The Cummins/Onan C38 D5 is a 3.3 L naturally aspirated engine. It powers generator sets from Cummins/Onan.
Also known as: Cummins C38 D5
| Displacement | 3.3 L |
|---|---|
| Aspiration | naturally aspirated |
How to read your Cummins/Onan engine serial & model number →
| Code | Meaning | Cause | Remedy |
|---|---|---|---|
| 1 | HIGH COOLANT TEMP — Lamp: Shutdown; Indicates engine has overheated (coolant temperature has risen above the shutdown trip point) | Allow engine to cool down completely before proceeding with the following checks: Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary; Check for obstructions to cooling airflow and correct as necessary; Check fan belt and repair or tighten if necessary; Check blower fan and circulation pumps on remote radiator installations; Reset control and restart after locating and correcting problem. | |
| 2 | LOW OIL PRESSURE — Lamp: Shutdown; Indicates engine oil pressure has dropped below the shutdown trip point | Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Reset control and restart. If oil switch is used, check switch performance. | |
| 12 | HIGH AC VOLTAGE — Lamp: Shutdown; Indicates that one or more of the phase voltages has exceeded 130% of nominal for 0 second, or has exceeded high ac voltage threshold of nominal for time delay seconds | ||
| 13 | LOW AC VOLTAGE — Lamp: Shutdown; Indicates that one or more of the phase voltages has dropped below low ac voltage threshold for time delay seconds | ||
| 14 | OVER FREQUENCY — Lamp: Shutdown; Indicates frequency is 10% above base frequency for approximately 10 seconds | ||
| 15 | UNDER FREQUENCY — Lamp: Shutdown; Indicates that engine speed has dropped below 90% of nominal for approximately 10 seconds | Check fuel supply, intake air supply and load. | |
| 27 | EXCITATION FAULT — Lamp: Shutdown; Indicates a loss of all three voltage sense leads or failure in excitation circuit | Check field wiring (X1 and X2) for shorts or opens. (Refer to Section 7.) | |
| 38 | FIELD OVERLOAD — Lamp: Shutdown; Indicates that the Field AVR Duty Cycle has been at the maximum for at least 15 seconds | ||
| 45 | SPEED SIGNAL LOST — Lamp: Shutdown; Indicates that no magnetic pickup pulses are sensed for a Loss of Speed delay. If a magnetic pickup is not installed, then speed sensing is performed by monitoring AC line frequency, this fault cannot occur | ||
| 46 | HIGH AC CURRENT — Lamp: Shutdown; Indicates that an individual phase of alternator output current has exceeded high current threshold of the rated output current continuously for more than time delay seconds | Check load and load lead connections. | |
| 61 | EMERGENCY STOP — Lamp: Shutdown; Indicates remote Emergency Stop | To reset the remote Emergency Stop button: Open (disable) remote emergency stop button; Move the rocker switch to the OFF position or press the OFF button; Select the desired operating mode (manual or remote). | |
| 71 | SPEED HZ MATCH — Lamp: Shutdown; Indicates that measured speed and measured AC output frequency do not agree | Check genset setup for number of flywheel teeth. | |
| 72 | FAIL TO CRANK — Lamp: Shutdown; The genset has failed to sense rotation for two start attempts. Indicates possible fault with control, speed sensing or starting system. Can only occur in gensets with magnetic pickup installed and enabled | ||
| 73 | FAIL TO START — Lamp: Shutdown; Indicates possible fuel system or air induction problem. (Engine cranks but fails to start) | Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required; Check for dirty fuel filter and replace if necessary; Check for dirty or plugged air filter and replace if necessary; Reset the control and restart after correcting the problem. | |
| 74 | FAIL TO STOP — Lamp: Shutdown; Genset continues to run after receiving shutdown command from the controller | ||
| 77 | SHUTDOWN AFTER BS — Lamp: Shutdown; A shutdown fault occurred while the Battle Short mode was enabled | Check fault history for faults that may have been bypassed. | |
