The Cummins/Onan C35 D6 is a 3.3 L naturally aspirated engine. It powers generator sets from Cummins/Onan.
Also known as: Cummins C35 D6
| Displacement | 3.3 L |
|---|---|
| Aspiration | naturally aspirated |
How to read your Cummins/Onan engine serial & model number →
| Code | Meaning | Cause | Remedy |
|---|---|---|---|
| 121 | Loss of Speed Sense (Shutdown) — No engine speed signal detected from one of two signals: engine crankshaft speed or engine camshaft position | Faulty Magnetic Pickup (MPU) sensor connections and wiring; improper installation of the MPU sensor; faulty MPU sensor; incorrect calibrations in PowerCommand controls; faulty control board; damaged flywheel ring gear | Inspect the MPU sensor and the main harness connector pins: disconnect the main harness connector from the MPU sensor; inspect for corroded, bent, broken, pushed back, expanded, or loose pins |
| 144 | Engine Coolant Temperature OOR Low (Warning) — Engine coolant temperature signal voltage is out of range – shorted low | Faulty coolant temperature sensor connections | Inspect the coolant temperature sensor and the main harness connector pins; Disconnect the main harness connector from the coolant temperature sensor; Inspect for corroded pins, bent or broken pins, pushed back or expanded pins; Inspect for evidence of moisture in or on the connector; Dry the connectors with Cummins electronic cleaner, Part Number 3824510; Inspect for missing or damaged connector seals; Inspect for dirt or debris in or on the connector pins |
| 144 | Engine Coolant Temperature OOR Low (Warning) — Engine coolant temperature signal voltage is out of range – shorted low | Faulty coolant temperature sensor | Check the resistance of the sensor; Disconnect the main harness connector from the coolant temperature sensor; Measure the resistance between the coolant temperature signal pin and the coolant temperature sensor return pin. Sensor resistance is approximately linear over two segments: 540 Ohms at -40 °F to 1100 ohms at 100 °F, and 1100 ohms at 100 °F to 1800 ohms at 230 °F. If calculated temperature differs from unit display by more than 8 °F, replace the sensor |
| Symptom | Cause | Remedy |
|---|---|---|
| Batteries can explode | Do not dispose of the battery in a fire, because it is capable of exploding. Do not open or mutilate the battery. Do not charge frozen batteries. Batteries present the risk of high short circuit current when servicing the generator set: remove watches, rings, or other metal objects; use tools with insulated handles. | |
| Exhaust gases are deadly | Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas, and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust system daily for leaks per the maintenance schedule. Ensure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment. Make sure the unit is well ventilated. | |
| Dizziness | IF YOU OR ANYONE ELSE EXPERIENCEANY 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. | |
| Muscular Twitching | IF YOU OR ANYONE ELSE EXPERIENCEANY 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. | |
| Vomiting | IF YOU OR ANYONE ELSE EXPERIENCEANY 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. | |
| Weakness and Sleepiness | IF YOU OR ANYONE ELSE EXPERIENCEANY 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. | |
| Inability to Think Coherently | IF YOU OR ANYONE ELSE EXPERIENCEANY 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. | |
| Low AC Voltage at Startup | Loss of residual magnetism in the exciter stator lamination (caused by extended storage; reversed magnetic field by flashing with wrong battery polarity; exciter stator rewind; mechanical shock (replacement)) | Restore magnetism: attach leads to a 12 VDC battery with a diode in the positive lead; run the generator at rated speed, no load; briefly (maximum one second) connect the positive lead to PCC terminal X+ (F1: P17-1) and the negative lead to PCC terminal XX- (F2: P17-2) |
| Unstable Voltage (No Load) | Engine governing unstable | Check for engine governor hunting with a frequency meter or tachometer, or cyclic irregularities in the engine with InPower; if any engine DTC fault codes are present, troubleshoot them using the E-Controls manual; check fuel supply pressure to ensure that it is consistent; ensure that the throttle assembly moves freely, clean it if necessary; check the spark plugs for buildup, ensure that a spark is present at each cylinder, repair or replace them if necessary; check for any exhaust restriction, clean or replace components as necessary; check for an intake leak, repair or replace components as necessary; check for proper function of the crankshaft and camshaft position sensors, and the wiring to the ECM from the sensors, repair or replace components as necessary; check the fuel mix control valve for proper operation, such that it can move freely and easily, clean or replace the valve if necessary |
| Unstable Voltage (No Load) | Loose or corroded connections | Check electrical connectors on terminals on the control board; check auxiliary terminals for loose connections; repair or replace as necessary |
| Unstable Voltage (No Load) | Intermittent ground on machine | Megger test all the windings, including the exciter stator; low insulation resistance can affect the PCC (disconnect the PCC before megger test) |
