725 Cummins/Onan generator fault/alarm codes with symptom, cause and remedy — compiled from Cummins/Onan service and controller documentation.
| Code | Meaning / symptom | Cause | Remedy |
|---|---|---|---|
| *4 | Green RUN lamp lights following engine start-up. | 7. Indicates all engine systems are normal. No corrective action required. | |
| *High engine temperature | High engine temperature shutdown. | Check— a. Coolant level. Replenish if necessary. b. City water cooled sets. Check water flow, valves, etc. c. Check sensor; check thermostat. d. Radiator model, check fan belts, radiator for obstructions, etc. | |
| *High engine temperature light ON | *High engine temperature light ON. No shutdown. | Disconnect wire at TB11-31. Light ON after relay reset. Replace engine monitor board. | |
| *High engine temperature shutdown | *High engine temperature shutdown. | A. Coolant level. Replenish if necessary. b. City water cooled sets. Check water flow, valves, etc. c. Check sensor; check thermostat. d. Radiator model, check fan belts, radiator for obstructions, etc. | A. Coolant level. Replenish if necessary. b. City water cooled sets. Check water flow, valves, etc. c. Check sensor; check thermostat. d. Radiator model, check fan belts, radiator for obstructions, etc. |
| *Low oil pressure | Low oil pressure shutdown. | Check— a. Oil level. Replenish if necessary. b. Sensor. Faulty sensor will shut down engine. c. Refer to engine service manual for troubleshooting guide for oil system. | |
| *Low oil pressure light ON | *Low oil pressure light ON. No shutdown. | Disconnect wire at TB11-30. Light ON after relay reset. Replace engine monitor board. | |
| *Low oil pressure shutdown | *Low oil pressure shutdown. | A. Oil level. Replenish if necessary. b. Sensor. Faulty sensor will shut down engine. c. Refer to engine service manual for troubleshooting guide for oil system. | A. Oil level. Replenish if necessary. b. Sensor. Faulty sensor will shut down engine. c. Refer to engine service manual for troubleshooting guide for oil system. |
| -01 | Fuel level in coach tanks | Prime genset fuel system | |
| -23 | HIGH COOLANT TEMP | ||
| 0 | Check electronic engine controls (fault code lamp) | ||
| 00-010 | Coolant Loss (External) | - Check: Coolant level - Cracked or leaking hoses - Loose hose clamps - Radiator or heat exchanger for leaks - Coolant in oil | |
| 00-014 | Coolant Temp Above Normal | - Check: Engine coolant level - High engine temp switch - Fault breaker - Coolant level switch - Perform checks in step 01 - Check: Pressure cap - Coolant pump - Coolant tank - Heat exchanger | |
| 00-021 | Engine Cranks but will not Start | Perform checks in Step 01 - Fuel supply - Spark plugs Perform checks in Step 02 - Battery - Ignition coil - Ignition module Perform checks in Step 03 - Fuel filter - Fuel pump - Carburetor Perform engine leak down test | |
| 00-022 | Eng Cranks But Will Not Start (Genset) | - Check: Battery condition - Fuel level in tank - Wire loose at K5 - Wire loose at start/stop preheat switch - Perform checks in step 01 - Check: Fuel pump - B+ at glow plugs - Fuel shutoff solenoid | |
| 00-024 | Engine Difficult to Start | Check - Fuel supply - Carburetor choke - Spark plugs Perform checks in Step 01 - Air cleaner element - Fuel filter - Intake manifold gaskets - Fuel pump - Carburetor - Ignition coil - Ignition module Perform engine leak down test | |
| 00-026 | Engine Idles Rough | Check - Fuel supply - Spark plugs Perform checks in Step 01 - Carburetor choke - Spark plug wires - Ignition coil | |
| 00-027 | Engine Noise Excessive | Check - Exhaust system - Engine mounting Perform checks in Step 01 - Valve lash - Starter to ring gear clearance | |
| 00-028 | Engine Overspeeds | Check - Governor adjustment - Throttle cable Perform checks in Step 01 - Governor ball spacer | |
| 00-031 | Engine Power Output Low | Check - Governor - Throttle cable - Carburetor choke - Fuel filter - Air cleaner element | |
| 00-037 | Engine Starts but will not Stay Running | Check - Fuel supply - Fuel pumps - Fuel lines - Voltage at ignition coil - Carburetor choke - Carburetor | |
| 00-041 | Genset Unstable (Hunts) | - Check: Fuel supply - Check: Clogged filter - Check: Air in fuel - Check: Loose wire connections | |
| 00-044 | Engine does not Crank or Cranks Slowly | Check - Battery - Voltage at the starter - Engine seizure - Loads - Starter | |
| 00-046 | Excessive Exhaust Smoke Under Load | - Check: Intake air restrictions - Overloaded generator - Valve settings - Perform checks in step 01 - Check: Injection pump timing | |
| 00-0AA | Engine Will Not Crank (Genset) | - Check: Low battery voltage - Terminal connection−loose or dirty - Battery cable size - Circuit breakers - Perform checks in step 01 - Check: Remote control - Connections on PCB control board - Start solenoid - Starter - Start/Stop switch - Start relay K1 | |
| 00-0AB | Starts But Stops When Switch Released | - Check: Oil level - Oil pressure switch - Engine speed - Perform checks in step 01 - Check: CB12 fault breaker - K12 relay operation - DC control breaker - Start/Stop switch operation - Governor lever setting | |
| 00-0AD | High/Low AC Output (Genset) | - Check: Broken or loose wires - Voltage regulator - Transformer regulator - Engine speed - Voltage adjustment pot setting - Output lead wiring configuration - Perform checks in step 01 - Check: Main rotor - Main stator - Excitor rotor - Excitor stator | |
| 00-0AG | No Output Voltage (Avr) (Genset) | - Check: Load breaker closed - Broken or loose wires - AC output to laod breakers - Field breaker CB21 - Excitor field wiring - Perform checks in step 01 - Check: Bridge rectifier CR21 - Rotating dioded CR1−CR6 - Voltage regulator VR21 - Residual voltage - Exiciter rotor - Exiciter stator - Main rotor - Main Stator | |
| 00-0AH | Unstable Voltage with Stable Engine | - Check: Proper output lead connection - Check: Genset output voltage - Check: Voltage at line side of genset breaker - Check: Voltage at load side of genset breaker - Check: Sense leads condition and fully seated in connector to voltage regulator | |
| 00-0AN | High Exhaust Temp (Marine) | - Check: Proper coolant flow out of exhaust - Exhaust temp switch for proper operation - Damaged exhaust temp switch - Plugged sea strainer - Damaged impeller | |
| 00-0AZ | Unbalanced Output Voltage | - Check: Proper output lead connection - Check: Genset output voltage - Check: Voltage at line side of genset breaker - Check: Voltage at load side of genset breaker - Check: Load at genset breaker - Check: Output lead configuration - Check: Voltage regulator plugs fully seated | |
| 00-0CM | Engine Oil Leak | - Clean contaminated area - Check: Oil level - Check: Loose hose or drain fittings - Check: Oil filter seal | |
| 010 | External Coolant Loss | -Visually check for: -Coolant level is OK -Cracked or leaking hoses -Loose clamps -Leaks or defects in radiator -Coolant in oil | |
| 1 | HIGH TEMPERATURE FAULT—CODE NO. 1 | (The engine coolant temperature exceeded 230° F [110° C]) | 1. Check the engine coolant level and add coolant as necessary. 2. Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset. 3. Watch the temperature gauge (optional) and run fewer appliances at the same time to keep down the engine temperature. |
| 1 or 2 digit code | Status light on the generator will repeatedly blink a 1 or 2 digit code after a protective shutdown | ||
| 1, 2, 3, or 4 | First level faults | ||
| 10 | LO FUEL lamp lights. Engine shuts down and LO OIL PRES lamp lights. | 10. Indicates engine has run out of fuel. Check fuel level and replenish as required. | |
| 101 | IDLE MODE Warning | Indicates that the engine is operating in idle mode. When the set is operating in the RUN mode, grounding the engine idle input causes generator build-up to be inhibited and the engine to be governed at 800 RPM. When ground is removed from this input, the set returns to normal speed and voltage. | Indicates that the engine is operating in idle mode. When the set is operating in the RUN mode, grounding the engine idle input causes generator build-up to be inhibited and the engine to be governed at 800 RPM. When ground is removed from this input, the set returns to normal speed and voltage. When the engine idle function is enabled, the control automatically sets lower oil pressure warning and shutdown trip points to reflect the lower operating speed. When the engine idle function is removed and the set reverts to normal operating speed, the control automatically resets oil pressure warning and shutdown trip points to the normal settings. |
| 102 | EMERGENCY STOP Shutdown | Indicates local or remote Emergency Stop. | Indicates local or remote Emergency Stop. To reset the local Emergency Stop button : Pull the button out or turn the switch clockwise (button with arrow) and allow it to pop out. Move the Run/Off/Auto switch to Off. Press the Reset switch. Select Run or Auto, as required. |
| 11 | OVERCURRENT FAULT | (AC output short) | 1. Turn off the genset line circuit breaker. If the genset no longer shuts down, the genset is probably okay—check for and repair a short circuit in the vehicle appliances, wiring or shorted battery charger transformer. 2. Check whether the vehicle engine and genset share the same starting battery. If so, and this fault occurs when cranking the vehicle engine, low battery voltage may be causing this shutdown. Increase battery capacity or install a separate battery and battery charging system for the genset. |
| 11000252 | Low Oil Pressure | Shut off the engine immediately to avoid damage | |
| 111 | Internal ECM error | ||
| 112 | Actuator not responding | ||
| 1123 | A shutdown occurs immediately after moving the customer installed Battle Short switch to OFF with an active but overridden shutdown fault or a shutdown fault that was overridden at any time. | Battle Short is suspended and a shutdown occurs immediately if any of the following critical shutdown faults occur: Overspeed − Fault code 234, Emergency Stop − Fault code 1433, Remote Emergency Stop − Fault code 1434, Speed Signal Lost − Fault code 121, Excitation Fault − Fault code 2335. Moving the customer installed Battle Short switch to OFF with an active but overridden shutdown fault or a shutdown fault that was overridden at any time. | |
| 1124 | Delayed Shutdown | ||
| 113 | Actuator sensor fault | ||
| 1131 | Battle Short mode is enabled. | This feature must only be used during supervised, temporary operation of the genset. The faults that are overridden during Battle Short mode consist of faults that can affect genset performance or cause permanent engine, alternator, or connected equipment damage. | |
| 115 | No speed signal | ||
| 116 | Time press sensor high | ||
| 117 | Time press sensor low | ||
| 118 | Pump press sensor high | ||
| 119 | Pump press sensor low | ||
| 12 | Overvoltage | (The controller is not able to regulate to rated voltage) | See an authorized Onan dealer. |
| 121 | Speed Signal Lost fault. | ||
| 122 | Manifold air press sensor | ||
| 1222 | Not in Auto Event | 1. Make sure you want to work in this mode. - If you do not, check relevant terminal blocks (TB10-6) on the SYNC1320 master synchronizer and related switches for misoperation. 2. Check cabling from the switches to the terminal blocks. 3. Make sure the control switch operation is OK. 4. Use InPower to verify that the SYNC1320 master synchronizer is properly processing contact data. | |
| 1223 | Utility Frequency Warning | The Utility frequency is greater than the upper drop-out threshold or it is less than the lower drop-out threshold and it stays there for a time period that is greater than the drop-out time delay. | 1. Check the lower and upper utility frequency drop-out settings on the SYNC1320 master synchronizer. - To determine if you are trying to synchronize to a dependable source, create a sensible bandwidth that tells you how good the Utility is. InPower or the setup tool can be used to accomplish this. 2. To avoid lengthy synchronizing operation, make sure the Utility frequency is not varying a lot all of the time. 3. Make sure the SYNC1320 master synchronizer is measuring frequency correctly. |
| 1224 | Generator Bus Overvoltage Warning | 1. Make sure the Genset overvoltage threshold is safe for the connected load and make sure that this value is not too close to the rated voltage. 2. Make sure that the drop-out time delay for this fault is not set too low. 3. Check the AVR system operation of each individual genset. 4. Make sure all AC voltage sensors are properly calibrated at the SYNC1320 master synchronizer and the gensets. 5. Use InPower to monitor and make any necessary adjustments. 6. If used, check external transformer connections. | |
| 1225 | Low Genset Voltage | 1. Make sure the Genset undervoltage threshold is safe for the connected load and make that this value is not too close to the rated voltage. 2. Make sure that the drop-out time delay for this fault is not set too low. 3. Check the AVR system operation of each individual genset. 4. Make sure all AC voltage sensors are properly calibrated at the SYNC1320 master synchronizer and the gensets. 5. Use InPower to monitor and make any necessary adjustments. 6. Make sure the wire size and distance is correct and check for loose connections. | |