| 92 - 95 | AUX I/O MODULE INPUT 9 – 12 — Lamp: Shutdown; The nature of the Aux I/O Module fault is an optional customer selection. Example inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc | Each of the fault functions can be programmed (using InPower service tool or access to Setup menu), as follows: Warning, Shutdown or Event (Default = Warning) (See fault code 234–237 for Warning and code 171–174 for Event); Change display name using up to 32 characters. | |
| 96 | OIL TEMP HIGH — Lamp: Shutdown; Indicates that the engine oil temperature is above normal and has reached the shutdown trip point. (I/O Module option.) | ||
| 98 | AMBIENT TEMP HIGH — Lamp: Shutdown; Indicates ambient temperature is above normal and has reached the shutdown trip point. (I/O Module option.) | ||
| 99 | FUEL LEVEL LOW — Lamp: Shutdown; Indicates that fuel level has reached the shutdown trip point. (I/O Module option.) | ||
| 102 | VOLTAGE BIAS OOR — Lamp: Shutdown; Indicates the voltage bias circuit output is out of range (OOR), high or low. (I/O Module option.) | ||
| 103 | SPEED BIAS OOR — Lamp: Shutdown; Indicates the speed bias circuit output is out of range (OOR), high or low. (I/O Module option.) | ||
| 106 | I/O MODULE LOST — Lamp: Shutdown; Indicates the data link between the I/O module and the Base board is lost | ||
| 163 - 170 | BASE I/O MODULE INPUT 1 – 8 — Lamp: None; The nature of the Base I/O Module event is an optional customer selection | Each event function can be programmed (using InPower service tool or access to Setup menu), as follows: Change display name using up to 32 characters; Select active low or high input. | |
| 171 - 174 | AUX I/O MODULE INPUT 9 – 12 — Lamp: None; The nature of the Aux I/O Module event is an optional customer selection | Each event function can be programmed (using InPower service tool or access to Setup menu), as follows: Change display name using up to 32 characters; Select active low or high input. | |
| 202 | PRE-HIGH COOL TMP — Lamp: Warning; Indicates engine is operating near cooling system capacity. Increase in load or higher ambient temperature may cause High Coolant Temp (1) shutdown | Review code 1 correction list for other possible causes. | |
| 203 | LOW COOLANT TEMP — Lamp: Warning; Set is not operating. Warning occurs when engine coolant temperature is 70F (21C) or lower. NOTE: In applications where the ambient temperature falls below 40F (4C), Low Coolant Temp may be indicated even though the coolant heaters are operating | Indicates engine coolant heater is not operating or is not circulating coolant; Coolant heater not connected to power supply; Low coolant level; Open heater element | Check for the following conditions: Coolant heater not connected to power supply. Check for blown fuse or disconnected heater cord and correct as required; Check for low coolant level and replenish if required. Look for possible coolant leakage points and repair as required; Open heater element. Check current draw of heater. Coolant temperature must be below 70F (default setting) for one minute to activate warning and be above 70F for five minutes before the warning can be cleared. |
| 212 | COOL SENSOR OOR — Lamp: Warning; Indicates that the control has sensed that the engine coolant temperature sensor output is out of range (high or low). This fault will only occur if water temperature sensor is equipped on the genset | Check sender/connectors/wires. | |
| 213 | LOW BATTERY — Lamp: Warning; Indicates battery voltage supply to the control is approaching a low level at which unpredictable operation will occur | Discharged or defective battery; Poor battery cable connections; Battery wiring/calibration; Engine DC alternator; Battery charge voltage float level | Check the battery charger fuse. Recharge or replace the battery; Clean the battery cable terminals and tighten all connections; Check battery wiring/calibration; Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage is not obtained; Check battery charge voltage float level if applicable (raise float level). |
| 214 | HIGH BATTERY — Lamp: Warning; Indicates battery voltage supply to the control is approaching a high level at which damage to the control can occur | Check float level on battery charger if applicable (lower float level); Check battery wiring/calibration. | |