| Unbalanced Voltage (With Load) | Engine governing unstable | Check with frequency meter or tachometer for engine governor hunting, or cyclic irregularities in the engine with InPower; if any engine DTC fault codes are present, troubleshoot those using the E-Controls manual; check fuel supply pressure to ensure that it is consistent; ensure that throttle assembly moves freely, clean if necessary; check the spark plugs for buildup, ensure that spark is present at each cylinder, repair or replace if necessary; check for any exhaust restriction, clean or replace if necessary; check for an intake leak, repair or replace if necessary; check for proper function of the crankshaft and camshaft position sensors, and the wiring to the ECM from the sensors, repair or replace if necessary; check the Fuel mix control valve for proper operation, such that it can move freely and easily, clean or replace if necessary |
| Unstable Voltage (With Load) | Engine governing unstable | Refer to the engine service manual (if applicable) or E-Controls service manual |
| Unstable Voltage (With Load) | Leading power factor load created by power factor correction capacitors | Isolate the power factor correction capacitors until sufficient motor load has been applied to counteract the leading power factor; adjust as required if corrects the issue |
| Unstable Voltage (With Load) | Fluctuations in load current (motor starting or reciprocating loads) | Check the load current on a stable supply (i.e., mains), or separately excite the machine; a variable DC supply is required for on load separate excitation tests |
| Unstable Voltage (With Load) | Automatic voltage regulator parameters configured incorrectly | Contact your local Cummins distributor |
| Poor Voltage Regulation (With Load) | Unbalanced load | Check voltage and load current on all phases; if unbalanced, redistribute the load more evenly across the phases |
| Poor Voltage Regulation (With Load) | Voltage drop between alternator and load, caused by losses in supply cable (power losses) | Check the voltage at both ends of the cable run at full load; large differences in voltages indicate a large volts drop along the cable; a larger diameter cable is required in severe cases |
| Poor Voltage Regulation (With Load) | Fault on main rectifier or excitation winding | Check the no load excitation voltage across automatic voltage regulator X+ (F1) and XX- (F2); voltage should be no higher than 12 VDC |
| Poor Voltage Regulation (With Load) | Under frequency roll-off protection activated | Under frequency roll-off protection is activated, indicating excessive load; check that under frequency roll-off set point and slope are correct; load on generator is in excess of rated, ensure that the load on the generator set does not exceed the generator kW rating; revisit the generator set sizing process to ensure that the generator set is correctly sized for the application, especially if new loads have been introduced into the system |
| High Voltage (With Load) | Unbalanced load | Check voltage on all three phases; if unbalanced, re-distribute loading over the three phases |
| High Voltage (With Load) | Leading power factor | Check for capacitive (leading) PF load (i.e. kVA correction fluorescent lights); apply motor (lagging) PF load, or switch off capacitors; a leading power factor load will give abnormally low DC excitation volts across X+ (F1) and XX-(F2) |
| Low Voltage (With Load) | Under frequency roll-off protection activated | Under frequency roll-off protection is activated, indicating excessive load; check that under frequency roll-off set point and slope are correct; load on generator is in excess of rated, ensure that the load on the generator set does not exceed the generator kW rating; revisit the generator set sizing process to ensure that the generator set is correctly sized for the application, especially if new loads have been introduced into the system |
| Low Voltage (With Load) | Faulty permanent magnet generator (PMG) (if used) | Start the generator set and run at rated speed; measure the voltages at the terminals P2 (J18-1) and P3 (J18-2); these should be balanced and within the range of 60 Hz generators 190 to 220 V |
| Low Voltage (With Load) | Fault on winding or rotating diodes | Any fault in this area will appear as high excitation voltage across X+ (F1) and XX- (F2); remove external leads from the alternator; use appropriate metering equipment (Wheatstone bridge or Kelvin bridge) to measure the winding resistance of the main rotor and stator; check diodes; test diodes on the main rotating rectifier assembly with a multimeter |
| Low Voltage (With Load) | Voltage drop between alternator and load, due to power losses in the cable | Check the voltage at both ends of the cable run at full load; differences in voltage levels indicate a voltage drop along the cable; in severe cases, a larger diameter cable is required; this will be worse during current surges (motor starting, etc.) |
| Fault Finding: Without AVR — Test 1: Resistance from sensing leads to ground is less than 1 MΩ | Insulation resistance less than 1 MΩ | Clean the main stator, allow it to dry, and repeat the test; if the same result is achieved, replace the alternator/main stator |
| Fault Finding: Without AVR — Test 2: Exciter stator resistance across X+ (F1) and XX- (F2) is not within 10% of the relevant value in the Windings section | Stator windings are damaged | Replace the exciter stator |
| Fault Finding: Without AVR — Test 3: Megger from XX- (F2) to ground, resistance value is less than 1 MΩ | Insulation resistance less than 1 MΩ | Clean the exciter stator, allow it to dry, and repeat the test; if the same result is achieved, replace the exciter stator |