| 1226 | Genset Frequency Error | Verify that the lower and upper generator bus frequency drop-out settings on the SYNC1320 master synchronizer create a sensible bandwidth that makes load-feeding a safe activity. InPower can be used to accomplish this. Be aware that the generator bus settings harmonize with the genset settings. Make sure the Utility frequency is not varying a lot all of the time. Verify that the SYNC1320 master synchronizer is measuring frequency correctly. Verify that the genset control is correctly calibrated. | |
| 1243 | Engine Derated | ||
| 1244 | Engine Normal Shutdown | ||
| 1245 | Engine Shutdown Fault | ||
| 1246 | Unknown Engine Fault | ||
| 1247 | CAN - Engine Unannounced Fault | ||
| 1248 | Engine Warning | ||
| 13 | Undervoltage | (The controller is not able to regulate to rated voltage) | Reduce the number of connected appliances, especially when air conditioners and battery chargers are running. |
| 1311 | Customer Input #1 | ||
| 1311 and 1312 | Customer Input #1 and #2 (Warning or Shutdown) | ||
| 1311 through 1318 | Customer Defined Fault | When any one of these customer defined inputs is detected by the control, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown or warning as indicated by the Warning or Shutdown lamp. Note: Customer fault messages are editable. The message displayed for the code shown (1311 through 1318) is determined by the customer. | |
| 1311, 1312, 1317, and 1318 | Customer Inputs #1-4 | ||
| 1312 | Config Input #2 Fault | ||
| 1317 | Low Coolant Level (Warning or Shutdown) | ||
| 1318 | Low Fuel (Warning or Shutdown) | ||
| 1322 | KW Setpoint OOR Hi | ||
| 1323 | KW Setpoint OOR Lo | ||
| 1324 | KVAR Setpoint OOR Hi | ||
| 1325 | KVAR Setpoint OOR Lo | ||
| 1328 | Genset CB Tripped | ||
| 1334 | Crit Scaler OR | ||
| 1335 | At least one of the following variables are out of range in utility bus and/or generator bus analog measurements. | Use Inpower to determine if the generator bus or the utility bus is the source of the problem. Verify that the meter calibration is okay. Verify that the SYNC1320 master synchronizer VT and CT ratios are correctly set. Verify that the VT and CT rated values match the ones set in the SYNC1320 master synchronizer. Check the number of turns on each of the built-in CTs to verify that they comply with requirements regarding 5A-secondary and 1A-secondary. Verify that the CT and VT polarities and connections are okay. | |
| 135 | Oil pressure sensor | ||
| 14 | Overfrequency | (The controller is not able to regulate to rated frequency) | Reset breaker and restart. Contact an authorized service center if breaker trips after resetting. |
| 141 | Oil Pressure Sensor Low | ||
| 1416 | FAIL TO SHUTDOWN | Status ï indicates that the “Fault Bypass” mode is enabled. This mode is primarily used by service personnel for troubleshooting purposes. | |
| 1417 | POWER DOWN ERROR | Possible drain on battery. Contact an authorized service center for service. | |
| 143 | Low oil pressure | ||
| 1433 | Emergency Stop fault. | ||
| 1433 / 1434 | EMERGENCY STOP ï LOCAL / EMERGENCY STOP ï REMOTE | To reset the local/remote Emergency Stop button: Pull the button out. Move the O/Manual/Auto switch to O (off). Press the front panel Fault Acknowledge button. Select Manual or Auto, as required. | |
| 1434 | Remote Emergency Stop fault. | ||
| 1435 | Low Coolant Temperature | ||
| 1437 | FAULT HISTORY: 1 OF 24 | ||
| 1438 | FAIL TO CRANK | A. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. b. Discharged or defective battery. Recharge or replace the battery. | |
| 1439 | FUEL LEVEL LOW IN DAY | Check fuel supply and replenish as required. | |
| 144 | Coolant temperature sensor | ||
| 1441 | Low Fuel Level | Indicates fuel supply is running low. Check fuel supply and replenish as required. | |
| 1442 | LAMP: Warning MESSAGE: BATTERY IS WEAK | Indicates battery voltage drops below 14.4 volts for two seconds, during starting. Discharged or defective battery. See Warning message 441 Low Battery Voltage. | |
| 1443 | LAMP: Warning MESSAGE: BATTERY IS DEAD | Indicates battery has dropped below genset operating range (3.5 volts when cranking) to power the starter and the control circuitry. See Warning message 441 Low Battery Voltage. | |
| 1444 | KW Overload | ||
| 1445 | Short Circuit | ||
| 1446 | High AC Voltage | ||
| 1447 | Low AC Voltage (Shutdown) | ||
| 1448 | Underfrequency | ||
| 1449 | Overfrequency | ||
| 145 | Coolant Temperature Sensor Low | ||
| 1451 | Genset/Bus V Mismatch | ||
| 1452 | Genset CB Fail To Close | ||
| 1453 | Genset CB Fail To Open | ||
| 1454 | Genset CB Pos Error | ||
| 1455 | Utility CB Pos Error | ||
| 1456 | Bus Out Of Sync Range | Verify that the Failure to Synchronize time is not too low. Verify that the Permissive Phase Window is not too tight. Verify that the Permissive Voltage Window is not too tight. Check to see that the Permissive Window time is not too high. If: Frequency match is at the high or low limit, or Voltage match is at the high or low limit, or Voltage match has failed, Then a synchronizer output warning is initiated. | |
| 1457 | Fail To Synchronize | Verify that the voltage bias and frequency bias signals to the gensets are arriving at the correct terminals. Verify that the SYNC1320 master synchronizer is sending bias signals to the gensets. Check the speed-governing system of each genset. Check the fuel quality. Make sure that all SYNC1320 master synchronizer and genset meters are properly calibrated. | |
| 1458 | Sync Ph Rot Mismatch | Use InPower to observe data processing on the SYNC1320 master synchronizer. Verify that Genset and Utility input voltage lines to the SYNC1320 master synchronizer match the ones shown on the terminal block as to Phase Rotation and line-to-line match. Make sure the Genset and Utility power lines are properly connected to relevant breakers. Improper connections can result in a catastrophic breaker closure. Check the Genset and Utility VT connections and polarities, if used. | |
| 1459 | Reverse Power | ||
| 146 | HIGH COOLANT TEMP WARNING | A. Reduce load if possible by turning off non-critical loads. b. Check air inlets and outlets and remove any obstructions to airflow. If engine can be stopped, follow 151 High Coolant Temp Alarm procedure. | |
| 1461 | Loss of Field | ||
| 1464 | Load Dump | ||
| 1466 | Modem Failure | ||
| 1468 | Network Error | ||
| 1469 | Speed/Hz Mismatch | ||
| 1471 | High AC Current (Warning) | ||
| 1472 | High AC Current (Shutdown) | ||
| 1475 | First Start Backup Fail | ||
| 1483 | Common Alarm | Search for the active warning and follow the appropriate relevant troubleshooting procedures elsewhere in this document. | |
| 15 | Underfrequency | (The controller is not able to regulate to rated frequency) | Reduce the number of connected appliances, especially when air conditioners and battery chargers are running. |
| 151 | HIGH COOLANT TEMP ALARM | A. Check jacket water coolant level and replenish if low. Look for coolant leakage and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check fan belt and repair if necessary. d. Reset control and restart after locating and correcting problem. | |
| 152 | LOW COOLANT TEMP | A. Coolant heater not connected to power supply. Check for blown fuse or disconnected heater cord and correct as required. b. Check for low jacket water coolant level and replenish if required. Look for possible coolant leakage points and repair as required. | |
| 153 | Manifold air temp sensor | ||
| 1540 | Common Warning | ||
| 1541 | Common Shutdown | ||
| 1573 | Config Input #1 Fault | ||
| 16 | Engine will not crank. | Indicates possible fault with control or starting system. Check for the following conditions: a. Fault lamp on. Correct fault and reset control. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Discharged or defective battery. Recharge or replace the battery. d. Emergency stop button (if equipped) pushed in. To reset, pull switch out and move Run/Stop/Remote switch to Stop position. Then push test switch to Reset/Lamp position. e. Contact an authorized service center if none of the above. | |
| 1689 | Reset Real Time Clock | ||
| 17 | Fuel Pump Fault | Field breaker is tripped. Reset breaker. Contact an authorized service center if voltage buildup causes breaker to trip. | |
| 18 | RUN or fault lamp(s) does not light when Lamp Test switch is engaged. | Contact an authorized service center for assistance. | |
| 1847 | Engine Coolant Temperature High (Shutdown with Cooldown) | ||
| 19 | Governor Actuator (EFI Only) | Indicates possible Start/Disconnect relay failure. Contact an authorized service center for assistance. | |
| 1912 | Utility Loss Of Phase | Check to see that there is no incoming missing line at the SYNC1320 master synchronizer relevant Utility voltage inputs. Make sure there are no loose connections. Since there is little chance that there is a real phase difference in Utility voltage phasors, focus on bad connections. | |
| 1913 | Genset Loss Of Phase | ||
| 1914 | Utility Ph Rotation Error | ||
| 1915 | Genset Phase Rotation | ||
| 197 | COOLANT LEVEL WARNING | A. Check jacket water coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Reset control and restart after locating and correcting problem. | |
| 1992 | Engine Crankshaft Speed Above Rated Speed (Warning) | ||
| 2 | Low Oil Pressure Fault | (The low oil pressure cutoff switch closed for more than 10 seconds) | 1. Check the engine oil level and add oil as necessary. 2. Drain the excess oil if the oil level is above the Full mark on the dipstick. (The oil will foam if the level is too high and result in possible loss of oil pressure.) |
| 200 | LOW OIL PRESSURE Warning | To check oil pressure, access the Oil Pressure menu prior to clearing the fault. | |
| 201 | LOW OIL PRESSURE Shutdown | 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. |
| 202 | Lamp: Warning | Indicates engine is operating near cooling system capacity (monitor condition). Increase in load or higher ambient temperature may cause High Coolant Temp (1) shutdown. | Review code 1 correction list for other possible causes. |
| 204 | OIL PRES SENDER Warning | Indicates that the engine oil pressure sender is out of its working range. Check that the engine oil pressure sender is properly connected. | |
| 21 | Starter Solenoid Circuit - controller senses a short circuit | (The controller sensed a starter control circuit short) | - Check Connections at starter motor - Shorts and/or grounds at solenoid |
| 210 | LOW COOLANT TEMP Warning | Set is not operating. Warning occurs when engine coolant temperature is 70° F (21° C) or lower. NOTE: In applications where the ambient temperature falls below 40°F (4°C), 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. Check for the following conditions: a. Coolant heater not connected to power supply. Check for blown fuse or disconnected heater cord and correct as required. b. Check for low coolant level and replenish if required. Look for possible coolant leakage points and repair as required. c. Open heater element. Check current draw of heater. | |
| 211 | HIGH COOLANT TEMP Warning | Indicates the engine coolant temperature is getting close to the recommended maximum temperature limit: 215° F (102° C) − standby or 207° F (97° C) − primary. If generator is powering non-critical and critical loads and cannot be shut down, use the following: a. Reduce load if possible by turning off non-critical loads. b. Check air inlets and outlets and remove any obstructions to airflow. If engine can be stopped, follow HIGH COOLANT TEMP 212 − SHUTDOWN procedure. To check coolant temperature, access the coolant temperature menu prior to clearing the fault. | |
| 212 | Shutdown lamp lights. | Engine has overheated (coolant temperature has risen above the shutdown trip point: 215°F (102°C) - standby or 207°F (97°C) - primary. | A. Check for obstructions to cooling airflow and correct as necessary. b. Check fan belt and repair or tighten if necessary. c. Check coolant mixture. d. Check blower fan and circulation pumps on remote radiator installations. e. Reset control and restart after locating and correcting problem. |
| 213 | COOLANT SENDER Warning | Indicates that the resistance of the coolant temperature sender is out of range. Check the resistance of the sender. Resistance should be 500 to 2k ohms. | |
| 214 | LOW COOLANT LVL Warning | Allow engine to cool down completely before proceeding. a. Check coolant level in both radiator and coolant recovery bottle and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Reset control and restart after locating and correcting problem. LOW COOLANT LVL Shutdown will not occur if genset is in Idle mode (low coolant warning only). | |
| 214, 215 | Shutdown lamp lights. MESSAGE: LOW COOLANT LVL or LOW COOLANT LVL | Indicates engine coolant level has fallen below the trip point. Allow engine to cool down completely before proceeding. a. Check coolant level in both radiator and coolant recovery bottle and replenish if low. Look for possible coolant leakage points and repair if necessary. b. If radiator level is low and coolant bottle level is correct, defective coolant bottle hose or radiator cap. c. Reset control and restart after locating and correcting problem. LOW COOLANT LVL Shutdown will not occur if genset is in Idle mode (low coolant warning only). | |