| 215 | PRE-LOW OIL PRESSURE — Lamp: Warning; Indicates engine oil pressure has dropped below the warning trip point. This warning will only occur if genset is equipped with an oil pressure sender | If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then follow code 2 procedure. | |
| 216 | HIGH AC CURRENT — Lamp: Warning; Indicates that one or more of the phase currents has exceeded high ac warning threshold for time delay seconds | Check load and load lead connections. | |
| 217 | OIL PRESS SENSOR OOR — Lamp: Warning; Indicates that the control has sensed that the engine oil pressure sensor output is out of range (high or low). This warning will only occur if genset is equipped with an oil pressure sender | Check sender/connectors/wires. | |
| 218 | BATTLE SHORT ACTIVE — Lamp: Warning; Indicates that the control is in Battle Short mode - used to bypass several fault shutdowns for genset operation during emergencies | ||
| 219 | CHARGER FAILURE — Lamp: Warning; Indicates the battery charging alternator has not reached an acceptable voltage range within the selected period (default = 120 seconds) | Refer to engine service manual if this fault occurs. If not failed, check wiring. | |
| 220 | FAIL TO SHUTDOWN — Lamp: Warning; Genset continues to run after receiving shutdown command from the controller. Battle Short feature enabled - used to bypass several critical fault shutdowns for genset operation during emergencies | ||
| 221 | WEAK BATTERY — Lamp: Warning; Indicates that during cranking, the battery voltage is at or below the weak battery warning trip point for a time greater than or equal to the weak battery set time | See code 213 for corrective action. | |
| 225 | ANNUNCIATOR OUTPUT CONFIGURATION ERROR — Lamp: Warning; Indicates a mismatch in the configuration of one of the annunciator relay outputs | ||
| 226 - 233 | Base I/O Module Input 1 — 8 — Lamp: Warning; The nature of the Base I/O Module fault is an optional customer selection. Example inputs: Low Fuel Day Tank, Water in Fuel, Ground Fault, etc | Each of the fault functions can be programmed (using InPower service tool or access to Setup menu), as follows: Warning, Shutdown or Event (Default = Warning) (See fault code 84–91 for shutdown and code 163–170 for Event); Change display name using up to 32 characters. | |
| 234-237 | AUX I/O MODULE INPUT 9–12 — Lamp: Warning; The nature of the Aux I/O Module fault is an optional customer selection. Example inputs: Low Fuel Day Tank, Water in Fuel, Ground Fault, etc | Each of the fault functions can be programmed (using InPower service tool or access to Setup menu), as follows: Warning, Shutdown or Event (Default = Warning) (See fault code 92–95 for shutdown and code 171–174 for Event); Change display name using up to 32 characters. | |
| 238 | OIL TEMP HIGH — Lamp: Warning; Indicates engine has begun to overheat (oil temperature has risen to an unacceptable level). Increase in load or higher ambient temperature may cause High Oil Temp (code 96) shutdown. (I/O Module Option.) | ||
| 239 | OIL TEMP OOR — Lamp: Warning; Indicates the oil temperature sensor output is out of range (OOR), high or low. (I/O Module option.) | ||
| 242 | AMBIENT TEMP HIGH — Lamp: Warning; Indicates the ambient temperature has exceeded the warning threshold for genset room temperature. Increase in load may cause Ambient Temp High (code 98) shutdown. (I/O Module Option.) | ||
| 243 | AMBIENT TEMP OOR — Lamp: Warning; Indicates the ambient temperature sensor output is out of range (OOR), high or low. (I/O Module Option) | ||
| 244 | FUEL LEVEL LOW — Lamp: Warning; Indicates that the fuel has dropped below the low fuel level trip point. Allows time to refill before fuel level low (code 99) shutdown occurs. (I/O Module Option) | ||
| 245 | FUEL LEVEL OOR — Lamp: Warning; Indicates the fuel level sensor output is out of range (OOR), high or low. (I/O Module Option) | ||
| 252 | I/O MODULE LOST — Lamp: Warning; Indicates an intermittent data link between the I/O module and the Base board | ||
| 1/202 | HIGH OR PRE-HIGH COOLANT TEMPERATURE (SHUTDOWN/SHUTDOWN) — Calibration-dependent. No action is taken by the Control for code 202. Engine will shut down for code 1 | Fault simulation was enabled with a PC based service tool | With a PC based service tool, verify that the fault simulation is not enabled for the coolant sensor. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. |