| Fault Finding: Without AVR — Test 4: AC output voltage balanced between phases within 1%, but greater than 10% below nominal | Main stator is functioning properly; fault in exciter rotor, rectifier, or related components | Proceed to Test 6; if Tests 6 and 7 already completed, proceed to Test 8 |
| Fault Finding: Without AVR — Test 4: AC output voltage unbalanced by greater than 1% | Main stator windings are faulty | Proceed to Test 5 |
| Fault Finding: Without AVR — Test 5: Winding resistances not within 10% of the relevant value from the Windings section, or not balanced within 1% | Winding resistance out of specification or unbalanced | Replace the alternator |
| Fault Finding: Without AVR — Test 6: One or more diodes do not function properly | Faulty diode(s) on the rotating rectifier | Replace all diodes, as well as the varistor; return to Test 4 |
| Fault Finding: Without AVR — Test 7: Varistor shows signs of a thermal event or measures no resistance in one or both directions | Varistor damaged or overheated | Replace all diodes and the varistor; return to Test 4 |
| Fault Finding: Without AVR — Test 8: Resistance across exciter rotor leads within 10% of the relevant value in the Windings section | Exciter rotor resistance within specification | Replace the exciter rotor/alternator assembly |
| Fault Finding: Without AVR — Test 9: Main rotor resistance more than 10% different than the relevant value from the Windings section | Main rotor resistance out of specification | Replace the main rotor/alternator assembly |
| Fault Finding: Without AVR — Test 10: One or more sense leads measure "open" | Open sense lead(s) | Replace the sensing leads |
| Fault Finding: Without AVR — Test 11: Output voltage not within 10% of nominal with EBS disconnected | EBS or control board fault | Replace the control board; proceed to Test 12 if the EBS/EBC service tool is available, if not, replace the EBS |
| Fault Finding: Without AVR — Test 12: EBS or EBC does not operate properly | Faulty EBS or EBC | Replace the faulty component |
| Fault Finding: Without AVR — Test 13: PMG voltages not 170-220V phase to phase and/or not balanced within 1% | PMG voltage out of specification or unbalanced | Proceed to Test 14 |
| Fault Finding: Without AVR — Test 14: PMG stator resistance not within 10% of the relevant value in the Windings section | PMG stator resistance out of specification | Replace the PMG stator |
| Fault Finding: Without AVR — Test 14: PMG stator resistance within 10% of the relevant value in the Windings section | PMG stator resistance within specification | Replace the PMG rotor |
| Engine Is Difficult to Start or Does Not Start | Battery voltage is low, interrupted, or open | Check the battery connections, unswitched battery supply circuit, and fuses |
| Engine Is Difficult to Start or Does Not Start | Fuel system issues | Inspect fuel lines and fuel connections for leaks, repair if leaks are found; open manual fuel valves if the manual fuel shutoff valve is closed; check the fuel shutoff valve solenoid and circuit if the fuel shutoff valve solenoid or circuit is malfunctioning |
| Engine Is Difficult to Start or Does Not Start | Air intake or exhaust issues | Check the air intake system for restriction, clean or replace the air filter and inlet piping as necessary; check the exhaust system for restrictions |
| Engine Is Difficult to Start or Does Not Start | Starting procedure/aid | Check for the correct operation of the starting aid |
| Engine Is Difficult to Start or Does Not Start | Engine speed governor issue | Refer to the engine service manual |
| Engine Is Difficult to Start or Does Not Start | Base engine problem | Check the engine for high crankcase pressure, low compression, damaged pistons, camshaft, and other parts; refer to the engine service manual |
| Engine Experiences Low Power, Poor Acceleration, or Poor Response | Excessive load | Ensure that the load on the generator set does not exceed the generator set kW rating; revisit the generator set sizing process to ensure that the generator set is correctly sized for the application, especially if new loads have been introduced into the system |
| Engine Experiences Low Power, Poor Acceleration, or Poor Response | Fuel system issues | Inspect fuel lines, fuel connections, and fuel filters for leaks, repair if leaks found; check the fuel shutoff valve solenoid and circuit if the fuel shutoff valve solenoid or circuit is malfunctioning |
| Engine Experiences Low Power, Poor Acceleration, or Poor Response | Air intake or exhaust issues | Check the air intake system for restriction, clean or replace the air filter and inlet piping as necessary; inspect the air intake and exhaust systems for air leaks; check the exhaust system for restrictions |
| Engine Experiences Low Power, Poor Acceleration, or Poor Response | Engine speed governor issue | Refer to the engine service manual |
| Engine Experiences Low Power, Poor Acceleration, or Poor Response | Other issues | Generator set power decreases above recommended altitude, refer to the Generator Set Data Sheet for the specific generator set for specifications; verify governor settings in the control if engine calibration values set in the control are not correct; check the engine for high crankcase pressure, low compression, damaged pistons, camshaft, and other parts, refer to the engine service manual |
| Engine Runs Rough or Misfires | Air intake or exhaust issues | Check the air intake system for restriction, clean or replace the air filter and inlet piping as necessary; check the exhaust system for restrictions |
