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Cummins/Onan Ford Engine Model Engine

Name: Cummins/Onan Ford Engine Model Engine
Brand: Cummins/Onan

The Cummins/Onan Ford Engine Model is an engine. It powers generator sets from Cummins/Onan, including the GGHE and GGHF.

Also known as: Cummins Ford Engine Model

On this pageSpecs Generator sets FAQ Service intervals Torque & specs Fluids Fault codes Procedures Wiring

Engine specifications

Generator sets powered by this engine

Cummins/Onan GGHE Cummins/Onan GGHF

How to read your Cummins/Onan engine serial & model number →

Common problems

Over Current 1471
Low Coolant Level 197
Weak Battery 1442
Under Frequency 1448
Too Long in Idle 2342
There is no remote circuit signal (12 VDC at auxiliary relay board A28-TB1-6) because the remote circuit is not functioning properly.
Fix: Apply 12 VDC to A28-TB1-6. If the engine cranks, find and repair the fault in the remote control circuit. See Section 7 for remote connections.
There is no remote circuit signal (12 VDC at auxiliary relay board A28-TB1-6) because fuse F3 on the ECM has blown. a
Fix: A. Replace the fuse with one of the same type and amp rating (15 A).<br>b. If fuse F3 blows again, find and repair the fault in the remote control circuit, such as a loose wire that may be shorting to ground or a shorted relay coil or other component. See Section 7 for remote connections.
The starter disconnects normally but neither the panel nor the remote Run indicator lamps light
Cause: AC (K10) starter disconnect circuit is not working
The Run-Stop-Remote switch is at Stop. (The Switch-Off light will be flashing.)
Fix: Push the Run-Stop-Remote switch to Remote.
The magnetic speed pick-up is defective or requires adjustment. 9
Fix: Refer to Magnetic Speed Pickup Unit Adjustment in Section 6.
The grounding strap between the control box and the battery negative (−) terminal or the ground wire between the control and engine ground is loose, damaged or missing
Fix: Check for continuity (zero ohms) between the grounding stud on the bottom of the control box and the battery negative (−) terminal. If there is no continuity or the grounding strap is loose or damaged, repair as necessary.
The engine runs until fault shutdown.
Fix: 1. The OVERSPEED lamp comes on and the engine shuts down. a. Reset the ECM by pushing the Run-Stop-Remote switch to Stop and the Reset switch to Reset and restart the set, monitoring engine speed. b. Adjust the governor for Type A fuel system/check operation of Type B integrated governor (see Section 6). c. Type A: If the governor cannot be adjusted to prevent shutdown due to overspeed, check for binding in the linkage. Repair and adjust the linkage as necessary. d. Type A and B: If the set still shuts down due to overspeed, re-install the magnetic speed pick-up unit to make sure the clearance with the flywheel gear teeth is correct (see Section 6). Replace the speed-pickup unit if output voltage at cranking speed is less than 1.5 VAC. (Intermittent open on magnetic speed pick-up lead can also cause an overspeed condition.) e. Replace the governor controller board (Type A) or integrated governor assembly (Type B) if the set still shuts down due to overspeed. 2a. The OVERSPEED lamp comes on and the engine shuts down within 1 to 5 seconds (no over-speed condition detected). (V6 Spec A & B, V10 Spec A−C) a. Remove K5-30 lead from K5. Start genset. If set shuts down and overspeed light is on, replace ECM (A11). b. Remove K5-30 lead from K5 and check lead continuity to ground. If ground present, replace ignition module. c. Connect K5-30. Remove lead K5-87 and check lead continuity to ground. If ground present, replace K5 relay. d. Remove K5-87 lead from K5 and start genset. If set shuts down and OVERSPEED lamp comes on, replace ECM (A11). e. Check Ford engine harness oil pressure lead for proper ground to intake manifold. Must be grounded to prevent false ignition module fault. 2b. The OVERSPEED lamp comes on and the engine shuts down within 1 to 5 seconds (no over-speed condition detected). (V6 Spec C) f. Remove connector from J2 of the ECM (A11) board and check pin J2-6 continuity to ground. If ground present, replace ignition module. g. Check Ford engine harness oil pressure lead for proper ground to intake manifold. Must be grounded to prevent false ignition module fault.
The engine ignition system is malfunctioning. 7
Fix: Refer to wiring diagrams in Section 7. V6 Engine: a. Check for battery VDC at coil while cranking. (Red wire with green stripe.) b. Spec C − Check Ford engine harness ground lead connection. c. Spec C − Check 10 amp fuse located on Ford engine harness power block. d. Check crank position sensor (315 to 385 ohms). e. Check ignition coil (0.5 to 1.3 ohms). f. Replace ignition module if above items are OK. V10 Engine: a. Check for battery VDC at ignitor coil while cranking. (Red wire with green stripe.) b. Spec D − Check three fuses located on Ford engine harness power block. c. Spec D − Check B+ power connection of Ford engine harness power lead (starter motor stud − B1). d. Check crank position sensor (315 to 385 ohms). e. Check cam position sensor (315 to 385 ohms). f. Check ignition coil primary (0.5 to 1.3 ohms). g. Replace ignition module if above items are OK.
The engine does not crank in RUN mode
Cause: The Emergency Stop switch has been used.; A Fault Shutdown is being indicated by one of the red lights on the control panel.; Cranking voltage is too low to crank the engine.
Fix: Pull the Emergency Switch button. To reset the engine con-; Service the set as necessary. To reset the engine control, push the Run-Stop-Remote switch to Stop and the Reset switch to Reset. Then push the Run-Stop-Remote switch to Run to start the genset.; a. Clean and tighten or replace the positive (+) and negative (−) battery cable connectors and cables at the battery and the set.; b. Recharge or replace the battery. Specific gravity for a fully charged battery is approximately 1.260 at 80° F (27° C).; c. If the set is in standby service, install a battery charger.; d. Replace the engine-driven battery charging alternator if normal battery charging voltage (12 to 14 VDC) is not obtained.
The engine cranks but does not start.
Fix: 10. Incorrect main fuel valve adjustment. Refer to Gaseous Fuel Adjustment (Type A or B) in Section 6. 11. Incorrect secondary regulator adjustment. Refer to Initial Secondary Regulator Adjustment in Section 6.