| 1/202 | HIGH OR PRE-HIGH COOLANT TEMPERATURE (SHUTDOWN/SHUTDOWN) — Calibration-dependent. No action is taken by the Control for code 202. Engine will shut down for code 1 | Engine or sensor circuitry problem | Check the sensor accuracy with a thermocouple or similar temperature probe. If the coolant temperature reading is accurate, the engine may be overheating. Refer to the engine service manual. If the coolant temperature reading is not accurate, go to next step. |
| 1/202 | HIGH OR PRE-HIGH COOLANT TEMPERATURE (SHUTDOWN/SHUTDOWN) — Calibration-dependent. No action is taken by the Control for code 202. Engine will shut down for code 1 | The sensor could be bad | Disconnect the sensor and connect a coolant temperature sensor simulator to the harness. If the control responds to the simulator, replace the sensor. If control does not respond, go to next step. |
| 1/202 | HIGH OR PRE-HIGH COOLANT TEMPERATURE (SHUTDOWN/SHUTDOWN) — Calibration-dependent. No action is taken by the Control for code 202. Engine will shut down for code 1 | The harness or Base board could be bad | Measure the resistance of the coolant sensor and reconnect harness to sensor. Remove connector P11 from Base board and check resistance between pins P11-18 (H20) and P11-6 (H20 COM). If resistance is not the same, harness is bad. If resistance is the same, Base board is bad. |
| 2/215 | LOW OIL OR PRE-LOW PRESSURE (WARNING/SHUTDOWN) OIL PRESSURE SENSOR TYPE : SENDER — Calibration-dependent. No action is taken by the Control for code 215. Engine will shut down for code 2 | Fault simulation was enabled with a PC based service tool | With a PC based service tool, verify that the fault simulation is not enabled for the oil pressure sensor. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. |
| 2/215 | LOW OIL OR PRE-LOW PRESSURE (WARNING/SHUTDOWN) OIL PRESSURE SENSOR TYPE : SENDER — Calibration-dependent. No action is taken by the Control for code 215. Engine will shut down for code 2 | Low oil level. Clogged lines or filters | Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. |
| 2/215 | LOW OIL OR PRE-LOW PRESSURE (WARNING/SHUTDOWN) OIL PRESSURE SENSOR TYPE : SENDER — Calibration-dependent. No action is taken by the Control for code 215. Engine will shut down for code 2 | Sensor or oil pump could be bad. Or the generator set may be shutting down on another fault | Disconnect the oil pressure sensor leads, and connect an oil pressure sensor simulator to the harness. If the control responds to the simulator, reconnect the sensor, disconnect the + signal wire at the fuel solenoid, and crank the engine. Check the oil pressure reading on the digital display. If the display shows an acceptable oil pressure, the problem may not be in the oil or oil sensing system. The genset may be shutting down on another fault (out of fuel, intermittent connector). Restart the genset and monitor the display panel for other faults. If the display does not show an acceptable oil pressure, replace the sensor. If the Control still doesn't display an oil pressure while cranking, the oil pump may be bad. Refer to the engine service manual. If the control does not respond to the simulator, go to next step. |
| 2/215 | LOW OIL OR PRE-LOW PRESSURE (WARNING/SHUTDOWN) OIL PRESSURE SENSOR TYPE : SENDER — Calibration-dependent. No action is taken by the Control for code 215. Engine will shut down for code 2 | Harness or Base board could be bad | If the control does not respond to the simulator, the Base board or the harness is bad. Check for +5 VDC at the sensor (lead marked S1). If there is no 5 VDC at the sensor: Check for 5 VDC at P11-17. If yes, harness is bad. If no, Base board is bad. If there is 5 VDC at the sensor, use the sensor simulator to generate a signal to P11-17 (OP OUT) and P11-5 (OP COMM). If the pressure signal (.5 to 4.5 VDC) does not get to P11, isolate to the harness. If the pressure signal does go to P11, the Base board is bad. |