| Engine Runs Rough or Misfires | Fuel system leaks | Inspect fuel lines, fuel connections, and fuel filters for leaks, repair if leaks found |
| Engine Runs Rough or Misfires | Engine speed governor issue | Refer to the engine service manual |
| Engine Runs Rough or Misfires | Base engine problem | Check the engine for high crankcase pressure, low compression, damaged pistons, camshaft, and other parts; refer to the engine service manual |
| Engine Shuts Off Unexpectedly or Dies During Deceleration | Emergency Stop/Remote Emergency Stop energized | Verify that either the Emergency Stop or the Remote Emergency Stop circuit is not energized |
| Engine Shuts Off Unexpectedly or Dies During Deceleration | Fuel system issues | Check the fuel supply for appropriate pressure and flow; verify that the fuel system valves are open if the manual fuel shutoff valve is closed |
| Engine Shuts Off Unexpectedly or Dies During Deceleration | Engine speed governor issue | Refer to the engine service manual |
| Engine Shuts Off Unexpectedly or Dies During Deceleration | Base engine problem | Check the engine for high crankcase pressure, low compression, damaged pistons, camshaft, and other parts; refer to the engine service manual |
| Engine Speed Surges Under Load or in Operating Range | Fuel system issues | Inspect fuel lines and fuel connections for leaks, repair if leaks found; verify that the fuel system valves are open if the manual fuel shutoff valve is closed; check the engine governor actuator and circuit if the engine governor actuator or circuit is malfunctioning |
| Engine Speed Surges Under Load or in Operating Range | Engine speed governor issue | Refer to the engine service manual |
| Engine Speed Surges Under Load or in Operating Range | Other issues | Dry the connectors with Cummins electronic cleaner, Part Number 3824510, if moisture is in the wiring harness connectors; check the engine for high crankcase pressure, low compression, damaged pistons, camshaft, and other parts, refer to the engine service manual |
| Poor Engine Transient Response | Excessive loads | Make sure that the load on the generator set does not exceed the generator set KW rating; re-visit the generator set sizing process to make sure that the generator set is correctly sized for the application, especially if new loads have been introduced into the system |
| Poor Engine Transient Response | Fuel system issues | Inspect fuel lines, fuel connections, and fuel filters for leaks, repair if leaks found; refer to the procedures in the troubleshooting and repair manual for the specific engine |
| Poor Engine Transient Response | Air intake or exhaust issues | Inspect the air intake and exhaust systems for air leaks; check the air intake system for restriction, clean or replace the air filter and inlet piping as necessary; check the exhaust system for restrictions; monitor the turbocharger boost pressure if the turbocharger is malfunctioning |
| Poor Engine Transient Response | Other issues | Engine power decreases above recommended altitude, refer to the Generator Set Data Sheet for the specific generator set for specifications; check engine-driven units for correct operation and check the cooling fan for correct operation and cycle time if engine parasitics are excessive; verify the governor settings in the control if the engine calibration values set in the control are not correct; check the engine for high crankcase pressure, low compression, damaged pistons, damaged camshaft, and other damaged parts |
| Engine Will Not Reach Rated Speed (RPM) | Excessive loads | Ensure that the load on the generator set does not exceed the generator set KW rating; re-visit the generator set sizing process to ensure that the generator set is correctly sized for the application, especially if new loads have been introduced into the system |
| Engine Will Not Reach Rated Speed (RPM) | Air intake or exhaust issues | Check the air intake system for restriction, clean or replace the air filter and inlet piping as necessary; check the exhaust system for restrictions |
| Engine Will Not Reach Rated Speed (RPM) | Engine speed governor issue | Refer to the engine service manual |
| Engine Will Not Reach Rated Speed (RPM) | Other issues | Generator set power decreases above the recommended altitude, refer to the Generator Set Data Sheet for the specific generator set for specifications; check the engine for high crankcase pressure, low compression, damaged pistons, camshaft, and other parts, refer to the engine service manual |
| Engine Noise Is Excessive | Lubrication issue(s) | Check the oil level and fill the system to the specified level if lubricating oil level is below specification; check the oil pressure if lubricating oil pressure is below specification; analyze the oil if lubricating oil is thin or diluted |
| Engine Noise Is Excessive | Cooling issue(s) | Check the coolant level if coolant temperature is above specification; check the fan drive belt if the fan drive belt is loose, tight, or not in alignment |
| Engine Noise Is Excessive | Air intake or exhaust leaks | Inspect the air intake and exhaust systems for air leaks |
| Engine Noise Is Excessive | Worn mounts | Check the engine mounts if engine mounts are worn, damaged, or incorrect |
| Engine Noise Is Excessive | Base engine problem | Check the engine for high crankcase pressure, low compression, damaged pistons, camshaft, and other parts; refer to the engine service manual |
Fault codes and symptom→remedy steps extracted from this engine’s service/owner documentation; verify against the official manual before servicing. Showing the first 80 of 274 entries.