| 214/215 | Indicates engine coolant level has fallen below the trip point. | Allow engine to cool down completely before proceeding. a. Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. | |
| 215 | LOW COOLANT LVL Shutdown | ||
| 22 | Governor Actuator Overload (EFI Only) | (The duration of operation at or near full-duty cycle was beyond the design limit) | - Check Load - Air intake restriction - Exhaust restriction - Air leak in fuel system |
| 220 | Shutdown lamp lights. MESSAGE: MAG PICKUP 220 − SHUTDOWN | Indicates mag pickup speed indication is not being sensed or does not match generator set output frequency. | A. Restart and check RPM on the digital display. b. Contact an authorized service center. |
| 221 | Shutdown lamp lights. MESSAGE: FAIL TO CRANK 221 − SHUTDOWN | Indicates possible fault with control or starting system. Check for the following conditions: a. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. b. Discharged or defective battery. Recharge or replace the battery. c. Contact an authorized service center for service of starter and start- ing system. | A. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. b. Discharged or defective battery. Recharge or replace the battery. c. Contact an authorized service center for service of starter and starting system. |
| 222 | Shutdown lamp lights. Engine will not crank. MESSAGE: OVERCRANK 222 − SHUTDOWN | A. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. b. Check for dirty fuel filter and replace if necessary. c. Check for dirty or plugged air filter and replace if necessary. d. Reset the control and restart after correcting the problem. Contact an authorized service center if none of the above. | |
| 223 | Shutdown lamp lights. Engine runs and then shuts down. MESSAGE: OVERSPEED 223 − SHUTDOWN | Contact an authorized service center. | |
| 224 | FAIL TO SYNCHRONIZE Warning/Shutdown | ||
| 226 | FAIL TO CLOSE Shutdown | ||
| 2263 | The fault number is shown on the digital display. | Battery temperature is too high (reaches 131 degrees F (55 degrees C)). | Move the battery into a cooler location. Charger will automatically begin charging again after the battery temperature lowers.; Replace the battery. |
| 23 | Oil Pressure Switch Fault | (The controller sensed a defective switch) | -Check -Perform fuel flow test -Governor linkage for binding -High idle adjustment -Injectors -Injection pump timing -Compression |
| 230 | Warning lamp lights. MESSAGE: LOW DC VOLTAGE 230 − WARNING | A. Discharged or defective battery. Check the battery charger fuse. Recharge or replace the battery. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Contact an authorized service center if none of the above. | |
| 231 | Warning lamp lights. MESSAGE: HIGH DC VOLTAGE 231 − WARNING | Contact an authorized service center. | |
| 232 | Warning lamp lights. MESSAGE: WEAK BATTERY 232 − WARNING | Discharged or defective battery. See Warning message 230, LOW DC VOLTAGE. | |
| 2323 | Network Faults 5 through 8 | ||
| 2323-2326 | Network Faults 5 through 8 | ||
| 2331 | Low Utility Voltage | AC input voltage is more than 10% below nominal rated voltage. | Check level of input voltage. Charger will not operate with voltage 10% or more below nominal. |
| 2335 | Excitation Fault. | ||
| 2336 | Memory Error | ||
| 234 | Overspeed fault. | ||
| 2341 | High Control Temperature | ||
| 2342 | Too Long In Idle | ||
| 235 | COOLANT LEVEL ALARM | A. Check jacket water coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Reset control and restart after locating and correcting problem. | |
| 2358 | High Utility Voltage | AC input voltage is more than 10% above nominal rated voltage. | Check level of input voltage. Charger will not operate with voltage 10% or more above nominal. |
| 236 | Position Sensor | ||
| 2396 | Utility CB Fail To Close | ||
| 2397 | Utility CB Fail To Open | ||
| 24 | Temperature Sending Unit | (The controller sensed a defective sender) | -Check -Connections in wiring harness -Switch continunity |
| 240 | Warning lamp lights. MESSAGE: LOW FUEL DAY 240 − WARNING | Check fuel supply and replenish as required. | |
| 241 | Warning lamp lights. MESSAGE: LOW FUEL 241 − WARNING | Check fuel supply and replenish as required. | |
| 250 | Shutdown lamp lights. MESSAGE: EEPROM ERROR 250 − SHUTDOWN | Indicates PCC memory error. Data corruption of critical operating parameters. Contact an authorized service center. | |
| 251 | Unknown J1939 Fault | Can be caused by battery disconnection/isolation without a run data save operation. | Contact an authorized service center. |
| 253 | OIL LEVEL ALARM | Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Reset control and restart. | |
| 2544 | Charger is overheating | Charger’s ambient temperature is too high.; Charger’s internal cooling fan is blocked, failed, or air inlets are covered. | Move the charger to a cooler location. The charger will automatically begin charging again after the internal temperature lowers.; Verify that the charger’s air inlets on the side of the charger are not blocked and nothing is interfering with fan rotation. |
| 2545 | Keyswitch Reset Required (Warning) | ||
| 260 | Warning/Shutdown | Contact an authorized service center. | |
| 261 | GROUND FAULT* | ||
| 262 | RUPTURE BASIN* | ||
| 263 | HIGH GEN TEMP* | ||
| 27 | Voltage Sense Lost | Battle Short mode is suspended and a shutdown occurs immediately | See an authorized Onan dealer. |
| 28 | Quadrature Sense Fault | (The controller was unable to sense the required parameter) | See an authorized Onan dealer. |
| 29 | High Battery Voltage | 1. Check battery bank connections and reconnect if necessary so that the 12 volt batteries serving the genset are connected in parallel (12 v | |
| 2967 | Governor Fault | ||
| 2968 | AVR Fault | ||
| 2969 | LON Failure | ||
| 2972 | Field Overload (Shutdown) | ||
| 3 | Service Check Fault | (A second-level fault occurred) | Check the second-level fault code by pressing STOP once. The second-level fault code will have two-digits. The faults are listed in numerical order in this table. |
| 3 ~ 6V | Only slight output voltage is delivered (3 ~ 6V) | Repair or replace. | |
| 301 | HIGH AC VOLTAGE | Contact an authorized service center. | |
| 302-102 | Brush rig out of position | Line up properly | |
| 302-68 | Open circuit in armature | Install a new armature | |
| 303 | LOW AC VOLTAGE | Contact an authorized service center. | |
| 31 | Overspeed Fault (HGJAD, E, F Models Only) | Battle Short mode is suspended and a shutdown occurs immediately | |
| 313 | UNDER FREQUENCY | Contact an authorized service center. | |
| 32 | Low Cranking Speed Sense | Controller sensed generator set cranking speed less than 180 rpm for greater than 3 seconds. | Clean and tighten positive (+) and negative (−) battery cable connections at the battery. Recharge or replace battery. Refer to the battery manufacturer’s recommendations. Verify engine oil viscosity is correct for the ambient temperature. If not, refill and replace engine oil with correct viscosity. Have unit serviced by an authorized Cummins Onan dealer. |
| 320 | OVERCURRENT | Contact an authorized service center. | |
| 321 | Shutdown lamp lights. MESSAGE: OVERCURRENT | Contact an authorized service center. | |
| 322 | SHORT CIRCUIT | Contact an authorized service center. | |
| 326 | OIL LEVEL WARNING | If generator is powering critical loads and cannot be shut down, wait until next shutdown period, then follow 688 High Oil Level Alarm procedure. If engine can be stopped follow 688 procedure. | |
| 33 | Fault Code 33 | ||
| 33, 44 | Not assigned due to misinterpretation risk | ||
| 330 | OVERLOAD | Contact an authorized service center. | |
| 335 | REVERSE POWER | Contact an authorized service center. | |
| 343 | Hardware Failure Warning | 1. At least one of the following faults is active. - Calibration Checksum Warning (Fault Code 2416) - EEPROM Write Failure Warning (Fault Code 353) - Utility Bus AC Metering Failure (Fault Code 1335) - Generator Bus AC Metering Failure (Fault Code 1335) 2. The hardware version is not compatible with the software version. | 1. Identify which of the faults is active by observing the fault displayed on the control panel or observing the lamps on the SYNC1320 control board, or by using InPower. 2. Take corrective steps for the active specific faults, as described in this section. 3. Cycle power to the SYNC1320 master synchronizer. 4. If the problem continues, replace the control board. |
| 35 | Control Card Failure | -Check -Control | |
| 353 | EEPROM Write Failure Warning | The current value in RAM memory (to-be-written value) does not match its post-written value in EEPROM. This problem occurs when you attempt to save a trim by using either InPower or the LCD display and it is not successful. This problem may also occur when the SYNC1320 master synchronizer tries to automatically save data on a periodic basis. | Clear the fault either by cycling power to the SYNC1320 master synchronizer or by resetting the processor via an InPower initial calibration. |
| 359 | ENGINE FAILED TO START | A. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. b. Discharged or defective battery. Recharge or replace the battery. | |
| 36 | Genset Stopped Without Fault Condition | Generator stopped without command by controller. | 1. Open any closed fuel supply valves. 2. Check the fuel tank and fill as necessary. (Note: The arrangement of pickup tubes in the fuel supply tank probably is such that the genset will run out of fuel before the propulsion engines.) 3. Check for mechanical damage and service as necessary. 4. Remove any blockage in the combustion air inlet (lower rear of left end of genset). 5. Tighten loose fuel line fittings so that air cannot be drawn in by genset lift pump suction. 6. Drain the fuel filter of water and sediment (Page 15) and prime the fuel system (Page 8). 7. Drain and/or replace fuel supply system filters and prime the fuel system (Page 8). |
| 37 | Invalid Set Configuration | See an authorized Onan dealer. | |
| 379 | Output Overload | Output current is excessive. Charger control may be failing. | Cycle through the Setup menus to try and clear the fault. If the fault returns, the charger control may have failed. |
| 38 | Field Overload (Overvoltage) | 1. Remove blockages to generator air flow at the left side and front of genset. 2. Reduce the number of appliances running at the same time, especially those with high motor starting loads such as air conditioners. 3. Have air conditioners and other appliances checked for proper operation. (A locked compressor rotor can cause very low power factor.) | |
| 4 | Overcrank | 1. Check and fill the fuel tank, as necessary. (Note: The genset fuel pickup is probably higher than the boat engine pickup.) 2. Prime the engine fuel system by holding the control switch at Stop/Prime for 30 seconds. 3. Open any closed fuel valves. 4. Secure the spark plug lead on the spark plug (Page 20). 5. Replace the spark plug (Page 20). 6. Service the air cleaner (Page 19). | |
| 4-6 | External Exerciser Does Not Repeat an Exercise | ||
| 400040 | Wait-to-Start | Wait for the Wait-to-Start lamp to turn off before starting the engine | |
| 40012 | This register contains the fault code number of currently active fault. | ||
| 40013 | This register contains the fault type of currently active fault 0=Normal 1=Warning 2=Derate 3=Shutdown with cool down 4=Shutdown. | ||
| 401 | The generator set does not start. | Possible causes include: low fuel level, faulty starter motor, or a malfunctioning ignition system. | Check the fuel level and refill if necessary. Test the starter motor for functionality. Inspect the ignition system for any issues. |
| 402 | The generator set produces low voltage output. | Possible causes include: dirty or clogged air filter, malfunctioning alternator, or a faulty voltage regulator. | Clean the air filter and check for any blockages. Inspect the alternator for signs of damage or wear. Test the voltage regulator to ensure it is functioning correctly. |
| 403 | The generator set produces high temperature warnings. | Possible causes include: insufficient coolant, malfunctioning thermostat, or a clogged radiator. | Check the coolant level and top up if necessary. Inspect the thermostat for any signs of failure. Clean the radiator to ensure proper airflow. |
| 406 | Complaints of engine surge, stumble, hesitation or hard starting | ||
| 41 | Generator Rotor Fault | See an authorized Onan dealer. | |
| 412 | Engine surge | ||
| 413 | Excessive high–low charging rates | ||
| 415 | Low Oil Pressure | ||
| 42 | Processor Fault | See an authorized Onan dealer. | |
| 420 | Excessive oil carry–over. | ||
| 427 | CAN Datalink Lost Message | ||
| 43 | Processor Fault - Fault Code 43 | See an authorized Onan dealer. | |
| 431 | Failure to start/stop when switched | ||
| 432 | Crankcase breather elements. | ||
| 437 | Exhaust Manifold Gasket Leakage | ||
| 441 | LOW BATTERY VOLTAGE | No battery connected.<br>No output breaker is in the “Off” (down) position.<br>Charger is set for 24V charging with a 12V battery connected.<br>Battery can no longer maintain charge.<br>The wire between the charger and the battery is loose or broken. | A. Discharged or defective battery. Check the battery charger fuse. Recharge or replace the battery. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage (24 to 26 VDC) is not obtained. d. Check float level if applicable (raise float level). |