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

Service intervals

Item	Action	Hours	Months	Notes
Air cleaner	Check	8 hr		Replace as necessary; perform more often in extremely dusty conditions.
Coolant heater(s)	Check	24 hr		Standby power schedule. Daily or after 8 hours.
Coolant level	Check	24 hr		Standby power schedule. Daily or after 8 hours.
Engine oil level	Check	24 hr		Standby power schedule. Daily or after 8 hours.
General set inspection	Inspect	8 hr		Daily/after 8 hours (X1). Check for oil, fuel, cooling and exhaust system leaks; check exhaust audibly and visually with set running.
Generator air outlet	Check	100 hr	1 mo	Standby power schedule. Daily or after 8 hours.
Generator set (general)	Inspect	24 hr		Standby power schedule. Daily or after 8 hours. Footnote 1: Check for oil, fuel, cooling and exhaust system leaks; check exhaust system audibly and visually with set running.
Crankcase oil	Change	50 hr		First service — Break-in: drain and replace the crankcase oil after the first 50 hours of operation on new generator sets.
Crankcase oil	Drain	50 hr		First service — Drain and replace crankcase oil after first 50 hours of operation on new generator sets.
Air cleaner (heavy duty filter)	Check	100 hr		Prime power schedule. 100 hours. Footnote 2: Perform more often in extremely dusty conditions. Footnote 3: Replace element every 2000 hours.
Air cleaner (normal duty filter)	Check	100 hr		X2 perform more often in extremely dusty conditions; X3 replace element after 500 hours
All hardware (fittings, clamps, fasteners, etc.)	Check	100 hr	1 mo
Battery electrolyte level	Check	100 hr	1 mo	Standby power schedule. Monthly or after 100 hours.
Drive belt	Check	500 hr	12 mo	X5 visually check belt for evidence of wear or slippage; replace if hard or brittle
Governor linkage	Check	100 hr	1 mo	Perform more often in extremely dusty conditions.
Hardware (fittings, clamps, fasteners)	Check	100 hr		Standby power schedule. Monthly or after 100 hours.
Engine oil and filter	Change	250 hr	6 mo	Perform more often in extremely dusty conditions.
Engine oil and filter (heavy duty filter)	Change	250 hr		Prime power schedule. 250 hours. Footnote 2: Perform more often in extremely dusty conditions.
Engine oil and filter (normal duty filter)	Change	250 hr	6 mo	X2 perform more often in extremely dusty conditions; X9 perform at least once a year
Exterior of radiator	Inspect	250 hr		Inspect for obstructions
Radiator hoses	Check	250 hr		Check for wear and cracks; X4 replace if hard or brittle
Radiator hoses for wear and cracks	Check	250 hr	6 mo	Replace if hard or brittle.
AC generator and controls	Check	500 hr	12 mo	Standby power schedule. Yearly or after 500 hours.
Anti-freeze	Check	500 hr	12 mo
Anti-freeze concentration	Check	500 hr	12 mo	Standby power schedule. Yearly or after 500 hours.
Catalytic converter restriction	Test	1000 hr	24 mo	X7 must be performed by a qualified mechanic; X8 replace every 8 years or 2000 hours
Cooling systems	Clean	500 hr	12 mo
Oxygen sensor	Inspect	1000 hr	24 mo	X6,7 inspect or replace; replace every 1,000 hours; must be performed by a qualified mechanic
Radiator exterior (obstructions)	Inspect	500 hr	12 mo	Standby power schedule. Yearly or after 500 hours.
Radiator hoses	Inspect	500 hr	12 mo	Standby power schedule. Yearly or after 500 hours. Footnote 4: Replace if hard or brittle.
Spark plugs	Inspect	1000 hr	12 mo	X6 replace every 1,000 hours
Spark plugs (prime power schedule)	Inspect	500 hr		Table 5-2 prime power; X7 replace every 2,000 hours
Engine coolant port caps	Inspect	1000 hr	24 mo	Standby power schedule. 2 years or after 1,000 hours. Footnote 10: Replace after 4 years or 1000 hours.
Radiator	Drain	1000 hr	24 mo	Standby power schedule. Drain and flush radiator. 2 years or after 1,000 hours.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Service specifications