Compiled from service & troubleshooting documentation across every generator set that uses the Cummins/Onan C35 D6.
Step-by-step procedures compiled from the Cummins/Onan service manual for this engine.
| Item | Action | Hours | Months | Notes |
|---|---|---|---|---|
| Exhaust system | Inspect | 8 hr | Visually and audibly inspect the exhaust system daily for leaks per the maintenance schedule; check for corrosion, obstruction, and leaks every time you start the generator set and every eight hours when you run it continuously | |
| Air cleaner restriction indicator | Check | 24 hr | If service indicator shows red, replace air cleaner elements and reset indicator. | |
| Coolant heater | Check | 24 hr | Verify power and operation; check for leaks. | |
| Coolant level of radiator(s) | Check | 24 hr | Top up with Cummins recommended coolant mix if low. | |
| Engine oil level | Check | 24 hr | Top up with recommended oil if low. | |
| Fuel level in fuel tank | Check | 24 hr | Refill as required. | |
| Fuel lines and hoses | Check | 24 hr | Check for leaks, worn or damaged hoses. | |
| Generator set enclosure | Inspect | 24 hr | Walk-around; ensure no inlets/outlets covered. | |
| Operator panel operation | Check | 24 hr | Check display; replace component if not functioning. | |
| Air intake system for leaks | Inspect | 50 hr | Visually inspect; check audibly when running. | |
| Battery connections | Check | 50 hr | Verify connections are secure. | |
| Charge alternator | Check | 50 hr | Check visually and audibly when running. | |
| Coolant lines and radiator hoses | Check | 50 hr | Check for leaks, wear, and cracks. | |
| Cooling fan blades | Inspect | 50 hr | Visually inspect through guarding. | |
| Drive belt condition and tension | Check | 50 hr | Check for wear or slippage. | |
| Exhaust components and hardware | Check | 50 hr | Visually inspect; check audibly when running. | |
| Radiator air flow | Inspect | 50 hr | Check for blockage, debris, wear or damage. | |
| Engine oil and filters | Replace | 200 hr | First service — After the initial 50 hour interval and every 200 hours thereafter (footnote 3). | |
| Fuel filter and water separator | Replace | 500 hr | ||
| Cooling system coolant | Replace | 24 mo |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| Type | Item | Value | Unit | Condition |
|---|---|---|---|---|
| Gap | MPU sensor tip to ring gear teeth clearance | 0.5 - 0.6 | mm | |
| Other | AFLEX-H (shake table test datum) | <=3.200 | g | AC156, tri-axial, 5% damping SRS |
| Other | AFLEX-V (shake table test datum) | <=1.333 | g | AC156, tri-axial, 5% damping SRS |
| Other | ARIG-H (shake table test datum) | <=2.400 | g | AC156, tri-axial, 5% damping SRS |
| Other | ARIG-V (shake table test datum) | <=0.533 | g | AC156, tri-axial, 5% damping SRS |
| Other | Flywheel teeth (Teeth Pulses Per Revolution) | 110 | PCC setting | |
| Other | Glow plug preheat time | 5 | glow plug calibration | |
| Other | Glow plug total glow plug time | 60 | glow plug calibration | |
| Other | Ground snow load limit | 30 | psf | For indoor (covered) and outdoor (exposed) installation |
| Other | Horizontal design seismic coefficient (z/h = 0.0) | 1.440 | g | Certified seismic design level, IBC Importance IP <= 1.5, Soil Classes A-E, Risk Categories I-IV, Design Categories A-F, SDS <= 2.000 g |
| Other | SDS (g) at z/h=1 for C10 D6 - C60 D6 | 2.0 | g | Certified SDS, z/h = 1 |
| Other | SDS (g) at z/h=1 for C50 D6C - C125 D6C | 2.5 | g | Certified SDS, z/h = 1 |
| Other | Speed/frequency mismatch threshold | 2.0 | Hz | PCC setting |
| Other | Speed/frequency mismatch threshold time | 1.5 | seconds | PCC setting |
| Other | ZPA-H (shake table test datum) | <=2.160 | g | AC156, tri-axial, 5% damping SRS |
| Other | ZPA-V (shake table test datum) | <=0.480 | g | AC156, tri-axial, 5% damping SRS |
| Resistance | Battery ground connection resistance | more than 1 | Ohm | indicates repair needed |
| Resistance | Coolant heater coil resistance | 10 to 60 | ohms | closed heater |
| Resistance | Coolant temperature sensor resistance | 540 Ohms at -40 F to 1100 Ohms at 100 F; 1100 Ohms at 100 F to 1800 Ohms at 230 F | Ohm | |