| 442 | HIGH BATTERY VOLTAGE | Charger is set for 12V charging with a 24V battery connected. | Check float level on battery charger if applicable (lower float level). Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage (24 to 26 VDC) is not obtained. |
| 45 | Speed Sense Fault | Battle Short mode is suspended and a shutdown occurs immediately | -Check -F2 Fuse -Starter circuits -K2 relay and connections -Rotor/stator windings for opens/shorts/ grounds |
| 46 | Generator Set Overload | Current is at 100% of rated operation at design limit. | Reduce the number of connected loads especially loads that require higher starting current such as air conditioners. Check and service air filter as necessary. Have unit serviced by an authorized Cummins Onan dealer. |
| 47 | Ignition Fault | -Check: -Glow plug operation -Low engine operating temperature -Valve settings -Air leaks in fuel system | |
| 471 | LOW OIL LEVEL | If generator is powering critical loads and cannot be shut down, wait until next shutdown period, then follow 253 Oil Level Alarm procedure. If engine can be stopped follow 253 procedure. | |
| 48 | Field Sense Fault | -Check: -Glow plug operation -Air leak in fuel system -Valve settings | |
| 4900 | Fault code 4900 | ||
| 5 | LO OIL PRES lamp lights. Engine shuts down. | 5. Indicates engine oil pressure has dropped to 14 psi (97 kPa). Check oil level, lines and filters. If oil system is okay but oil level is low, replenish. Reset control and restart. Contact an Onan Dealer or Distributor if oil pressure is not in the range of 50 to 70 psi (345 to 483 kPa). | |
| 51 | Processor Failure | Implementation of the thermal damage curve with instantaneous trip level calculated based on current transformer ratio and application power rating. | |
| 5134 | Unknown Shutdown at Idle | ||
| 52 | Fuel Injector Fault | ||
| 5365 | Fault Code on Secondary Source (Information that the Fueling Has Been Shifted to Secondary Source) | ||
| 54 | MAT Sensor Fault | ||
| 56 | MAP Sensor Fault | ||
| 5669 | Engine Combustion (Shutdown) | ||
| 57 | Overprime Fault | ||
| 58 | Exhaust Gas Temperature Shutdown | ||
| 59 | High AC voltage shutdown (Output voltage on any phase exceeds pre-set values). | ||
| 6 | OVERCRANK lamp lights and engine stops cranking. | 6. Indicates possible fuel system problem. a. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. b. Check for dirty fuel filter and replace if necessary (see MAINTENANCE section). c. Check for dirty or plugged air filter and replace if necessary (see MAINTENANCE section). d. Refer to Step 5. e. Reset the control and restart after correcting the problem. Contact an Onan Dealer or Distributor for service if none of the above. | |
| 6-5 | System Does Not Test With Load | ||
| 61 | Emergency Stop | Battle Short mode is suspended and a shutdown occurs immediately | |
| 611 | ENGINE HOT | This type of shutdown should be avoided. Can cause possible loss of performance and engine damage. | |
| 6518 | Cold Start Idle Active (Event) | ||
| 688 | HIGH OIL LEVEL ALARM | Check oil level. Drain oil to operating level. | |
| 7 | LOSS OF RAW WATER FLOW | 1. Open the sea cock. 2. Close the sea cock and clean the sea water strainer. If the strainer is above the water line, fill it with water to assist priming. Secure the strainer cover and reopen the sea cock. 3. Reconnect or replace any disconnected or leaking raw water hoses (Page 19). 4. Remove any blockage from the strainer on the through-hull fitting on the bottom side of the hull. 5. Replace the raw water impeller (Page 23). | |
| 76 | Alternator Over Temp | ||
| 77 | Battle Short feature is disabled after an overridden shutdown fault occurred whilst in Battle Short mode | ||
| 78 | Low Fuel Pressure | ||
| 781 | CAN Datalink Failure | ||
| 79 | Failure To Transfer To Generator Set | ||
| 8 | OVERLOAD | Reduce load and restart | |
| 81 | Exhaust Gas Temperature Sensor Open | ||
| 81 o | Over frequency shutdown/warning | Generator set is operating at a potentially damaging frequency level. | |
| 81 u | Generator set output frequency cannot be maintained. | Generator set output frequency cannot be maintained. | |
| 81u | Under frequency shutdown | ||
| 82 | Exhaust Gas Temperature Sensor Shorted | ||
| 9 | LO FUEL lamp lights. Engine continues to run. | 9. Indicates diesel fuel supply is running low. Check fuel supply and replenish as required. | |
| 9115 | Unrecoverable battery fail | The battery can no longer hold a charge or has been damaged excessively due to extremely deep discharge. | Replace the battery and cycle through the Setup menus to clear the fault. |
| 96 | Lamp: Shutdown | Indicates that the engine oil temperature is above normal and has reached the shutdown trip point. | |
| 98-4001 | Engine is not getting fuel. | Prime the fuel system. Check fuel supply and fuel solenoid. If necessary, check for fuel tank empty, shutoff valves binding, linkage loose or broken wires, fuel lines kinked, loose connections, clogged fuel filters, and transfer pump. | |
| 9801-LLO | Low Oil Pressure Shutdown (LOPKO) | ||
| A052J727 (Issue 1) | The screen will display a description of the fault, the numeric fault code, and the hour the fault occurred in total generator set running time (see figure below). | Refer to Section 6.4 on page 60 to diagnose and correct the problem. | |
| A11-4 | Overspeed | Check engine manufacturer's manual for troubleshooting guide | |
| A11-5 | Overcrank | Check loss of fuel or ignition failure | |
| BF | BF | ||
| BFA | BFA | ||
| Bad Batter Connection | Battery connections are loose or wires are not properly connected. | Clean and tighten all battery terminals. Check for loose wires and correct connections. | |
| Battle short mode | Shutdown faults are bypassed | Refer to the Control Application Guide or Manual for list of these faults | |
| CB1 | Circuit Breaker CB1 | ||
| CB1 OPEN | Shutdown because the DC output circuit breaker is Open (off or tripped). | (This shutdown is disabled when the control switch is in MANUAL. When the control switch is in AUTO, the genset will start, warm up and then shut down.) | |
| CB21 | Exciter Circuit Breaker | Are the rotating diodes CR1 through CR6 on the exciter rotor OK? Is the exciter stator winding OK? Is the generator main field winding OK? is the exciter rotor winding OK? Replace CB21 circuit breaker. Test CR21 to method D. Is CR21 OK? Replace CR21. | |
| CHECK ENG | Fault lamp lights but no fault exists. Engine gauges show oil pressure, engine temperature, and frequency (speed) are within normal limits. | The monitor board or a sensor may be at fault. Contact an authorized service center for service. | |
| CODE 1245 | CAN ENGINE SHUTDOWN (SHUTDOWN) | ||
| CODE 1311, 1312, 1317, 1318 | Customer input (WARNING/shutdown) | ||
| CODE 1438 | FAIL TO CRANK (SHUTDOWN) | ||
| CODE 1442 | WEAK BATTERY (WARNING) | ||
| CODE 1443 | BATTERY FAILED (SHUTDOWN) | ||
| CODE 1444 | KW OVERLOAD (WARNING) | ||
| CODE 1445 | SHORT CIRCUIT (SHUTDOWN) | ||
| CODE 1446 | HIGH AC VOLTAGE (SHUTDOWN) | ||
| CODE 1447 | LOW AC VOLTAGE (SHUTDOWN) | ||
| CODE 1448 | UNDER FREQUENCY (SHUTDOWN) | ||
| CODE 1449 | OVER FREQUENCY (warning) | ||
| CODE 1471/1472 | OVER CURRENT (WARNING/SHUTDOWN) | ||
| CODE 19 | Controller sensed governor actuator circuit open or shorted. | Have unit serviced by an authorized Cummins Onan dealer. | |
| CODE 197/235 | LOW COOLANT LEVEL (WARNING/SHUTDOWN) | ||
| CODE 427 | CAN DATALINK LOST MESSAGES (WARNING) | ||
| CODE 441 | LOW BATTERY VOLTAGE (WARNING) | ||
| CODE 442 | HIGH BATTERY VOLTAGE (WARNING) | ||
| CODE 781 | CAN DATALINK FAILED (SHUTDOWN) | ||
| CODE NO. 1 | HIGH ENGINE TEMPERATURE FAULT SHUTDOWN—CODE NO. 1 | 1. Check for and remove any objects blocking the air inlet or outlet openings. 2. Reduce the electrical load. (Note that high altitude and high ambient temperature decrease engine cooling capacity.) 3. Clean the engine cooling fins and blower blades. See Periodic Maintenance. 4. Review the installation and housing design against the specifications and requirements of the Installation Manual. | |
| CODE NO. 12 | OVERVOLTAGE FAULT SHUTDOWN | See the Service Manual. | |
| CODE NO. 13 | UNDERVOLTAGE FAULT SHUTDOWN | Turn the genset line circuit breaker OFF. If the genset runs without shutting down, run the genset with fewer connected loads. | |
| CODE NO. 14 | OVERFREQUENCY FAULT SHUTDOWN | Make sure the governor rod is not hanging up on the spark plug cable (Page 8). | |
| CODE NO. 15 | UNDERFREQUENCY FAULT SHUTDOWN | 1. Turn the genset line circuit breaker OFF. If the genset runs without shutting down, run the genset with fewer connected loads. 2. Make sure the governor rod is not hanging up on the spark plug cable (Page 8). 3. Replace Fuse F3 (carburetor de-icer) if blown. 4. Fill the LPG fuel tank if less than half full. On cold days the LPG container may have to be kept at least half full to provide the rate of vaporization required to keep up with genset fuel demand. LPG with more than 2.5 percent butane will not vaporize below 32° F (0° C). Use HD-5 grade LPG. 5. Secure the spark plug cables at the spark plugs and at the ignition coil. 6. Check for proper fuel selection and change if necessary (Page 6). 7. Check the engine air filter and remove any blockage. 8. Check for a blocked exhaust system and service as necessary. 9. Replace the spark plugs and/or spark plug cables. | |
| CODE NO. 17 | ENGINE ACCESSORY FAULT SHUTDOWN | See the Service Manual. | |
| CODE NO. 19 | GOVERNOR ACTUATOR FAULT SHUTDOWN | See the Service Manual. | |
| CODE NO. 2 | LOW OIL PRESSURE FAULT SHUTDOWN—CODE NO. 2 | 1. Check engine oil level and add oil as necessary. Repair oil leaks. 2. Drain excess oil. (Excess oil leads to foaming and a consequent loss of oil pressure.) | |
| CODE NO. 22 | GOVERNOR ACTUATOR OVERLOAD SHUTDOWN—Duration of operation at or near full-duty cycle beyond design limit | Corrective Action: Reduce the number of connected appliances, especially when air conditioners and battery chargers are running. Service the air cleaner (Page Section 4.5). Check for and repair a blocked exhaust system. | |
| CODE NO. 23 | LOW OIL PRESSURE CUTOFF SWITCH FAULT ALERT | See the Service Manual. | |
| CODE NO. 24 | TEMPERATURE SENDER FAULT ALERT | See the Service Manual. (Note that under this condition the controller will limit genset output to 3.5 kW.) | |
| CODE NO. 27 | VOLTAGE SENSE SHUTDOWN—Controller unable to sense output voltage | Corrective Action: See an authorized Onan dealer. | |
| CODE NO. 29 | HIGH BATTERY VOLTAGE SHUTDOWN—Voltage across battery system greater than 19 volts | Corrective Action: Check battery bank connections and reconnect if necessary so that the 12 volt batteries serving the genset are connected in parallel (12 volt) rather than in series (24 volt). Select a lower battery boost charge rate. | |
| CODE NO. 3 | 100 HOUR MAINTENANCE ALERT—CODE NO. 3 | Perform the required maintenance according to Periodic Maintenance. The alert can only be reset by means of a software command via network or PC. See your authorized Onan dealer. | |
| CODE NO. 31 | OVERSPEED SHUTDOWN—Engine speed greater than 3400 rpm | Corrective Action: See an authorized Onan dealer. | |
| CODE NO. 32 | LOW CRANKING SPEED SHUTDOWN—Cranking speed less than 180 rpm for more than 2 seconds | Corrective Action: Clean and tighten the positive (+) and negative (-) battery cable connections at the battery and at the genset. Recharge or replace the battery. Refer to the battery manufacturer's recommendations. Replace engine oil with oil of proper viscosity for ambient temperatures (Page Section 2.5). (High oil viscosity can slow down cranking speed.) | |
| CODE NO. 34 | HIGH ENGINE TEMPERATURE ALERT | 1. Check for and remove any objects blocking the air inlet or outlet openings. 2. Reduce the electrical load. (Note that high altitude and high ambient temperature decrease engine cooling capacity.) 3. Clean the engine cooling fins and blower blades. See Periodic Maintenance. | |
| CODE NO. 35 | CONTROL CARD FAULT SHUTDOWN | See the Service Manual. | |
| CODE NO. 36 | ENGINE STOPPED SHUTDOWN—Engine stopped without command by controller | 1. Check and fill the fuel tank, as necessary. (Note: The genset fuel pickup is probably higher than the boat engine pickup.) 2. Secure the spark plug lead on the spark plug (Page 20). 3. Replace the spark plug (Page 20). 4. Service the air cleaner (Page 19). 5. Check for mechanical damage. | |
| CODE NO. 37 | INVALID SET CONFIGURATION ALERT | See your authorized Onan dealer. Special software and a PC are required to re-configure the controller. | |
| CODE NO. 38 | OVERCURRENT (FIELD OVERLOAD) SHUTDOWN—Low power factor loads | Corrective Action: Reduce the number of appliances running at the same time, especially those with high motor starting loads such as air conditioners. Have air conditioners and other appliances checked for proper operation. (A locked compressor rotor can cause very low power factor.) | |
| CODE NO. 39 | WEAK BATTERY ALERT | 1. Clean and tighten the positive (+) and negative (–) battery cable connections at the battery and at the genset. 2. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations. 3. Check for and remove any parasitic loads on the battery. | |