Type	Item	Value	Unit	Condition
Gap	Spark Plug Gap	0.044	in. (1.1 mm)
Gap	Spark plug gap	0.044 (1.1 mm)	in (mm)
Other	B+ fused output	10	amps, 12/24 volt
Other	Battery charging alternator (max. rating)	37	A
Other	Battery specific gravity (fully charged, corrected)	1.260		corrected by adding 0.004 per 10 F above 80 F (27 C)
Other	Battery specific gravity (recharge below)	1.215
Other	Cool-down at idle time delay	0-30	minutes
Other	Customer Output relay rating (TB1)	2	amps at 30 VDC	normally open contacts
Other	Exhaust connection	3	inch NPT
Other	Frequency adjust range	+/-5	percent	nominal frequency
Other	Low Fuel warning (yellow lamp)	5	inches (127 mm) WC or less	dual or single fuel systems
Other	Overcrank timed cranking period	approximately 75	seconds, including two rest periods
Other	Rated to idle delay	0-10	seconds	default 0; beginning Version 2.303
Other	Relay contact rating (K10/K11/K12)	10	amps at 600 VAC
Other	Secondary regulator initial adjustment (distance from top of regulator to top of set screw), NG, 60 Hz	12.1	mm
Other	Secondary regulator initial adjustment, NG, 60 Hz	13.35	mm
Other	Secondary regulator initial adjustment, NG, 60 Hz	15.9	mm
Other	Starting crank/rest cycle defaults	3 start cycles of 15 seconds cranking and 15 seconds rest (configurable 1-7)
Other	Switched B+ fused output	5	amps, 12/24 volt	activated on run command
Other	Time delay to start	0-300	seconds	default 0
Other	Time delay to stop	0-600	seconds	default 0
Other	Voltage adjust range	+/-5	percent	nominal voltage
Other	Warm-up at idle time delay	0-300	seconds
Pressure	Exhaust Backpressure (max allowed)	20	inch H2O (5.0 kPa)
Pressure	Exhaust backpressure (max. allowed)	20	inch H2O (5.0 kPa)
Pressure	Exhaust backpressure maximum allowed	20	inch H2O (5.0 kPa)
Pressure	Fuel flow inlet pressure (maximum)	13.6	inch H2O (3.4 kPa)	NG/LPG vapor withdrawal
Pressure	Fuel flow inlet pressure (maximum)	312	psi (2,153 kPa)	LPG liquid withdrawal
Pressure	Fuel flow inlet pressure (minimum)	7.0	inch H2O (1.7 kPa)	NG/LPG
Pressure	Fuel flow inlet pressure maximum (LPG liquid withdrawal)	312	psi (2,153 kPa)	maximum
Pressure	Fuel flow inlet pressure maximum (NG/LPG vapor withdrawal)	13.6	inch H2O (3.4 kPa)	maximum
Pressure	Fuel flow inlet pressure minimum (NG/LPG vapor)	7.0	inch H2O (1.7 kPa)	minimum
Pressure	Fuel flow inlet pressure, LPG liquid withdrawal	312	psi (2,153 kPa)
Pressure	Fuel flow inlet pressure, maximum NG/LPG vapor withdrawal	13.6	inch H2O (3.4 kPa)
Pressure	Fuel flow inlet pressure, minimum NG/LPG	7.0	inch H2O (1.7 kPa)
Pressure	Fuel inlet pressure maximum LPG liquid withdrawal	312	psi (2,153 kPa)
Pressure	Fuel inlet pressure maximum NG/LPG vapor withdrawal	13.6	inch H2O (3.4 kPa)
Pressure	Fuel inlet pressure minimum NG/LPG	7.0	inch H2O (1.7 kPa)
Pressure	LOP jumper alternate shutdown setting	14	psi (97 kPa)	alternate jumper position (not recommended, see caution)
Pressure	LP gas leak-test pressure (minimum)	90	psi (621 kPa)	at inlet of primary regulator
Pressure	LPG Liquid Withdrawal Supply Pressure (maximum)	312	psi (2,153 kPa)	any operating condition
Pressure	LPG gas pressure at mixer, full load	approximately -1.0	inches WC
Pressure	LPG gas pressure at mixer, no load	approximately -0.5	inches WC
Pressure	Low Oil Pressure shutdown (red lamp), LOP jumper set to 25 psi	less than 25	psi (173 kPa)
Pressure	Low fuel pressure alarm	5	inches (127 mm) WC	marginally low fuel supply pressure
Pressure	Low fuel pressure alarm (engine control module)	3	inches (76.2 mm) water column	primary fuel pressure below
Pressure	Low oil pressure shutdown	25	psi (172.4 kPa)
Pressure	Mixer-side LP gas pressure (full load)	negative 1.0	inch WC (0.249 kPa)	full load
Pressure	Mixer-side LP gas pressure (no load)	negative 0.5	inches WC (0.13 kPa)	no load
Pressure	Mixer-side LP gas pressure at full load	-1.0	inch WC (0.249 kPa)	full load
Pressure	Mixer-side LP gas pressure at no load	-0.5	inch WC (0.13 kPa)	no load
Pressure	Mixer-side NG gas pressure	approximately 5	inches WC (1.3 kPa)	at full load
Pressure	Mixer-side NG gas pressure at full load	5	inch WC (1.3 kPa)	full load
Pressure	NG gas pressure at mixer, full load	approximately 5	inches WC
Pressure	NG/LPG Fuel Supply Pressure (maximum, vapor)	13.6	inch H2O (3.4 kPa)	NG/LPG vapor withdrawal
Pressure	NG/LPG Fuel Supply Pressure (minimum)	7.0	inch H2O (1.7 kPa)	NG/LPG vapor withdrawal
Pressure	Natural gas fuel supply pressure, maximum	13.6	inches WC (3.4 kPa)
Pressure	Natural gas fuel supply pressure, minimum	7	inches WC (1.7 kPa)
Pressure	Normal engine oil pressure	40-65	psi (276-449 kPa)	at normal operating temperature
Pressure	Normal oil pressure	276 to 552	kPa	at normal operating temperature

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Recommended fluids

Fluid	Grade	Standard	Ambient	Capacity	Notes
Coolant	50/50 coolant solution (50% pure water, 50% antifreeze)			32.2 L	Capacity with standard radiator 8.5 Gal (32.2 L). If temperatures below -37°F (-38°C) possible, use 65% antifreeze / 35% water. Do not use antifreeze with anti-leak additives. Use soft, low-mineral water.
Coolant	50/50 coolant solution (50% pure water and 50% anti-freeze)		above -37°C	32.2 L	Cooling system capacity with standard radiator 8.5 Gal (32.2 L). If temperatures below -37 deg F (-38 deg C) are possible, use 65% antifreeze / 35% water. Do not use an antifreeze containing anti-leak additives. Use clean soft water low in mineral content.
Coolant	50/50 coolant solution (50% pure water and 50% antifreeze)		above -37°C	8.5 Gal (32.2 L)	If temperatures below -37 F (-38 C) possible use 65% antifreeze and 35% water. Do not use antifreeze with anti-leak additives. Use clean, low-mineral soft water.
Engine oil	SAE 10W30, 5W30, 15W40	API SJ, SH or SL		6.5 Qts (6.2 L)	Standby Power (normal oil filter). Pick grade for the lowest expected temperature; if ambient consistently below -13 F (-25 C) use a SAE5W synthetic oil.
Engine oil	SAE 10W30, SAE 5W30, SAE 15W40	API classification SJ, SH or SL		6.2 L	Standby Power oil capacity 6.5 Qts (6.2 L) with normal oil filter; Prime Power 11 Qts (10.4 L) with heavy duty oil filter. If ambient temperature is consistently below -13 deg F (-25 deg C), use a SAE5W synthetic oil. Select grade for the lowest expected temperature.
Engine oil	SAE 5W synthetic (if ambient consistently below -13°F/-25°C)	API classification SJ or SJ/CD		6.2 L	Select viscosity grade per ambient temperature chart (Figure 5-1); oil capacity with filters 6.5 Qts (6.2 L).
Fuel	Natural Gas and/or Propane (Liquid or Vapor)				Fuel inlet pressure min 7.0 inch H2O NG/LPG; max 13.6 inch H2O NG/LPG vapor withdrawal, 312 psi LPG liquid withdrawal
Fuel	Propane (Liquid or Vapor); Natural Gas
Fuel	Propane (liquid or vapor) / Natural Gas				Fuel flow inlet pressure min 7.0 inch H2O (1.7 kPa) NG/LPG; max 13.6 inch H2O (3.4 kPa) NG/LPG vapor withdrawal; max 312 psi (2,153 kPa) LPG liquid withdrawal.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Fault codes

Code	Name	Meaning	Severity	Action
1123	Shutdown After BS		Shutdown
1124	Delayed Shutdown		Warning
1131	Battle Sh Active		Warning
121	Speed Signal Lost		Shutdown
1311	Customer Input #1	Optional customer selection (example: Low Fuel Day Tank, Water In Fuel, Ground Fault, Low Starting Hydraulic Pressure, Low Starting Air Pressure). Default display name Customer Fault 1; default status None.		Each fault function can be programmed (using service tool): enable/disable input (default enable), status/warning/shutdown, active closed or open, change display name up to 19 characters.
1312	Customer Input #2	Optional customer selection. Default display name Ground Fault; default Warning.		Programmable using service tool (enable/disable, status, active state, display name).
1317	Customer Input #3	Optional customer selection. Default display name Low Fuel; default Warning.		Programmable using service tool (enable/disable, status, active state, display name).
1318	Service Engine (begin spec J)	Warning lamp. Emissions criteria might not be met due to engine running in open loop, lean mixture, rich mixture, or a failed fuel system component.	Warning
1334	Crit Scaler OR		Shutdown
1335	Noncrit Scaler OR		Warning
135	Oil Pressure Sensor H		Warning
141	Oil Pressure Sensor L		Warning
1416	Fail To Shutdown		Warning
1417	Powr Down Error	Warning lamp. The controller cannot power down because of some unknown condition; possible drain on battery.	Warning	Contact an authorized service center for service.
143	Pre-Low Oil Pres	Warning lamp. Indicates engine oil pressure has dropped to an unacceptable level.	Warning	If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then follow code 415 procedure.
1433	Emergency Stop	Shutdown lamp. Indicates local Emergency Stop.	Shutdown	To reset: pull the button out; move the O/Manual/Auto switch to O; press the front panel Fault Acknowledge/Reset button; select Manual or Auto as required.
1434	Remote E-Stop	Shutdown lamp. Indicates remote Emergency Stop.	Shutdown	See code 1433 to reset.
1435	Low Coolant Temp	Warning lamp. Set is not operating; warning occurs when engine coolant temperature is 70 deg F (21 deg C) or lower.	Warning	Indicates engine coolant heater is not operating or is not circulating coolant. Check coolant heater power supply (blown fuse or disconnected heater cord). Check for low coolant level and replenish; look for coolant leakage points and repair.
1438	Fail To Crank	Shutdown lamp. Possible fault with control, speed sensing or starting system.	Shutdown	See code 441 for corrective action.
144	Coolant Sensor High		Warning
1442	Weak Battery	Warning lamp. During cranking, 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.	Warning	See code 441 for corrective action.
1443	Battery Failed	Shutdown lamp. Dead battery - engine will not start.	Shutdown	See code 441 for corrective action.
1444	KW Overload		Warning
1445	Short Circuit		Shutdown
1446	High AC Voltage		Shutdown
1447	Low AC Voltage		Shutdown
1448	Under Frequency	Shutdown lamp. Possible fuel system problem or overload condition.	Shutdown	Check for dirty or plugged air filter and replace if necessary. Check operation by disconnecting load and restarting generator set. Fuel system requires adjustment; contact an authorized service center. Gaseous fuel delivery to the set is inadequate; contact an authorized service center. Reset the control and restart after correcting the problem.
1449	Over Frequency		Warning
145	Coolant Sensor Low		Warning
1452	Gen CB Not Close		Warning
1453	Gen CB Not Open		Warning
1459	Reverse Power		Shutdown
146	Pre-High Coolant Temp	Warning lamp. Engine has begun to overheat (coolant temperature has risen to an unacceptable level).	Warning	Reduce load if possible by turning off non-critical loads. Check air inlets and outlets and remove obstructions to airflow. If engine can be stopped, follow code 151 procedure.
1461	Loss Of Field		Shutdown
1466	Modem Failure		Warning
1468	Network Error		Warning
1469	Speed/Hz Match		Shutdown
1471	Over Current		Warning
1472	Over Current		Shutdown
151	High Coolant Temp	Shutdown lamp. Engine has overheated (coolant temperature above the shutdown trip point).	Shutdown	Allow engine to cool completely. Check coolant level and replenish; look for coolant leaks. Check for obstructions to cooling airflow. Check fan belt and repair or tighten. Check blower fan and circulation pumps on remote radiator installations. Reset control and restart after correcting problem.
197	Low Coolant Level	Warning lamp (Optional). Engine coolant level has fallen below the warning trip point.	Warning	If powering critical loads and cannot be shut down, wait until next shutdown period, then follow code 235 procedure. If engine can be stopped, follow code 235 procedure.
2327	PTC Fault		Warning
2329	Low S1 Frequency		Warning
2331	Low S1 Voltage		Warning
2335	Excitation Fault		Shutdown
2336	Memory Error		Shutdown
2337	Pwr Tran Disabled		Warning
2338	Pwr Tran Failure		Warning
2339	Pwr Down Enabled		Warning
234	Overspeed		Shutdown
2341	High Control Temp		Warning
2342	Too Long In Idle (10 min.)	Warning lamp. Genset has been in Idle mode too long (10 minutes maximum).	Warning
235	Low Coolant Level	Shutdown lamp (Optional). Engine coolant level has fallen below the shutdown trip point.	Shutdown	Allow engine to cool completely. Check coolant level and replenish if low; look for coolant leakage points and repair. Reset control and restart after locating and correcting problem.
2358	High S1 Voltage		Warning
2396	S1 CB Not Close		Warning
2397	S1 CB Not Open		Warning
2966	PTC Timeout		Warning
2967	Governor Fault		Warning
2968	AVR Fault		Warning
2969	LON Failure		Warning
2972	Field Overload		Shutdown
359	Fail To Start	Shutdown lamp. Possible fuel system problem (engine cranks but fails to start).	Shutdown	Open any closed fuel shutoff valve. Check for dirty or plugged air filter and replace if necessary. Gaseous fuel delivery to the set is inadequate; contact an authorized service center. Reset the control and restart after correcting the problem.
415	Low Oil Pressure	Shutdown lamp. Engine oil pressure has dropped below the shutdown trip point.	Shutdown	Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Reset control and restart.
441	Low Bat Voltage	Warning lamp. Battery voltage supply to the control is approaching a low level at which unpredictable operation will occur.	Warning	Check battery charger fuse; recharge or replace the battery. Clean the battery cable terminals and tighten all connections. Check battery charge voltage float level if applicable (raise float level).
442	High Bat Voltage	Warning lamp. Battery voltage supply to the control is approaching a high level at which damage to the control can occur.	Warning	Check float level on battery charger if applicable (lower float level).
Fault 1	Fault 1 (red)	Engine shut down because of a system fault; part of a 10-second time-delay shutdown circuit (customer-wired).	Shutdown
Fault 2	Fault 2 (red)	Engine shut down because of a system fault; part of a non-time-delay shutdown circuit (customer-wired).	Shutdown
High Engine Temperature	High Engine Temperature (red)	Engine shut down due to excessively high coolant temperature (greater than 230°F / 110°C).	Shutdown
Low Engine Temperature	Low Engine Temperature (yellow)	Engine temperature less than 65°F (18°C) or 90°F (32°C); possibility engine might not start.	Warning
Low Fuel	Low Fuel (yellow, optional)	Fuel supply pressure is 5 inches (127 mm) WC or less; also indicates operation on secondary fuel supply for dual-fuel sets.	Warning
Low Oil Pressure	Low Oil Pressure (red)	Engine shut down due to excessively low oil pressure (less than 25 psi / 173 kPa).	Shutdown
Overcrank	Overcrank (red)	Engine did not start during the timed cranking period (approx. 75 seconds, including two rest periods).	Shutdown
Overspeed	Overspeed (red)	Engine shut down due to overspeed condition.	Shutdown
Pre High Engine Temperature	Pre High Engine Temperature (yellow)	Engine coolant temperature abnormally high (greater than 220°F / 104°C).	Warning
Pre Low Oil Pressure	Pre Low Oil Pressure (yellow)	Engine oil pressure abnormally low (less than 30 psi / 207 kPa).	Warning
Run	Run indicator (green)	Starter has disconnected and set is running.	Info
Switch-off	Switch-off (flashing red)	Run/Stop/Remote switch is in the Stop position, preventing remote/automatic operation.	Info

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Procedures

Gaseous Fuel Adjustments adjustment

⚠ Fuel is highly flammable and may cause severe personal injury and property damage. Do not allow cigarettes, flame, pilot lights, arcing switches or equipment in area or areas sharing ventilation.

Tools: exhaust gas analyzer (for emission sensitive areas)

Start engine and let the set warm up under a partial load (at least 1/4 rated load).
If no-load through 1/4 load instability: disconnect loads, shut down, disconnect governor linkage at carburetor.
Start engine and hold throttle closed by hand; adjust throttle idle position screw for 25-35 Hz.
Turn idle adjusting screw counterclockwise until speed becomes unstable; turn clockwise just enough to regain stability and reconnect governor linkage.
Connect full rated load and turn power adjust valve to full-rich; slowly turn toward lean until engine begins to lose speed, then back toward rich until full load is carried smoothly.
If equipped for natural gas and LPG, switch to LPG by closing manual shutoff valve in natural gas supply line.
Reconnect full rated load and turn LPG flow adjustment valve clockwise until engine begins to lose speed, then slowly back counterclockwise until full load is carried smoothly.

Gaseous Fuel System Adjustments adjustment

⚠ Fuel is highly flammable and may cause severe personal injury and property damage. Do not allow cigarettes, flame, pilot lights, arcing switches or equipment in area or areas sharing ventilation.

Tools: exhaust gas analyzer (for emission sensitive areas)

Start the engine and let the set warm up under a partial load (at least 1/4 rated load). Start with natural gas if dual fuel.
Connect full rated load and turn the power adjust valve two turns counterclockwise.
Slowly turn the manual fuel valve clockwise (lean) until the engine begins to lose speed.
Slowly turn counterclockwise (rich) until the engine carries full load smoothly.
If dual fuel, switch to LPG by closing the manual shutoff valve in the natural gas supply line.
Reconnect full rated load and turn the LPG flow adjustment valve clockwise until the engine begins to lose speed.
Slowly turn it back counterclockwise until the engine carries full load smoothly.

Magnetic Speed Pickup Unit Adjustment adjustment

Measure MPU resistance; replace if not between 1,000 and 1,050 ohms.
With MPU removed, rotate ring gear until a tooth lines up in the center of the mounting hole.
Thread pickup in gently by hand until it just touches the ring gear tooth.
Back the pickup out 1/4 turn and set the locknut.
Verify MPU output voltage at cranking speed is at least 1.5 VAC; replace MPU if less.

Type A Gaseous Fuel Adjustment (Naturally Aspirated) adjustment

⚠ Gaseous fuels are flammable and explosive

Disconnect all loads, shut down set, and disconnect governor linkage at the carburetor.
Start engine and hold throttle closed by hand to prevent overspeed.
Adjust throttle idle position screw to obtain a frequency of 25-35 Hz.
Turn idle adjusting screw counterclockwise until engine becomes unstable, then clockwise to regain stability.
Reconnect governor linkage.
Connect full rated load and turn main fuel valve to full-rich, then lean until engine loses speed, then back to rich.
If equipped for LPG, switch to LPG and adjust LPG flow valve similarly under full load.

Verify Overspeed Fault Detection diagnostic

Tools: special tool P/N 420-0604

For Type A sets, move the throttle lever/linkage to increase RPM to the overspeed shutdown range.
For Type B sets, remove the two screws securing the throttle body cover and remove cover.
Use special tool P/N 420-0604 to turn the end of the throttle shaft.
With genset operating at no load, slowly rotate the shaft clockwise until RPM reaches the overspeed limit and shuts down.
Replace the throttle body cover after completing the test.

AC Electrical Connections installation

⚠ Do not connect generator set directly to any building electrical system

⚠ Reconfiguring to different voltages can damage generator or windings; consult distributor

Place the control panel run switch in OFF position; remove AC power from battery charger; remove negative battery cable.
Install transfer switch for standby service applications.
Reconfigure generator output leads on connection terminal block per Reconnection Diagram as needed for nameplate voltage.
Bolt stranded load wires to the appropriate U/V/W/N terminals.
Balance loads so current flow from each line terminal is within 10 percent of median value.
Install current transformers (CT21/CT22/CT23) per Reconnection Diagram with dot facing toward the generator.
Ground the genset to earth in one location only.