| Resistance | Diode reverse direction resistance (good) | above 20 | MOhm | reverse direction at 1000 VDC |
| 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 | Starter solenoid wiring continuity (relay 87 to SW) | less than 5 | Ohm | |
| Resistance | Stator insulation resistance | 1.0 | Meg-Ohm | minimum to Earth (Ground) |
| Resistance | Temperature sender harness lead resistance | less than 0.5 | Ohm | each lead from connection to PCC |
| Resistance | Varistor resistance (good) | greater than 100 | MOhm | |
| Resistance | Winding test conditions | 20 | C | winding temperature for insulation measurement |
| Resistance | Windings minimum insulation resistance (in-service) | 5 | MOhm | 1 minute at 500 V test voltage |
| Resistance | Windings minimum insulation resistance (new) | 10 | MOhm | 1 minute at 500 V test voltage |
| Speed | Frequency-to-speed gain select | 30 | RPM/Hz | PCC setting |
| Speed | Overspeed Trip Level (60 Hz) | 2250 | PCC threshold | |
| Speed | Secondary Overspeed Trip Speed (60 Hz) | 2250 | PCC threshold | |
| Speed | Starter Disconnect Speed | 400 | RPM | InPower setting |
| Speed | Starter Disconnect Speed (code 5134) | 450 | RPM | InPower setting |
| Temperature | High coolant temperature shutdown threshold | 230 F / 110 | C | shutdown |
| Temperature | High coolant temperature warning threshold | 220 F / 105 | C | warning |
| Temperature | Low coolant temperature warning threshold | 70 F (21 C) | 4BT3.3 engines | |
| Torque | AVR cover to NDE bracket | 5 | Nm | |
| Torque | AVR to NDE bracket | 5 | Nm | |
| Torque | Air cleaner strap clamp | 3.4 to 4.5 | Nm | |
| Torque | Alternator drive disc bolt and adaptor bolt (section 12.5) | 52 +/- 5 | Nm | |
| Torque | Alternator drive disc bolts and adaptor bolts | 47 to 57 | Nm |
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 |
|---|---|---|---|---|---|
| Coolant | 50/50 coolant solution (50% pure water and 50% ethylene glycol) | ||||
| Coolant | 50/50 coolant solution (50% water / 50% ethylene glycol) | ||||
| Engine oil | 15W40 | 7.9 L (8.35 qt) | Refer to the Engine Operator Manual | ||
| Fuel | ASTM number 2D fuel | ASTM 2D | |||
| Fuel | Number 2 diesel fuel | Direct injection | |||
| Grease | Dow Corning silicone heat sink compound type 340 or similar | Apply to base of replacement diode only |
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. |
| 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. |
| 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. |
| 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. |
| 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. |
| 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. |
| 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. |
| 38 | FIELD OVERLOAD | Field AVR Duty Cycle has been at maximum for at least 15 seconds. | Shutdown | |
| 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 | |
| 121 | Loss of Speed Sense | No engine speed signal detected from crankshaft speed or camshaft position. | Shutdown | Inspect MPU sensor and harness; set MPU tip clearance 0.5-0.6 mm; verify calibration. |
| 135 | Oil Pressure Sensor OOR - High | Engine oil pressure sensor signal out of range - shorted high. | Warning | Inspect sensor connections; check supply 4.75-5.25 VDC and signal voltage. |
| 135/141 | Oil Pressure Sensor OOR - Warning | Warning | ||
| 141 | Oil Pressure Sensor OOR - Low | Engine oil pressure sensor signal out of range - shorted low. | Warning | Inspect sensor connections; check supply and signal voltage. |
| 143 | Engine Oil Pressure Low | Engine oil pressure below low oil pressure warning threshold (40 psig for 5 seconds). | Warning | Check oil level, external leaks, sensor accuracy, oil cooler, regulator, oil pump. |
| 144 | Engine Coolant Temperature OOR Low | Engine coolant temperature signal out of range - shorted low. | Warning | Inspect sensor connections; check sensor resistance; verify calibration. |
| 145 | Engine Coolant Temperature OOR High | Engine coolant temperature signal out of range - shorted high. | Warning | Inspect sensor connections; check sensor resistance; verify calibration. |
| 146 | Engine Coolant Temperature Above Normal | Engine coolant temperature exceeded warning threshold (220 F / 105 C). | Warning | Check ambient temperature, coolant level, cooling components, sensor, thermostat, water pump. |
| 151 | Engine Coolant Temperature High | Engine coolant temperature exceeded shutdown threshold (230 F / 110 C). | Shutdown | Check cooling system, coolant level, sensor, thermostat, water pump. |
| 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. |
| 234 | Engine Speed High | Engine speed signals indicate engine speed greater than shutdown threshold. | Shutdown | Check MPU sensor and installation; verify overspeed trip level and flywheel teeth (110). |
| 359 | Engine Fail to Start | Engine failed to start after expiration of last crank time. | Shutdown | Check flywheel teeth setting (110), starter disconnect speed (400 RPM), fuel supply, glow plugs. |
| 415 | Engine Oil Pressure Low | Engine oil pressure below low oil pressure shutdown threshold (35 psig). | Shutdown | Check oil level, external leaks, sensor accuracy, oil cooler, oil pump. |
| 441 | Low Battery Voltage | Battery voltage is low. | Warning | Check battery cables, battery condition, ground connection, DC alternator, charger. |
| 442 | High Battery Voltage | Battery voltage above high battery threshold (16 V for 60 seconds). | Warning | Verify charger set to 12 VDC; check fault threshold; check engine DC alternator. |
| 1311 | Customer Input #1 | Configurable customer input 1 fault. | Warning | Check TB1-12; check external wiring; verify fault function settings. |
| 1312 | Customer Input #2 | Configurable customer input 2 fault. | Warning | Check TB1-14; check external wiring; verify fault function settings. |
| 1317 | Low Coolant Level | Optional coolant level sensor indicates low coolant level. | Warning | Add coolant; check coolant level sensor connections and operation; verify calibration. |
| 1318 | Low Fuel | Optional low fuel level switch indicates low fuel. | Warning | Add fuel; verify switch operation; check wiring; verify settings. |
| 1417 | Power Down Failure | The PCC has failed to go to sleep. | Warning | Verify calibration; cycle B+ power; replace baseboard if fault persists. |
| 1433 | Local E-Stop | State of the Local Emergency Stop has been changed. | Shutdown | Reset local E-Stop; check E-Stop switch and wiring. |
| 1434 | Remote E-Stop | State of the Remote Emergency Stop has been changed. | Shutdown | Reset remote E-Stop; install jumper TB1-16 to TB1-15; check switch and wiring. |
| 1435 | Low Coolant Temperature | Engine coolant temperature below low coolant temperature warning threshold (70 F / 21 C). | Warning | Verify LCT threshold; check coolant heater operation; check ambient temperature. |
| 1438 | Fail to Crank | Engine failed to crank after the generator control received a start signal. | Shutdown | Check battery, starter, starter solenoid, starter relay, CAM/Crank sense. |
| 1442 | Weak Battery | Battery voltage dropped below weak battery voltage threshold (8 V for 2 seconds) while cranking. | Warning | Check battery, connections, charging voltage, DC alternator, harness. |
| 1446 | High AC Voltage | One or more phase voltages exceeded high AC voltage threshold (110% of nominal, 10 seconds). | Warning | Check threshold, PCC AVR circuit, generator output connections, PMG, EBS. |
| 1447 | Low AC Voltage | One or more phase voltages dropped below low AC voltage threshold (85%, 10 seconds). | Shutdown | Check AVR settings, rotating rectifier diodes, overload, residual magnetism, connections. |
| 1448 | Underfrequency | Frequency dropped below underfrequency threshold (6 Hz) for 10 seconds. | Shutdown | Check overrides, threshold, overload, engine governor. |
| 1449 | Overfrequency | Frequency went above overfrequency threshold (6 Hz) for 10 seconds. | Shutdown | Verify overfrequency threshold and time delay; check engine governor. |
| 1469 | Speed/Hz Mismatch | Perceived engine speed and generator set output frequency do not match. | Shutdown | Check flywheel teeth (110), MPU signal, thresholds (2.0 Hz, 1.5 s), gain (30 RPM/Hz). |
| 1471 | High AC Current | Generator output current exceeded warning limit threshold (110% for 60 seconds). | Warning | Check for short, overload, CTs and CT setup, rating setup, fault override. |
| 1472 | High AC Current | Generator output current exceeded shutdown set limit (150% for 10 seconds). | Shutdown | Check for short/overload, CTs and CT setup, rating setup, fault override. |
| 1853 | Annunciator Input 1 Fault | Customer fault 1 (input 1, LED 1) on the universal annunciator is active. | Warning | Check condition and wiring at TB1-1; verify configuration; replace annunciator if faulty. |
| 1854 | Annunciator Input 2 Fault | Customer fault 2 (input 2, LED 2) on the universal annunciator is active. | Warning | Check condition and wiring at TB1-2; verify configuration; replace annunciator if faulty. |
| 1855 | Annunciator Input 3 Fault | Customer fault 3 (input 3, LED 3) on the universal annunciator is active. | Warning | Check condition and wiring at TB1-3; verify configuration; replace annunciator if faulty. |
| 1944 | Annunciator Configuration Error | More than one network device configured to activate one annunciator output relay. | Warning | Check network configuration and devices for duplicate use of the same relay output. |
| 2335 | Excitation Fault (Loss of AC Sense) | Control lost voltage sensing or lost zero cross sensing. | Shutdown | Check configuration, fuse F5 (10 Amp), harness connections, residual magnetism, excitation coil, control board. |
| 2676 | Alternator Frequency Conflict | Alternator line frequency and alternator excitation frequency do not match. | Shutdown | Check alternator line frequency gain; check J22 and J18 connections; check harness and control board. |
| 2677 | Fail to Stop | Generator set continues to run after receiving shutdown command from controller. | Shutdown | Check stuck fuel actuator/fuel shutoff valve; check governor module and wiring. |
| 2729 | IO Module Lost | Intermittent data link between I/O module and PCC (no input fault levels set to Shutdown). | Warning | Check AUX 101 wiring to PCC 1302; verify System IO Board Enable is disabled. |
| 2731 | IO Module Lost | Intermittent data link between I/O module and PCC (at least one input fault set to Shutdown). | Shutdown | Check AUX 101 wiring to PCC 1302; verify I/O settings. |
| 2897 | Factory Memory Block Corrupt | The control detected a corrupted memory block. | Warning | Connect with InPower 10.0+; select Initial Calibration (Recover Device). |
| 2898 | Periodic or Fault Memory Block Corrupt | The control detected a corrupted memory block. | Warning | Connect with InPower 10.0+; select Initial Calibration (Recover Device). |
| 2899 | User Memory Block Corrupt | The control detected a corrupted memory block. | Warning | Connect with InPower 10.0+; select Initial Calibration (Recover Device). |
| 2911 | Trim Memory Block Corrupt | The control detected a corrupted memory block. | Warning | Connect with InPower 10.0+; select Initial Calibration (Recover Device). |
| 2972 | Field Overload | Field AVR Duty Cycle operated at maximum output longer than Max Field Time parameter. | Shutdown | Check voltage sensing into baseboard; check AVR output; check application. |
| 5134 | Unknown Shutdown | PCC detected that engine RPM decreased to zero while not in run at rated mode. | Shutdown | Check calibration, air intake/exhaust restriction, MPU signal, start disconnect, fuel supply. |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
⚠ Must be performed by a qualified technician.
Tools: InPower service tool
⚠ 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
⚠ Improper installation can lead to electrocution and property damage.
Tools: Insulated wrench, Torque wrench
⚠ Do not connect battery cables until installation is complete to prevent accidental startup.
⚠ Accidental or remote starting of the generator set can cause severe personal injury or death.
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 C35 D6 has a displacement of 3.3 liters.
The Cummins/Onan C35 D6 powers 1 generator set(s), including Cummins/Onan C35 D6.
A commonly reported issue on generators using the Cummins/Onan C35 D6 is: Low Battery Voltage — Battery voltage is low. Cause: Damaged battery cable connections. Fix: Inspect the battery cable connections for loose connections and/or corrosion, and repair as necessary.