| 2/215 | LOW OIL OR PRE-LOW PRESSURE (WARNING/SHUTDOWN) OIL PRESSURE SENSOR TYPE : SENDER — Calibration-dependent. No action is taken by the Control for code 215. Engine will shut down for code 2 | Low Oil Pressure fault set points could be incorrect | Verify set points against the normal operating pressures of the engine. Refer to engine manual. |
| 12 | HIGH AC VOLTAGE (SHUTDOWN) — Engine will shut down | Fault simulation was enabled with a PC based service tool | With a PC based service tool, verify that the related fault simulation is not enabled. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. |
| 12 | HIGH AC VOLTAGE (SHUTDOWN) — Engine will shut down | Single step large block load removal | Clear fault and restart genset. |
| 12 | HIGH AC VOLTAGE (SHUTDOWN) — Engine will shut down | Fault threshold is not set correctly with PC based service tool | Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold. |
| 12 | HIGH AC VOLTAGE (SHUTDOWN) — Engine will shut down | Base board or generator is bad | Refer to Generator/Base Board Isolation Procedure in Section 7 to determine if the Base board is causing the high AC voltage shutdown fault. |
| 12 | HIGH AC VOLTAGE (SHUTDOWN) — Engine will shut down | Voltage sense connections/set up could be incorrect | See Section 17 for proper corrective actions. |
| 13 | LOW ACE VOLTAGE (SHUTDOWN) — Engine will shut down | Fault simulation was enabled with a PC based service tool | With a PC based service tool, verify that the related fault simulation is not enabled. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. |
| 13 | LOW ACE VOLTAGE (SHUTDOWN) — Engine will shut down | Fault threshold is not set correctly with a PC based service tool | Reset the threshold to the lowest allowable setting. Determine the required operating range before adjusting the threshold. |
| 13 | LOW ACE VOLTAGE (SHUTDOWN) — Engine will shut down | Overload | Check the load and correct any overload. Check operation by disconnecting load and restarting generator set. |
| 13 | LOW ACE VOLTAGE (SHUTDOWN) — Engine will shut down | Improper connections have been made at the generator output terminals | Reconnect according to the appropriate reconnection diagram. See Section 9. |
| 13 | LOW ACE VOLTAGE (SHUTDOWN) — Engine will shut down | Voltage sense or setup wiring connection could be incorrect | Check that excitation inputs P13-5 and P13-6 are connected to the correct voltage. |
| 13 | LOW ACE VOLTAGE (SHUTDOWN) — Engine will shut down | The rotating rectifier assembly (diodes CR1 through CR6) is faulty | Check each diode. See genset service manual |
| 13 | LOW ACE VOLTAGE (SHUTDOWN) — Engine will shut down | Loose connector or Base board is bad | Repair connections (P13) or replace the Base board if necessary. |
| 13 | LOW ACE VOLTAGE (SHUTDOWN) — Engine will shut down | Voltage sense connections/setup could be incorrect | See section 17 for proper connections |
| Symptom | Cause | Remedy |
|---|---|---|
| Engine does not crank in manual mode (no fault message) — Engine will not start | No power supplied to control; Poor battery cable connections | Clean the battery cable terminals and tighten all connections; Remove connector P11 and check for B+ at P11-3 & 15 and GND at P11-9 & 10. If B+ or ground missing, isolate to harness and TB BAT terminal mounted on engine block. If B+ and ground check OK, cycle power to base board by reconnecting P11 and retry operation. |
| Engine does not crank in manual mode (no fault message) — Engine will not start | No power supplied to front membrane panel | Check for B+ at TB1-1 and GND at TB1-4. If B+ or ground missing, the base board is bad. If B+ and ground check OK, remove P1 from back of front membrane panel. Check for B+ at P1-3 and ground at P1-5. If B+ or ground missing, repair harness. |
| Engine does not crank in manual mode (no fault message) — Engine will not start | Base board not properly calibrated or corrupt calibration | Confirm that the installed calibration part number matches the serial plate information. Re-enter calibration file if necessary. |
| Engine does not crank in manual mode (no fault message) — Engine will not start | The Emergency Stop switch or wiring is defective | With Emergency Stop push button not activated (switch closed), remove configurable leads from TB1-15 and TB1-16 and check for continuity between these two leads. If circuit is open, isolate to Emergency Stop switch and wiring. If there is continuity, go to next step. |