| CODE NO. 4 | LOW OIL LEVEL ALERT—CODE NO. 4 | Check the engine oil level and add oil as necessary. Repair oil leaks. | |
| CODE NO. 41 | GENERATOR FIELD FAULT SHUTDOWN | See the Service Manual. | |
| CODE NO. 42 | PROCESSOR SHUTDOWN—Microprocessor ROM error during self-test | Corrective Action: See an authorized Onan dealer. | |
| CODE NO. 43 | PROCESSOR SHUTDOWN—Microprocessor RAM error during self-test | Corrective Action: See an authorized Onan dealer. | |
| CODE NO. 45 | SPEED SENSE SHUTDOWN—Controller unable to sense quadrature frequency | Corrective Action: See an authorized Onan dealer. | |
| CODE NO. 47 | IGNITION SHUTDOWN—Controller unable to sense ignition | Corrective Action: See an authorized Onan dealer. | |
| CODE NO. 48 | GENERATOR FIELD SENSE SHUTDOWN—Controller unable to sense field voltage | Corrective Action: See an authorized Onan dealer. | |
| CODE NO. 5 | FAILURE TO START FAULT SHUTDOWN—CODE NO. 5 | Corrective Action—Engine Does Not Crank: 1. Replace Fuse F2 if blown. 2. Clean and tighten the positive (+) and negative (–) battery cable connections at the battery and at the genset (Page 8). 3. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations. Corrective Action—Engine Cranks But Does Not Start: 1. Open any closed fuel shutoff valve. 2. Fill the LPG fuel tank if less than half full. On cold days the LPG container may have to be kept at least half full to provide the rate of vaporization required to keep up with genset fuel demand. LPG with more than 2.5 percent butane will not vaporize below 32° F (0° C). Use HD-5 grade LPG. 3. Secure the spark plug cables at the spark plugs and at the ignition coil. 4. Make sure the governor rod is not hanging up on the spark plug cable (Page 8). 5. Check for proper fuel selection and change if necessary (Page 6). 6. Check the engine air filter and remove any blockage. 7. Check for a blocked exhaust system and service as necessary. 8. Replace the spark plugs and/or spark plug cables. | |
| CODE NO. 51 | PROCESSOR SHUTDOWN—Microprocessor malfunction | Corrective Action: See an authorized Onan dealer. | |
| CODE NO. 52 | FUEL INJECTOR SHUTDOWN | (Open or short circuit in fuel injector) | See an authorized Onan dealer. |
| CODE NO. 54 | MAT SENDER SHUTDOWN | (Open or short circuit in MAT sender) | See an authorized Onan dealer. |
| CODE NO. 56 | MAP SENDER SHUTDOWN | (Open or short circuit in MAP sender) | See an authorized Onan dealer. |
| CODE NO. 57 | OVERPRIME SHUTDOWN | (Prime mode exceeded 3 minutes) | Check for and remove any object that may be holding either control switch (remote or local) in the prime position. |
| CODE NO. 58 | Exhaust Gas Temp Shutdown/Fault | (Exhaust gas temperatures reach 650C (1202F) for 2 secs when the set is running) | See an authorized Onan dealer |
| CODE NO. 6 | CONTROL SWITCH OFF ALERT—CODE NO. 6 | ||
| CODE NO. 7 | LOSS OF UTILITY POWER ALERT | Verify that the genset is supplying the load. | |
| CODE NO. 8 | CABINET FAULT ALERT | Service the fault as necessary. | |
| CODE NO. 9 | LOW GAS SUPPLY PRESSURE ALERT | 1. Open all shutoff valves in the fuel supply line. 2. Fill the LPG container. On cold days the LPG container may have to be kept at least half full to provide the rate of vaporization required to keep up with genset fuel demand. LPG with more than 2.5 percent butane will not vaporize below 32° F (0° C). Use HD-5 grade LPG. | |
| COMM POWER FAIL | Indicates that commercial AC power is not available. | ||
| COOLANT SENDER 213 | Warning lamp lights. MESSAGE: COOLANT SENDER 213 − WARNING | Indicates that the resistance of the coolant temperature sender is out of range. Check the resistance of the sender. Resistance should be 500 to 2k ohms. | |
| CR1 | Rotating Diode (CR1) | Check continuity between VR21-1 and T7, apply shorting jumper if no continuity. Replace circuit breaker CB21 if necessary. | |
| CR2 | Rotating Diode (CR2) | Check continuity between VR21-1 and T7, apply shorting jumper if no continuity. Replace circuit breaker CB21 if necessary. | |
| CR21 | Defective component on CR21 | Check continuity between VR21-1 and T7, apply shorting jumper if no continuity. Replace circuit breaker CB21 if necessary. | |
| CR3 | Rotating Diode (CR3) | Check continuity between VR21-1 and T7, apply shorting jumper if no continuity. Replace circuit breaker CB21 if necessary. | |
| CR4 | Silicon Controlled Rectifier (SCR) 4 | Check continuity between VR21-1 and T7, apply shorting jumper if no continuity. Replace circuit breaker CB21 if necessary. | |
| CRS | Silicon Controlled Rectifier (SCR) S | Check continuity between VR21-1 and T7, apply shorting jumper if no continuity. Replace circuit breaker CB21 if necessary. | |
| CUSTOMER FAULT 1 | Shutdown lamp lights. MESSAGE: CUSTOMER FAULT 1 260 − SHUTDOWN or GROUND FAULT 261 − SHUTDOWN or DAY TANK 262 − SHUTDOWN or HIGH GEN TEMP 263 − SHUTDOWN | When any one of these customer defined inputs is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown or a warning. As indicated by the Shutdown lamp, a shutdown response has been preselected. | |
| CUSTOMER FAULT 1 260 | Shutdown lamp lights. MESSAGE: CUSTOMER FAULT 1 260 − SHUTDOWN or GROUND FAULT 261 − SHUTDOWN | When any one of these customer defined inputs is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown or a warning. As indicated by the Shutdown lamp, a shutdown response has been preselected. | |
| Check Engine | ‘Check Engine’ Fault Shutdown | ||
| Code 1 | Engine Over Temperature | ||
| Code 1121 | Fail To Disconnect | ||
| Code 1122 | Delayed Rated To Idle Transition | ||
| Code 1124 | Delayed Shutdown | ||
| Code 1131 | Battle Short Active | ||
| Code 1132 | Controlled Shutdown | ||
| Code 12 | Over Voltage | ||
| Code 1219 | Utility CB Tripped | ||
| Code 1223 | Utility Frequency Error | ||
| Code 1224 | High Genset Voltage | ||
| Code 1225 | Low Genset Voltage | ||
| Code 1226 | Genset Frequency Error | ||
| Code 1243 | Engine Derated | ||
| Code 1244 | Engine Normal Shutdown | ||
| Code 1245 | Engine Shutdown Fault | ||
| Code 13 | Under Voltage | ||
| Code 135 | Oil Pressure Sensor OOR High | ||
| Code 14 | Over Frequency | ||
| Code 141 | - Oil pressure sensor output out of range low | ||
| Code 143 | - Engine oil pressure low (warning) | ||
| Code 144 | - Engine coolant temperature out of range low (warning) | ||
| Code 145 | Engine Coolant Temperature OOR Low | ||
| Code 146 | Engine Coolant Temperature Moderately Above Normal | ||
| Code 15 | Under Frequency | ||
| Code 151 | Engine Coolant Temperature High - Critical | ||
| Code 153 | Intake Manifold Temperature OOR - High | ||
| Code 154 | Intake Manifold Temperature OOR - Low | ||
| Code 155 | Intake Manifold Temperature High - Critical | ||
| Code 19 | Governor Actuator | ||
| Code 197 | Low Coolant Level | ||
| Code 2 | Low Oil Pressure | ||
| Code 212 | Engine Oil Temperature OOR High | ||
| Code 213 | Engine Oil Temperature OOR Low | ||
| Code 214 | Engine Oil Temperature High - Critical | ||
| Code 22 | Governor Actuator Overload | ||
| Code 234 | Engine Speed High - Critical | ||
| Code 236 | Engine Speed/Position Sensor Circuit | ||
| Code 24 | Faulty Temperature Sender | ||
| Code 27 | Voltage Sense | ||
| Code 29 | High Battery Voltage | ||
| Code 3 | Service Check | ||
| Code 319 | Real-Time Clock Backup Battery – Very Low Voltage | ||
| Code 32 | Low Cranking Speed | ||
| Code 35 | Control Card Failure | ||
| Code 359 | Fail To Start | ||
| Code 36 | Engine Stopped | ||
| Code 4 | Over Crank | ||
| Code 415 | Engine Oil Pressure Low - Critical | ||
| Code 421 | Engine Oil Temperature Moderately Above Normal | ||
| Code 427 | CAN Data Link Degraded | ||
| Code 4332 | Loss of Communication with (device) on Channel 1 or 2 | ||
| Code 4333 | Fail to Send SMS Notification | ||
| Code 4337 | SIM Card Not Detected/SIM Card Error | ||
| Code 4341 | External Memory Read/Write Error | ||
| Code 4342 | Configured Data Log Storage Device (SD/USB) is Removed | ||
| Code 4343 | Storage Space is Almost Full | ||
| Code 4344 | Storage Space is Full | ||
| Code 4351 | AUX102 Not Detected | ||
| Code 4355 | Software Update Successful | ||
| Code 4356 | Software Update Failed | ||
| Code 4357 | System Error | ||
| Code 441 | Low Battery Voltage | ||
| Code 442 | High Battery Voltage | ||
| Code 4594 | <Sensor> has High Warning | ||
| Code 4595 | <Sensor> has Low Warning | ||
| Code 4596 | <Sensor> Voltage Above Critical High Threshold | ||
| Code 4597 | <Sensor> Voltage Below Critical Low Threshold | ||
| Code 488 | Intake Manifold Temperature Moderately Above Normal | ||
| Code 5138 | Genset Control Not in Auto | ||
| Code 5139 | Auto Transfer Switch Not in Auto | ||
| Code 5141 | Source 1 Connected | ||
| Code 5142 | Source 2 Connected | ||
| Code 5143 | Genset Running | ||
| Code 5144 | Genset Stopped | ||
| Code 5341 | <Sensor> is Active | ||
| Code 5342 | <Sensor> is Inactive | ||
| Code 611 | Engine Hot Shut Down | ||
| Code 762 | Real-Time Clock Backup Battery Voltage Above Normal Operating Range | ||
| Code 763 | Real-Time Clock Backup Battery Voltage Below Normal Operating Range | ||
| Code 781 | The ECM CAN Datalink Has Failed | ||
| Code No. 1 | Code No. 1 - High Engine Temperature | ||
| Code No. 12 | Code No. 12 - High AC Voltage | ||
| Code No. 13 | Code No. 13 - Low AC Voltage | ||
| Code No. 14 | Code No. 14 - High AC Frequency | ||
| Code No. 15 | Code No. 15 - Low AC Frequency | ||
| Code No. 16 | Engine Fault | Above Normal | |
| Code No. 2 | Code No. 2 - Low Oil Pressure | ||
| Code No. 22 | Code No. 22 - Governor Overload | ||
| Code No. 23 | Code No. 23 - Faulty Oil Pressure Sender | ||
| Code No. 24 | Code No. 24 - Faulty Temperature Sender | ||
| Code No. 27 | Code No. 27 - Loss of AC Voltage Sense | ||
| Code No. 29 | Code No. 29 - High Battery Voltage | ||
| Code No. 3 | Code No. 3 - Service Check | ||
| Code No. 32 | Code No. 32 - Starting Fault | ||
| Code No. 4 | Code No. 4 - Overcrank | ||
| Code No. 5 | Code No. 5 - Warning Shutdown due to CO | ||
| Code No. 7 | Code No. 7 - Loss of Raw Water Flow | ||
| DS12 | Emergency Shutdown | ||
| DS13 | Low Oil Pressure | ||
| DS14 | High Water Temperature | ||
| DS15 | Overspeed | ||
| Derate | Output power reduced in response to a fault condition | If operating on an isolated bus, commands issued to reduce load; if in utility parallel mode, active reduction by lowering base load kW | |
| E | ENGINE MALFUNCTION SHUTDOWN | ||
| E-DEAD STATUS INDICATOR LIGHT | Poor connections, faulty wiring or dead battery | 1. Try starting the genset at the operator’s console if it does not start at the remote panel. 2. Clean and tighten the battery cable connections at the battery and at the genset. 3. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations. | |
| EEPROM ERROR | Warning lamp lights. MESSAGE: EEPROM ERROR 251 − WARNING or 252 − WARNING | Indicates PCC memory error. Data corruption of noncritical operating parameters. | |
| EEPROM ERROR 250 | Shutdown lamp lights. MESSAGE: EEPROM ERROR 250 − SHUTDOWN | Indicates PCC memory error. Data corruption of critical operating parameters. | |
| EEPROM ERROR 251 | Warning lamp lights. MESSAGE: EEPROM ERROR 251 − WARNING or 252 − WARNING | Indicates PCC memory error. Data corruption of noncritical operating parameters. | |
| ENG COOLANT SENDER | Shutdown or Warning lamp lights. | Resistance of the coolant temperature sender is out of range. | Contact an authorized service center. |
| ENG TEMP | Hl ENG TEMP lamp lights. Engine shuts down. | Engine has overheated (engine temperature has risen above 215°F/102°C) or coolant level is low. | A. Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check for a slipping fan belt and tighten if loose. d. Reset control and restart after locating and correcting problem. Contact an authorized service center if none of the above. |
| ENGINE SHUTDOWN | Shutdown due to something other than annunciated by the other lamps. It could be low oil pressure (GCAB and GCAC). | ||
| ENGINE SPEED TOO Low | Governor incorrectly adjusted | Adjust for proper speed | |
| ENGINE WILL NOT CRANK | *15. Engine will not crank. | A. Fault lamp on. Correct fault and reset control. b. Poor battery cable connections ... Clean the battery cable terminals and tighten all connections. c. Discharged or defective battery; Recharge or replace the battery. d. Contact an Onan dealer or distributor for assistance if none of the above. | |
| ES-1852 | Overload Detector | Shut down the output device | |
| ES-1859-1 | Overvoltage Monitor | Shut down the output device and trip an optional circuit breaker | |
| Engine | Will not crank. | Indicates possible fault with control or starting system. Check for the following conditions: a. Fault lamp on. Correct fault and reset control. b. Poor battery cable connections ... Clean the battery cable terminals and tighten all connections. c. Discharged or defective | |
| Engine Cranks but will not Start | Engine Cranks but will not Start | ||
| F | LOW OIL PRESSURE SHUTDOWN | ||
| F01 | Generator does not start | Possible causes include low battery voltage, faulty starter motor, or incorrect wiring | Check the battery voltage; replace if necessary. Test the starter motor. Verify all connections are correct and secure. Refer to the fault code table for more details. |
| F02 | Generator produces insufficient power output | Possible causes include clogged air filter, low fuel level, or malfunctioning alternator | Clean or replace the air filter. Check the fuel level; refill if necessary. Inspect the alternator for any signs of damage or wear. Refer to the fault code table for more details. |
| F03 | Generator overheats | Possible causes include clogged cooling system, low coolant level, or malfunctioning thermostat | Clean the radiator fins and check for debris blockages. Check the coolant level; top up if necessary. Test the thermostat to ensure it is functioning correctly. Refer to the fault code table for more details. |
| F04 | Generator produces excessive noise during operation | Possible causes include loose engine components, worn-out bearings, or malfunctioning muffler | Inspect all moving parts and tighten any loose bolts. Replace worn-out bearings as needed. Check the muffler for damage; replace if necessary. Refer to the fault code table for more details. |
| F05 | Generator emits black smoke during operation | Possible causes include rich fuel mixture, clogged air filter, or malfunctioning fuel injection system | Adjust the fuel mixture according to the manufacturer’s specifications. Clean or replace the air filter. Inspect and clean the fuel injection system components. Refer to the fault code table for more details. |
| F06 | Generator produces blue smoke during operation | Possible causes include oil dilution, worn-out piston rings, or malfunctioning exhaust valve | Check the oil level; top up if necessary. Inspect the piston rings for wear and replace as needed. Test the exhaust valves to ensure they are functioning correctly. Refer to the fault code table for more details. |
| F07 | Generator produces white smoke during operation | Possible causes include coolant leakage, water in fuel system, or malfunctioning thermostat | Inspect the cooling system for any leaks; repair if necessary. Check the fuel system for signs of water contamination; replace fuel as needed. Test the thermostat to ensure it is functioning correctly. Refer to the fault code table for more details. |
| F08 | Generator produces excessive fuel consumption. | Check the air filter for blockage or damage. Verify that the fuel supply is adequate and check for any fuel system issues. Refer to the Fault Code Table for further troubleshooting. | |
| F1 | Blown Fuse (F1) | Replace with a 20 amp (yellow) blade-type fuse (Page 29). If the new fuse blows, check for ground faults in harnesses 338-4084, 338-4085 and 338-4087 and replace as necessary (Page 23 or 26). | |
| F2 | Fuse F2 on engine monitor board A11 has blown. | A. Replace the fuse with one of the same type and amp rating (20 A). b. If fuse F2 blows again, either the wire between terminal A11-TB1-10 and emergency stop switch S14 terminal S14-C-1 or between S14-C-2 and relay K11 terminal 85 may be loose and shorting to ground. Repair as necessary. c. If fuse F2 still blows, replace relay K11. | |
| F4 | Fuse F4 on engine monitor board A11 has blown. | A. Replace the fuse with one of the same type and amp rating (5 A). b. If fuse F4 blows again, the lead to terminal 3 on switch S12 (Run-Stop-Remote) or to terminal 5 on switch S11 (Lamp Test-Reset−Preheat) or a lead in the indicator lamp (A12) harness or engine gauge (M11 through M16) harness may be loose and shorting to ground. Repair as necessary. | |
| FAIL TO CRANK | Engine will not crank. | A. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. b. Discharged or defective battery. Recharge or replace the battery. c. Contact an authorized service center for service of starter and starting system. | |
| FAIL TO CRANK 221 | Shutdown lamp lights. Engine stops cranking. MESSAGE: FAIL TO CRANK 221 − SHUTDOWN | Indicates possible fault with control or starting system. Check for the following conditions: a. Check fuse F3 on the Engine Interface board. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Discharged or defective battery. Recharge or replace the battery. | |
| FAIL TO CRANK 221 - SHUTDOWN | Shutdown lamp lights. Engine will not crank. MESSAGE: FAIL TO CRANK 221 − SHUTDOWN | A. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. b. Discharged or defective battery. Recharge or replace the battery. c. Contact an authorized service center for service of starter and starting system. | |
| FAULT | Fault lamp lights but no fault exists. Engine gauges show oil pressure, engine temperature and frequency (speed) are within normal limits. | Reset control. If control will not reset, the monitor board or a sensor may be at fault. Contact an Onan dealer or distributor for service. | |
| FAULT 1 | The FAULT 1 or FAULT 2 fault lamp lights. Engine shuts down immediately, engine runs for several seconds and then shuts down, or engine continues to run. | The standard undesignated fault functions are programmed to shut down the set when a fault is sensed. | |
| FAULT 1 (red) | Undedicated fault. May be factory programmed as a shutdown or non-shutdown, and as a timed or non-timed fault. (Normally set for timed shutdown). | @ FAULT 1 (red) an undedicated fault. May be factory programmed as a shutdown or non-shutdown, and as a timed or non-timed (normally set for timed shutdown). | |
| FAULT 1 or FAULT 2 | Engine shuts down immediately, engine runs for several seconds and then shuts down, or engine continues to run. | Engine gauges show oil pressure, engine temperature, and frequency (speed) are within normal limits. | |
| FAULT 2 | Same features as Fault 1 (Normally set for non-timed shutdown). | Correct fault and reset control. | |
| FAULT 2 (red) | Same features as Fault 1 (Normally set for non-timed shutdown). | @ FAULT 2 (red) same features as Fault 1 (normally set for timed shutdown). | |
| FAULT LAMP | *13. Fault lamp lights but no fault exists. Engine gauges show oil pressure, engine temperature and frequency (speed) are within normal limits. | Reset control. If control will not reset, the monitor board or a sensor may be at fault. Contact an Onan dealer or distributor for service. | |
| Fault 1 | High Engine Temperature Shutdown | ||
| Fault Code Blinking | Restoring Fault Code Blinking | ||
| Fault Code Table | Status Indicators | ||
| Faulty Alternator-GI | Alternator fails to charge when running at 1800 RPM. | Replace alternator. | |
| Faulty Choke- E I | Choke is stuck in the open or closed position. | Manually check choke arm for free movement. Replace if voltage at choke terminal does not drop to zero during cranking and run. | |
| Faulty Contacts- K2 | Contacts of relay K2 are faulty or not functioning properly. | Check contacts of relay K2 for faults. | |
| Faulty Disconnect Circuit | Disconnect circuit is faulty or not functioning properly. | Check for faults in the disconnect circuit. | |
| Faulty Fue I Pump -E2 | Fuel pump is not operating properly when manually tested. | Replace fuel pump if it does not operate with the lead connected to +12V. | |
| Faulty LOP Switch-S2 | Low oil pressure switch is faulty or not functioning properly. | Replace low oil pressure switch if voltage from terminal 11-12 does not drop to zero volts with proper oil level and engine running. | |
| Faulty Regulator- VR | Regulator is faulty or not functioning properly. | Replace regulator VRI if the charging current does not meet specifications. | |
| Faulty Relay-K3 | Relay K3 is faulty or not functioning properly. | Check relay K3 if it is faulty. | |
| Faulty Start Solenoid- KI | Start solenoid is not functioning correctly during cranking. | Check K1 coil voltage. Replace start solenoid if the voltage is not present at any of the specified terminals. | |
| Faulty Starter - BI | Starter brushes are faulty or not functioning properly. | Replace starter brushes and/or substitute with a new starter if defective. | |
| Faulty Stop Switch-S3 | Stop switch is faulty or not functioning properly. | Check stop switch S3 if it is faulty. | |
| Fuse Out- F I | Fuse is blown. | Replace fuse if voltage at terminals 5 to GND is not 12 volts. | |
| G | HIGH WATER TEMPERATURE SHUTDOWN | ||
| GAS HAZARD | Shutdown because of a possible gas leak. | ||
| GREEN RUN LAMP | *17. Green RUN lamp does not light following engine start-up. | Indicates possible Start/Disconnect relay failure. Contact an Onan dealer or distributor for assistance. | |
| GROUND FAULT | Warning lamp lights. MESSAGE: CUSTOMER FAULT 1 260 − WARNING or GROUND FAULT | ||
| Generator overvoltage | Generator overvoltage. | A. Replace SCR block. b. Replace voltage regulator. | |
| Grounded LOP Circuit | Oil pressure sensor wire is grounded. | Check oil pressure sensor wire for short to ground by visually tracking the wire routing under cover edges. Move wire to free space if necessary. | |
| H | OVERSPEED CONDITION | ||
| H! ENG TEMP | Engine has shut down because of critically high temperature. | ||
| HET | High Engine Temperature | ||
| HI ENG TEMP | HI ENG TEMP lamp lights. Engine shuts down. | Engine has overheated (engine temperature has risen above 227°F/104°C) or coolant level is low (sets with coolant level sensor). | Indicates engine has overheated (engine temperature has risen above 215° F/102° C) or coolant level is low (sets with coolant level sensor). Allow engine to cool down completely before proceeding with the following checks: a. Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check for a slipping fan belt and tighten if loose. d. Reset control and restart after locating and correcting problem. Contact an authorized service center if none of the above. |
| HIGH AC VOLTAGE | Shutdown lamp lights. MESSAGE: HIGH AC VOLTAGE 301 − SHUTDOWN | Indicates that one or more of the phase voltages has exceeded 130% of nominal, or has exceeded 110% of nominal for 10 seconds. | |
| HIGH COOLANT TEMP | Shutdown lamp lights. | Allow engine to cool down completely before proceeding with the following checks: a. Check coolant level and replenish if low. Look for coolant leakage and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check fan belt and repair or tighten if necessary. d. Reset control and restart after locating and correcting problem. Contact an authorized service center if none of the above. | |
| HIGH COOLANT TEMP 212 | Shutdown lamp lights. MESSAGE: HIGH COOLANT TEMP 212 − SHUTDOWN | Indicates engine has overheated (coolant temperature has risen above the shutdown trip point: 223° F (106° C) − standby or 215° F (102° C) − prime.) | Allow engine to cool down completely before proceeding with the following checks: a. Check for obstructions to cooling airflow and correct as necessary. b. Check fan belt and repair or tighten if necessary. c. Check coolant mixture. d. Check blower fan and circulation pumps on remote radiator installations. e. Reset control and restart after locating and correcting problem. |
| HIGH COOLANT TEMPERATURE | The coolant temperature switch closes at 250°F (121°C) and actuates the fault circuit. | Check the coolant level in radiator after allowing engine to cool down. Ensure the pump belt is okay and has proper tension. Also check cooling system cleanliness (freedom from contaminants, rust, sludge build-up, etc.). | Check the coolant level in radiator after allowing engine to cool down. Ensure the pump belt is okay and has proper tension. Also check cooling system cleanliness. |
| HIGH DC VOLTAGE 231 | Warning lamp lights. MESSAGE: HIGH DC VOLTAGE 231 − WARNING | Indicates battery voltage exceeds 32 VDC. Check voltage float level on battery charger if applicable (lower float level). Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage is not obtained. | |
| HIGH ENG TEMP | HIGH ENG TEMP lamp lights. Engine shuts down. | Indicates engine has overheated and engine temperature has risen above 215°F (102°C) or coolant level is low (sets with coolant level sensor). Allow engine to cool down completely before proceeding with the following checks: a. Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check for a slipping fan belt and tighten if loose. d Reset control and restart after locating and correcting problem. Contact an Onan dealer or distributor if none of the above. | |
| HIGH GEN TEMP | Warning lamp lights. MESSAGE: CUSTOMTER FAULT 1 263 − WARNING or HIGH GEN TEMP | ||
| HIGH OIL PRESSURE | Low engine power (will not reach governed speed) | Check for other causes. Of by-pass stuck closed. Clean. | |
| HUNTING CONDITION | GOVERNOR ACTS SLOWLY | Defective breather valve. Clean or replace. Binding in linkage. Clean and lubricate link age. | |
| High Engine Temperature | High engine temperature (higher than 220 ±6°F) | ||
| High Exhaust Temperature | High exhaust temperature (higher than 190 ±9°F) | ||
| High engine temperature | *High engine temperature shutdown. | A. Coolant level. Replenish is necessary. b. City water cooled sets. Check water flow, valves, etc. c. Check sensor; check thermostat. d. Radiator model, check fan belts, radiator for obstructions, etc. | |
| High engine temperature light ON | High engine temperature light ON, no shutdown | Disconnect wire at TB11-31. Light ON after relay reset. Replace engine monitor board. | |
| High engine temperature shutdown | High engine temperature shutdown | Check coolant level and replenish if necessary; check water flow, valves, etc. for city water cooled sets; check thermostat sensor; check radiator model, fan belts, radiator for obstructions. | |
| Hl ENG TEMP | Hl ENG TEMP lamp lights. Engine shuts down. | Engine has overheated (engine temperature has risen above 215°F/102°C) or coolant level is low. | A. Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check for a slipping fan belt and tighten if loose. d. Reset control and restart after locating and correcting problem. Contact an authorized service center if none of the above. |
| K11 | Relay K11 is faulty. | Push the Run-Stop-Remote switch to Run and check for battery voltage (12 VDC) at relay K11 terminals 85 and 87 while the engine is cranking. Replace relay K11 if there is voltage at terminal 85 but not at terminal 87. | |
| K13 | K13 - HET | ||
| K17 | K17 - PHET | ||
| K19 | K19 - PLOP | ||
| K4 - Fault 2 | K4 - Fault 2 | ||
| K5 - Fault 1 | K5 - Fault 1 | ||
| LO ENG TEMP | Indicates engine coolant heater is not operating standby mode but is not operating. | A. Coolant heater not connected to power supply. b. Check for low coolant level and replenish if required. Look for possible coolant leakage points and repair as required. c. Contact an Onan dealer or distributor if none of the above. | A. Coolant heater not connected to power supply. Check for blown fuse or disconnected heater cord and correct as required. b. Check for low coolant level and replenish if required. Look for possible coolant leakage points and repair as required. c. Contact an authorized service center if none of the above. |
| LO ENG TEMP lamp lights | Set is in standby mode but is not operating. | Lamp lights when engine coolant temperature is 70° F (21° C) or lower. Since the lamp goes out after the engine warms up, there should be no cause for alarm even during initial generator set operation. | |
| LO FUEL | LO FUEL lamp lights. Engine continues to run. | Indicates gasoline fuel supply is running low. Check fuel supply and replenish as required. | |
| LO FUEL (Pressure) | LO FUEL (Pressure) lamp lights. Shutdown will occur if unit runs out of fuel. | Install the fuel hose and regulator supplied with the unit and connect to a propane fu | |
| LO FUEL LAMP | LO FUEL LAMP lights. Engine shuts down and LO OIL PRES lamp lights. | Indicates engine has run out of fuel. Check fuel level and replenish as required. | |
| LO OIL PRES | LO OIL PRES lamp lights. Engine shuts down. | Engine oil pressure has dropped to 14 psi (97 kPa). | Indicates engine oil pressure has dropped to 25 psi (172 kPa). Check oil level and filters. If oil system is OK but oil level is low, replenish. Reset control and restart. Contact an authorized service center if oil pressure is not in the range of 40 to 65psi (275 to 448 kPa). |
| LOP | Low Oil Pressure | ||
| LOW AC VOLTAGE | Shutdown lamp lights. MESSAGE: LOW AC VOLTAGE 303 ï SHUTDOWN | Indicates that one or more of the phase voltages has dropped below 85% of nominal for 10 seconds. | Contact an authorized service center. |
| LOW COOLANT LVL | Shutdown lamp lights. MESSAGE: LOW COOLANT LVL 214 − WARNING or LOW COOLANT LVL 215 − SHUTDOWN | Indicates engine coolant level has fallen below the trip point. Allow engine to cool down completely before proceeding. | A. Check coolant level in both radiator and coolant recovery bottle and replenish if low. b. If radiator level is low and coolant bottle level is correct, defective coolant bottle hose or radiator cap. c. Reset control and restart after locating and correcting problem. |
| LOW COOLANT LVL 214 | Shutdown lamp lights. MESSAGE: LOW COOLANT LVL 214 − WARNING or LOW COOLANT LVL 215 − SHUTDOWN | Engine coolant level has fallen below the trip point. | Indicates engine coolant level has fallen below the trip point. Allow engine to cool down completely before proceeding. a. Check coolant level in both radiator and coolant recovery bottle and replenish if low. Look for possible coolant leakage points and repair if necessary. b. Reset control and restart after locating and correcting problem. LOW COOLANT LVL Shutdown will not occur if genset is in Idle mode (low coolant warning only). |
| LOW DC VOLTAGE | Warning lamp lights. | A. Discharged or defective battery. Check the battery charger fuse. Recharge or replace the battery. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Contact an authorized service center if none of the above. | |
| LOW DC VOLTAGE 230 | Warning lamp lights. MESSAGE: LOW DC VOLTAGE 230 − WARNING | Indicates battery voltage is below 10 VDC. a. Discharged or defective battery. Check the battery charger fuse. Recharge or replace the battery. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Check engine DC alternator. Replace engine DC alternator if normal battery charging voltage is not obtained. d. Check battery charge voltage float level if applicable (raise float level). | |
| LOW ENG TEMP | Engine temperature is marginally low for starting. Indicates inoperative coolant heater. | ||
| LOW FUEL-DAY | Shutdown lamp lights. MESSAGE: LOW FUEL−DAY 240 − WARNING or LOW FUEL 241 − WARNING | Indicates day tank fuel supply is running low. Check fuel supply and replenish as required. | |
| LOW FUEL-DAY 240 | Shutdown lamp lights. MESSAGE: LOW FUEL−DAY 240 − WARNING or LOW FUEL 241 − WARNING | Indicates day tank fuel supply is running low. Check fuel supply and replenish as required. | |
| LOW OIL CONSUMPTION | Clogged oil passages | Clean all lines and oil passages | |
| LOW OIL PRESSURE | The DC control has sensors that continuously monitor the engine for abnormal conditions such as low oil pressure and high coolant temperature. If one of these conditions occur, the control stops the engine. | If low, add oil to bring level up to full mark. Inspect engine exterior for leaks and repair as necessary. Be sure the correct viscosity oil is used for existing ambient temperature (see Maintenance section). The oil pressure switch actuates the fault circuit if pressure drops below 9 psi (62 kPa). | Remove the dipstick and check oil level. If low, add oil to bring level up to full mark. Inspect engine exterior for leaks and repair as necessary. Be sure the correct viscosity oil is used for existing ambient temperature. |
| LOW VOLT SHUTDOWN | Shutdown because minimum DC bus voltage cannot be attained (18 VDC or 36 VDC). | ||
| Low Battery - BT I | Battery specific gravity is low, indicating the need to recharge or replace the battery. | Check specific gravity. Recharge or replace battery if necessary. | |
| Low Oi PRESSURE | Worn bearings | Rebuild engine | |
| Low Oil Level | Oil level is low. | Refill to proper oil level. | |
| Low Oil Pressure | Low oil pressure (lower than 14 ±2 PSI) | Check fuel supply and for dirty fuel filters. Replace if necessary. Check oil level and replenish if needed. | |
| Low oil pressure | *Low oil pressure shutdown. | A. Oil level. Replenish if necessary. b. Sensor. Faulty sensor will shut down engine. | C. Refer to engine service manual for troubleshooting guide for oil system. |
| Low oil pressure light ON | Low oil pressure light ON, no shutdown | Disconnect wire at TB11-30. Light ON after relay reset. Replace engine monitor board. | |
| Low oil pressure shutdown | Low oil pressure shutdown. | Check— a. Oil level. Replenish if necessary. b. Sensor. Faulty sensor will shut down engine. c. Refer to engine service manual for troubleshooting guide for oil system. | |
| Low or No Fuel | Fuel level is low. | Refill fuel tank. | |
| M191is | Compressor Belt Tension System | ||
| M1993s | Service Access | ||
| M19946 | Bypass Thermostat | ||
| MAG PICKUP 220 | Shutdown lamp lights. MESSAGE: MAG PICKUP 220 − SHUTDOWN | Indicates mag pickup speed indication is not being sensed or does not match generator set output frequency. a. Restart and check RPM on the digital display. | |
| NO AC OUTPUT VOLTAGE | *16. No AC output voltage. | Field breaker is tripped. Reset breaker. Contact an Onan dealer or distributor if voltage buildup causes breaker to trip. | |
| NO. 1 | HIGH TEMPERATURE—FAULT CODE NO. 1 (Engine coolant or inverter heat sink temperature exceeded design limit) | Corrective Action: Check the second-level fault code by touching Stop. The second-level fault will be either No. 33 or No. 34. | |
| NO. 11 | OVERCURRENT FAULT—CODE NO. 11 (AC output short) | Corrective Action: 1. Turn off the genset line circuit breaker. If the genset no longer shuts down, the genset is probably okay—check for and repair a short circuit in the vehicle appliances, wiring or shorted battery charger transformer. 2. Check whether the vehicle engine and genset share the same starting battery. If so, and this fault occurs when cranking the vehicle engine, low battery voltage may be causing this shutdown. Increase battery capacity or install a separate battery and battery charging system for the genset. | |
| NO. 12 | INVERTER OVERVOLTAGE FAULT—CODE NO. 12 (Controller not able to regulate to rated voltage) | Corrective Action: Check whether the vehicle engine and genset share the same starting battery. If so, and this fault occurs when cranking the vehicle engine, low battery voltage may be causing this shutdown. Increase battery capacity or install a separate battery and battery charging system for the genset. | |
| NO. 13 | INVERTER UNDERVOLTAGE FAULT—CODE NO. 13 (Controller not able to regulate to rated voltage) | Corrective Action: Check whether the vehicle engine and genset share the same starting battery. If so, and this fault occurs when cranking the vehicle engine, low battery voltage may be causing this shutdown. Increase battery capacity or install a separate battery and battery charging system for the genset. | |
| NO. 14 | INVERTER OVERFREQUENCY FAULT—CODE NO. 14 (Controller not able to regulate to rated frequency) | Corrective Action: Reduce the number of connected appliances, especially when air conditioners and battery chargers are running. | |
| NO. 15 | INVERTER UNDERFREQUENCY FAULT—CODE NO. 15 (Controller not able to regulate to rated frequency) | Corrective Action: 1. Reduce the number of connected appliances, especially when air conditioners and battery chargers are running. 2. Have air conditioners and other appliances checked for proper operation. (A locked compressor rotor can cause very low power factor.) | |
| NO. 19 | GOVERNOR ACTUATOR FAULT—The controller sensed that the actuator circuit is either open or shorted | Corrective Action: See an authorized Onan dealer. | |
| NO. 2 | LOW OIL PRESSURE—FAULT CODE NO. 2 (Low oil pressure cutoff switch did not open) | Corrective Action: 1. Check engine oil level and add oil as necessary (Page 15). 2. Drain excess oil (above dipstick Full mark). | |
| NO. 22 | GOVERNOR OVERLOAD FAULT—The duration of operation at or near full-duty cycle was beyond the design limit | 1. Reduce the number of appliances running at the same time, especially those with high motor starting loads such as air conditioners. 2. Check for fuel (air) leaks at all fuel fittings and tighten as necessary. Prime the engine fuel system by holding the control switch at Stop for one minute. 3. Replace the engine air filter (Page 17) and clean the spark-arrest muffler (Page 18). 4. Replace the fuel filter (Page 19). | |
| NO. 23 | LOW OIL PRESSURE CUTOFF SWITCH FAULT | Corrective Action: See an authorized Onan dealer. | |
| NO. 24 | TEMPERATURE SENDER FAULT—The controller sensed that the sender circuit is either open or shorted | Corrective Action: See an authorized Onan dealer. | |
| NO. 25 | ENGINE ABOVE SPEED TARGET FAULT | Corrective Action: See an authorized Onan dealer. | |
| NO. 26 | ENGINE BELOW SPEED TARGET FAULT | Corrective Action: 1. Reduce the number of connected appliances, especially when air conditioners and battery chargers are running. 2. Prime the engine fuel system by holding the control switch down in its Stop position for at least 1 minute. | |
| NO. 27 | AC VOLTAGE SENSE FAULT—The controller was unable to sense output voltage | Corrective Action: See an authorized Onan dealer. | |
| NO. 28 | DC SENSE LOST FAULT | Corrective Action: Open the circuit breaker. If the fault does not persist, check for and disconnect excessive loads from the genset before starting. | |
| NO. 29 | HIGH BATTERY VOLTAGE FAULT—The controller sensed battery system voltage greater than 19 volts | 1. Check battery bank connections and reconnect, if necessary, so that the 12 volt batteries serving the genset are connected in parallel (12 volt) rather than in series (24 volt). 2. Select a lower battery booster charge rate. | |
| NO. 3 | SERVICE CHECK FAULT—CODE NO. 3 (A second-level fault occurred) | Corrective Action: Check the second-level fault code by touching Stop. The second-level fault will be one of the following in this table. | |
| NO. 31 | OVERSPEED FAULT | Corrective Action: See an authorized Onan dealer. | |
| NO. 32 | LOW CRANKING SPEED FAULT—Cranking speed less than 100 rpm [2.5 Hz, generator] for more than 12 seconds | 1. Have the vehicle propulsion engine running while trying to start the genset. (The battery charging alternator may be able to maintain starting voltage high enough to get the genset started.) 2. Clean and tighten the battery cable connections at the battery and at the genset. 3. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations. 4. Replace engine oil with oil of proper viscosity for ambient temperatures. (High oil viscosity can slow down cranking speed.) | |