AC Voltage Reconnection installation

⚠ Reconfiguring to higher voltages can exceed winding voltage capability and damage generator

⚠ Reconfiguring to lower voltages can increase line current beyond breaker rating

Check available generator output voltages and maximum current ratings on generator nameplate.
Reconfigure generator output leads per Reconnection Diagram on control housing side access cover if required.
Check stator lead terminal block connections and perform necessary reconnect to obtain required voltage.
Route current transformers (CT1, CT2, CT3) per Reconnection Diagram, dot facing generator, current flowing into dot.

Exhaust System Installation installation

⚠ Inhalation of exhaust gases can result in severe personal injury or death

Pipe exhaust gases to outside of enclosure, locating outlets away from air inlets.
Use sealed joint type (NPT) fittings for indoor installations.
Install approved thimble where exhaust pipes pass through walls or partitions.
Pitch horizontal exhaust pipe runs downward away from engine; install condensation trap if pipe must turn upward.
Shield or insulate exhaust lines; allow at least 12 inches (305 mm) clearance from combustible walls.
Use flexible exhaust pipe section between engine and remainder of exhaust system.

Fuel System Installation installation

⚠ Fuel leaks create fire and explosion hazards which can result in severe personal injury or death

Use flexible fuel hose(s) between engine fuel system and fuel supply line.
Install dry-type fuel filter ahead of service pressure regulator.
Route and secure fuel lines maintaining 2 inch (51 mm) minimum clearance from electrical wiring and hot exhaust parts.
Install manual and electric shutoff valves ahead of flexible fuel hose(s).
Test all fuel-system connections for leaks with soap and water solution while system is under pressure (LP minimum 90 psi/621 kPa at primary regulator inlet).

Mounting the Generator Set installation

⚠ Use of unapproved isolators may result in harmful resonances and void warranty

Mount generator set on substantial, level, non-combustible base such as concrete pad.
Use 5/8 inch or 16 mm anchored mounting bolts to secure skid to floor.
Secure skid using flat washer and hex nut for each bolt.
Insert 1-1/2 x 6 inch pipe over mounting bolts to allow adjustment alignment to skid holes.
Provide at least 1 meter (3 feet) clearance on all sides for maintenance and service access.

Ventilation and Cooling Installation installation

⚠ Engine/radiator cooling air may carry deadly carbon monoxide; must be discharged outdoors

Discharge all radiator cooling air to the outdoors.
Size vents/ducts so free area is as large as the exposed radiator area.
Make inlet vent opening 1-1/2 times larger than the radiator area.
Locate cooling air outlet directly in front of and as close as possible to the radiator.
Attach a removable canvas or sheet metal duct to the air outlet opening.

Air Filter Cleaning maintenance

⚠ Do not clean filter housing while still installed. Loose dirt entering intake could damage carburetor or engine.

Tools: low pressure air source (30 psi)

Remove wing nut in center of filter cover; remove cover and filter.
Tap filter on a flat surface to remove dirt.
Place a light source inside filter and inspect for air passage.
Apply low pressure air source (30 psi) to inside of filter to remove as much dirt as possible.
Inspect interior housing; vacuum clean if dirty or remove housing and wipe clean.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Voltage reconnection

Connection	Leads	Notes
Current Transformer routing: CT1-U load leads (A phase), CT2-V load leads (B phase), CT3-W load leads (C phase)	CT1, CT2, CT3	Dot on CT must face toward generator; dual secondaries post 2 (high voltage) or post 3 (low voltage)
Generator reconnection terminal block, terminals U/V/W/N correspond to L1/L2/L3/L0	U, V, W, N	Load balancing within 10 percent of median line current
U, V, W, N terminals correspond to L1, L2, L3, L0	U=A phase (CT21), V=B phase (CT22), W=C phase (CT23)	Reconnection Diagram located on upper side cover of control housing

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Common questions

Which generators use the Cummins/Onan Ford Engine Model engine?

The Cummins/Onan Ford Engine Model powers 2 generator set(s), including Cummins/Onan GGHE, Cummins/Onan GGHF.

What is a common problem with the Cummins/Onan Ford Engine Model engine?

A commonly reported issue on generators using the Cummins/Onan Ford Engine Model is: Over Current.