| Engine does not crank in manual mode (no fault message) — Engine will not start | The menu display manual Run button, harness or the Base board is bad | Check for continuity between P11-4 (RUN) to P11-8 (GND). If no continuity when pressing the manual Run button, isolate to front membrane panel and wiring. If there is continuity, the Base board is bad. |
| Engine does not crank in manual mode (no fault message) — Engine will not start | Oil Pressure switch or wiring is defective | Remove P11 connection and check wiring between P11-6 and P11-7 to the switch; Verify control is configured for the type of switch installed; Verify proper operation of the switch |
| Engine does not crank in manual mode (no fault message) — Engine will not start | Oil Pressure sender, setup on wiring is defective | Remove P11 connection and check wiring between P11-6, P11-17 and P11-5 (for 3-wire sender) to the sender; Verify control is configured for the type of sender; Verify operation of the sender |
| Engine does not crank in remote mode (no fault message) — Engine will 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. |
| Engine does not crank in remote mode (no fault message) — Engine will not start in remote mode, but starts in manual mode | 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. |
| CONFIGURABLE INPUT #1 & #2 — Lamp: Shutdown; The nature of the fault is an optional configurable selection. Example inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc | Each of the fault functions can be programmed (using service tool or operator panel), as follows: Warning or Shutdown (Default: Warning) (See fault code 204/205 for Warning); Change display name using up to 32 characters. | |
| CONFIGURABLE INPUT #1, #2 — Lamp: Warning; The nature of the fault is an optional configurable selection. Example inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc | Each of the fault functions can be programmed (using service tool), as follows: Warning or Shutdown (Default: Warning) (See fault code 75/76 for Shutdown); Change display name using up to 32 characters. |
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 109 entries.
Compiled from service & troubleshooting documentation across every generator set that uses the Cummins/Onan C38 D5.
Step-by-step procedures compiled from the Cummins/Onan service manual for this engine.
| 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. |
| 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 | Speed Signal Lost - Shutdown | Shutdown | ||
| 135/141 | Oil Pressure Sensor OOR - Warning | Warning | ||
| 143 | Pre-Low Oil Pressure - Warning | Warning | ||
| 145 | Coolant Sensor OOR - Warning | Warning | ||
| 146 | Pre-High Coolant Temp - Warning | Warning | ||
| 151 | High Coolant Temp - Shutdown | Shutdown | ||
| 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 | Overspeed - Shutdown | Shutdown | ||
| 359 | Fail to Start - Shutdown | Shutdown | ||
| 415 | Low Oil Pressure - Shutdown | Shutdown | ||
| 441 | Low Battery - Warning | Warning | ||
| 442 | High Battery - Warning | Warning | ||
| 1311 | CUST_FAULT #1 - Warning | Warning | ||
| 1312 | CUST_FAULT #2 - Warning | Warning | ||
| 1317 | CUST_FAULT #3 - 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 | ||
| 1471 | High AC Current - Warning | Warning | ||
| 1472 | High AC Current - Shutdown | Shutdown | ||
| 1944 | Annunciator Error - Warning | Warning | ||
| 2335 | Excitation Fault - Shutdown | Shutdown | ||
| 2677 | Fail to Stop - Shutdown | 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 C38 D5 has a displacement of 3.3 liters.
The Cummins/Onan C38 D5 powers 1 generator set(s), including Cummins/Onan C38 D5.
A commonly reported issue on generators using the Cummins/Onan C38 D5 is: LOW ACE VOLTAGE (SHUTDOWN) — Engine will shut down. Cause: Fault simulation was enabled with a PC based service tool. Fix: With a PC based service tool, verify that the related fault simulation is not enabled. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides..