR OUTPUT CONFIGURATION ERROR | Mismatch in configuration of one of the annunciator relay outputs. | Warning | Check network setup for duplicate use of same annunciator relay output; troubleshoot network devices. |
| 2335 | Excitation Fault - Shutdown | Shutdown | ||
| 234 | Overspeed - Shutdown | Shutdown | ||
| 2677 | Fail to Stop - Shutdown | Shutdown | ||
| 27 | EXCITATION FAULT | Loss of all three voltage sense leads or failure in excitation circuit. | Shutdown | Check field wiring (X1 and X2) for shorts or opens. |
| 31 | OVERSPEED | Engine exceeded normal operating speed; default thresholds 1725 RPM (50 Hz) or 2075 RPM (60 Hz). | Shutdown | Check cold engine, single step large block load removal, fault simulation, threshold, MPU, governor, flywheel teeth, fuel stop settings. |
| 359 | Fail to Start - Shutdown | Shutdown | ||
| 38 | FIELD OVERLOAD | Field AVR Duty Cycle has been at maximum for at least 15 seconds. | Shutdown | |
| 415 | Low Oil Pressure - Shutdown | Shutdown | ||
| 441 | Low Battery - Warning | Warning | ||
| 442 | High Battery - Warning | Warning | ||
| 45 | SPEED SIGNAL LOST | No magnetic pickup pulses are sensed for Loss of Speed delay; if no MPU, speed sensing is by AC line frequency and fault cannot occur. | Shutdown | Inspect MPU wires/connector pins; test MPU for 3.5 to 15 VAC while cranking; check P11-12 to P11-24; replace Base board if needed. |
| 46 | HIGH AC CURRENT | Individual phase alternator output current exceeded high current threshold continuously for more than time delay. | Shutdown | Check load and load lead connections. |
| 61 | EMERGENCY STOP | Remote Emergency Stop. | Shutdown | Open (disable) remote emergency stop button; move rocker switch to OFF or press OFF; select desired operating mode. |
| 71 | SPEED HZ MATCH | Measured speed and measured AC output frequency do not agree. | Shutdown | Check genset setup for number of flywheel teeth. |
| 72 | FAIL TO CRANK | Genset failed to sense rotation for two start attempts; possible control, speed sensing or starting system fault. | Shutdown | Check starter, K7 starter relay, Emergency Stop switch/wiring, MPU circuit or Base board. |
| 73 | FAIL TO START | Engine cranks but fails to start; possible fuel system or air induction problem. | Shutdown | Check fuel tank, leaks, plugged fuel lines, fuel filter, air filter; reset and restart; check glow plugs and governor linkage. |
| 74 | FAIL TO STOP | Genset continues to run after receiving shutdown command from controller. | Shutdown | |
| 75,76 | CONFIGURABLE INPUT #1 & #2 | Optional configurable input fault. | Shutdown | Disconnect signal lead from TB1 and reset control; check CUST_IN1 TB1-14 and CUST_IN2 TB1-12. |
| 77 | SHUTDOWN AFTER BS | A shutdown fault occurred while Battle Short mode was enabled. | Shutdown | Check fault history for faults that may have been bypassed. |
| 81,82,83 | ANNUNCIATOR FAULT 1,2,3 | Optional configurable annunciator fault. | Shutdown |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
⚠ Hazardous voltage
⚠ Test involves unregulated excitation; disconnect loads
Tools: 12 volt battery, Jumper leads, Voltmeter
⚠ Layers of dust can cause diodes to overheat and fail.
Tools: Ohmmeter
Tools: Wheatstone bridge, Ohmmeter
Tools: Wheatstone bridge, Digital ohmmeter, Insulation resistance meter
Tools: Wheatstone bridge, Digital ohmmeter, Torque wrench
Tools: Wheatstone bridge, Insulation tester
⚠ Do not use fan blade to bar over engine.
Tools: MPU sensor, Lock nut
⚠ Electrostatic discharge will damage circuit boards.
Tools: Grounding wrist strap, InPower Service Tool, PCC1301 Interface Kit
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| Voltage | Phase | Connection | Leads | Notes |
|---|---|---|---|---|
| above 300 volts L-L | X1 & X2 | CT secondaries | CTs have dual secondaries (3 pins marked X1, X2 & X3). | |
| below 300 volts L-L | X1 & X3 | CT secondaries | CTs have dual secondaries (3 pins marked X1, X2 & X3). |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
The Cummins/Onan C33 D5 has a displacement of 3.3 liters.
The Cummins/Onan C33 D5 powers 1 generator set(s), including Cummins/Onan C33 D5.
A commonly reported issue on generators using the Cummins/Onan C33 D5 is: Voltage on any phase has dropped below a preset value.. Fix: Adjustable over a range of 50-95% of voltage, time delay 2-20 seconds. Default value is 90% for 5 seconds..