| NO. 33 | HIGH ENGINE COOLANT TEMPERATURE FAULT | Corrective Action: 1. Check the engine coolant level and add coolant and repair leaks as necessary (Page 20). 2. Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset. 3. Reduce the number of appliances connected at the same time. (Note that high altitude and high ambient temperature decrease engine cooling capacity.) 4. Clean and flush the cooling system to remove coolant passage fouling. 5. If the genset overheats only underway, see the coach manufacture regarding air baffles or other means to direct cooling air into the genset. | |
| NO. 34 | HIGH INVERTER TEMPERATURE FAULT | Corrective Action: 1. Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset. 2. Reduce the number of appliances connected at the same time. (Note that high altitude and high ambient temperature decrease cooling capacity.) | |
| NO. 35 | CONTROL CARD FAULT—Microprocessor EEPROM error during self-test | Corrective Action: See an authorized Onan dealer. | |
| NO. 36 | ENGINE STOPPED FAULT—The genset stopped without a command from the controller | 1. Check the fuel level and refill as necessary. (Note: The genset fuel pickup is probably higher than the vehicle engine fuel pickup.) 2. Check for fuel (air) leaks at all fuel fittings and tighten as necessary. Prime the engine fuel system by holding the control switch at Stop for one minute. 3. Check the engine air filter (Page 17) and remove any blockage. 4. Check for mechanical damage. 5. Replace the fuel filter (Page 19). | |
| NO. 37 | INVALID GENSET CONFIGURATION FAULT | Corrective Action: See an authorized Onan dealer. | |
| NO. 38 | OVERCURRENT FAULT—CODE NO. 38 (Low power factor loads) | 1. Reduce the number of appliances running at the same time, especially those with high motor starting loads such as air conditioners. 2. Have air conditioners and other appliances checked for proper operation. (A locked compressor rotor can cause very low power factor.) | |
| NO. 39 | LOW BATTERY VOLTAGE: Marginal battery, connections, or charging system, or parasitic loads | 1. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery and genset (Page 18). 2. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations. | |
| NO. 41 | GENERATOR ROTOR FAULT—CODE NO. 41 (Controller unable to sense field or output voltage) | See an authorized Onan dealer. | |
| NO. 42 | PROCESSOR FAULT—CODE NO. 42 (Microprocessor ROM error during self-test) | See an authorized Onan dealer. | |
| NO. 43 | PROCESSOR FAULT—CODE NO. 43 (Microprocessor RAM error during self-test) | See an authorized Onan dealer. | |
| NO. 45 | SPEED SENSE FAULT—CODE NO. 45 (Controller unable to sense quadrature frequency) | See an authorized Onan dealer. | |
| NO. 46 | INVERTER POWER SUPPLY FAULT—CODE NO. 46 | 1. Avoid running the genset while cranking the vehicle engine in installations where the genset batteries are used to supplement the vehicle engine batteries. 2. Clean and tighten the positive (+) and negative (–) battery cable connections at the battery, vehicle frame and genset (Page 17). 3. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations. 4. Install or service a battery charging system in the vehicle if the genset is not so equipped. | |
| NO. 47 | IGNITION FAULT—CODE NO. 47 (Controller unable to sense ignition) | See an authorized Onan dealer. | |
| NO. 48 | GENERATOR FIELD SENSE FAULT—CODE NO. 48 (Controller unable to sense field voltage) | See an authorized Onan dealer. | |
| NO. 57 | OVERPRIME FAULT—Prime mode exceeded 3 minutes | Check for and remove any object that may be holding either control switch (remote or local) in the prime (stop) position. | |
| NO. 58 | HIGH EXHAUST TEMPERATURE: Exhaust temperature exceeded design limits | 1. Check for and reconnect or replace any disconnected or leaking raw water hoses (Page 19). 2. Check for and replace a worn raw water impeller (Page 23). | |
| NO. 61 | EMERGENCY SHUTDOWN: Genset was shut down by a fire suppression system or other external control connected to genset | Make all necessary repairs to the genset and connected equipment and reset the external control which shut down the genset. | |
| No. 16 | Engine Pre-Alarms | ||
| No. 33 | High temperatures and temperature rises indicate that warm discharge air is recirculating back into the genset compartment or that the inlet or outlet air opening is restricted. | Find out why and correct as necessary to meet the temperature specifications. | |
| No. 4 | The genset does not start after two or three tries. | Wait 5 seconds for the control to reset before trying again. | |
| O/U VOLTAGE | 10. The O/U VOLTAGE lamp lights. Engine shuts down. | Contact an authorized service center for service. | |
| OS | Overspeed | ||
| OSKO | Overspeed Cut Out | ||
| OV | Output voltage | Set the switch to the desired AC or DC position | |
| OVER CRANK | OVER CRANK—CODE NO. 4 | Cranking time exceeded 35 seconds | 1. Check fuel level and refill as necessary. (Note: The genset fuel pickup is probably higher than the vehicle engine fuel pickup.) 2. Prime the engine fuel system for one minute (p. 2-4). 3. Check the engine air filter and remove any blockage (p. 3-4). 4. Change the engine oil to oil of the proper viscosity for the ambient temperature. High oil viscosity can slow down cranking speed. 5. Check all fuel fittings for fuel and air leaks and tighten as necessary. Reprime. 6. Replace the fuel filter (p. 3-6). |
| OVER TEMPERATURE (INVERTER) | Inverter temperature detected to be over 70°C | Reduce loads, verify heat sink cleanliness and air flow; if issue persists after cooling, replace inverter | |
| OVERCRANK | *6. OVERCRANK lamp lights and engine stops cranking. | A. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. b. Check for dirty fuel filter and replace if necessary (see Maintenance section), c. Check for dirty or plugged air filter and replace if necessary (see Maintenance section). d. Check for loose connections in the ignition primary, ignition secondary, or solenoid valve | A. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. b. Check for dirty fuel filter and replace if necessary (see Maintenance section), c. Check for dirty or plugged air filter and replace if necessary (see Maintenance section), d. Check for loose connections in the ignition primary, ignition secondary, or solenoid valve circuits and correct as required, e. Reset the control and restart after correcting the problem. Contact an Onan dealer or distributor for service if none of the above. |
| OVERCRANK 222 | Shutdown lamp lights. Engine stops cranking. MESSAGE: OVERCRANK 222 − SHUTDOWN | Possible fuel system problem. | A. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. b. Check for dirty fuel filter and replace if necessary. c. Check for dirty or plugged air filter and replace if necessary. d. Reset the control and restart after correcting the problem. Contact an authorized service center if none of the above. |
| OVERCURRENT | Shutdown lamp lights. MESSAGE: OVERCURRENT 320 ï WARNING | Indicates that generator output current has exceeded 110% of rated for 60 seconds. | Contact an authorized service center. |
| OVERLOAD | Too many applications connected or inverter defective | Indicates that three-phase power output exceeds 105% of standby (or 115% of prime) rating. After five seconds, the Load Dump output is ac- tivated. After 60 seconds, the OVERLOAD warning is activated. | Measure current draw, reduce loads, test with load bank, check stator and replace if necessary; perform stator check before replacement |
| OVERSPEED | Engine runs and then shuts down, OVERSPEED lamp lights | Contact an Onan dealer or distributor for service | |
| OVERSPEED 223 | Shutdown lamp lights. Engine runs and then shuts down. MESSAGE: OVERSPEED 223 − SHUTDOWN | Indicates engine has exceeded normal operating speed. (115% ±1% of nominal). | |
| OVERTEMP | Shutdown because of high engine or heat sink temperature. | ||
| OVERVOLT | Shutdown because DC bus exceeded maximum allowable voltage: 29.5 VDC or 59 VDC (or other). | ||
| One blink | Shutdown due to high engine coolant temperature | ||
| Overcrank | Overcrank fault lamp lights and engine stops cranking after about 75 seconds. | Check for empty fuel tank, empty fuel filters, system leaks, or plugged fuel filters and fuel supply lines. Correct as required. | |
| Overspeed | Overspeed shutdown. | Check governor and throttle linkages for freedom of movement. Check overspeed switch. | |
| Overspeed light ON, no shutdown | Overspeed light ON, no shutdown. | Disconnect wire at TB11-29. Light ON after reset; replace engine monitor board. | |
| Overspeed light on, no shutdown | Overspeed light on, no shutdown. | Disconnect wire at TB11-29. Light on after reset; replace engine monitor board. | |
| Overspeed shutdown | Overspeed shutdown. | Check governor and throttle linkages for freedom of movement. Check overspeed switch. | |
| Overspeed shutdown. | Overspeed shutdown. | Check governor and throttle linkages for freedom of movement. Check overspeed switch. | |
| P.N. 06090 | Pressure gauge inoperative or not registering accurately | ||
| P.N. 06100 | Oil leaking from underside of crankcase | Replace oil gauge or cover O.ring, and drain plug O.ring | |
| PAD SHEAR | Shutdown because the genset has shifted from its installed position. | ||
| PRE HET/LOP | PRE HET/LOP lamp lights. Engine continues to operate. | Engine has begun to overheat and engine temperature has risen to approximately 205°F (97°C) or coolant level is low. | A. Reduce load if possible by turning off non-critical loads. b. Check air inlets and outlets and remove any obstructions to airflow. 2B. Indicates engine oil pressure has dropped to 30 psi (207 kPa). If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then follow step 4. If engine can be stopped follow procedure in Steps 3 and 4. |
| PRE HI ENG TEMP | Engine temperature is marginally high. | ||
| PRE HI ENGINE TEMP | PRE HI ENGINE TEMP lamp lights. Engine continues to operate. | Indicates engine has begun to overheat and engine temperature has risen to approximately 205° F (97° C). If generator is powering non-critical and critical loads and cannot be shut down, use the following: a. Reduce load if possible by turning off non-critical loads. b. Check air inlets and outlets and remove any obstructions to airflow. If engine can be stopped, follow procedure in step 3. | |
| PRE Hi ENGINE TEMP | 2. PRE Hi ENGINE TEMP lamp lights. Engine continues to operate. | Indicates engine has begun to overheat and engine temperature has risen to approximately 205°F (97°C). If engine can be stopped, follow procedures in step 3. Use the following procedures if generator is powering Critical loads and cannot be shutdown. a. Check air inlets and outlets and remove any obstructions to airflow. b. Open doors or windows in generator area to increase ventilation. c. Reduce load if possible by turning off non-critical loads. | |
| PRE LO OIL PRES | PRE LO OIL PRES lamp lights. Engine continues to operate. | Engine oil pressure has dropped to 20 psi (138 kPa). | Indicates engine oil pressure has dropped to 30 psi (207 kPa). If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then follow step 5 procedure. If engine can be stopped, follow procedures in step 5. |
| PRE:LO OIL PRES | *4. PRE:LO OIL PRES lamp lights. Engine continues to operate. | Indicates engine oil pressure has dropped to 30 psi (207 kPa). If engine can be stopped, follow procedures in step 5. If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then follow step 9 procedure. | |
| PRELO OIL PRES | PRELO OIL PRES lamp lights. Engine continues to operate. | Indicates engine oil pressure has dropped to 20 psi (138 kPa). If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then follow step 5 procedure. If engine can be stopped, follow procedure in step 5. | |
| Printed Circuit Board Faults | PC control board has faults. | Check all faults 16 thru 23 on the PC control board with care. Remove control cover and relay covers to manually operate relays. | |
| RAIN | Rain | Repair as soon as convenient | |
| REMOTE CIRCUIT BREAKER | *14. Remote circuit breaker is tripped. Reset breaker but will not start automatically or from a remote panel (Note: Run/Stop/Remote switch must be in the REMOTE position for automatic or remote starting). | ||
| REVERSE POWER | Shutdown lamp lights. MESSAGE: REVERSE POWER 335 ï SHUTDOWN | Indicates improper CT or PT phasing. (Non-parallel units only.) | Contact an authorized service center. |
| RUN | Run | ||
| RUPTURE BASIN | Warning lamp lights. MESSAGE: CUSTOMTER FAULT 1 262 − WARNING or RUPTURE BASIN | ||
| Red | Active Fault is present | ||
| Remote circuit breaker | Remote circuit breaker is tripped. | Reset breaker but will not start automatically or from a remote panel (Note: Run/Stop/Remote switch must be in the REMOTE position for automatic or remote starting). Contact an Onan dealer or distributor if breaker trips after resetting. | |
| SC-1609 | STOPPING SET AT CONTROL PANEL | ||
| SC-1610 | PERMISSIVE AUTOMATIC START SWITCH | ||
| SC1635c | The engine does not start | Check the following while the genset is operating: START / STOP / REMOTE SWITCH INDICATOR LAMPS, CIRCUIT BREAKERS | |
| SHORT CIRCUIT | Shutdown lamp lights. MESSAGE: SHORT CIRCUIT 322 ï SHUTDOWN | Indicates that generator output current has exceeded 175% of rated. | Contact an authorized service center. |
| SHUTDOWN | Shutdown lamp lights. MESSAGE: HIGH AC VOLTAGE 301 − SHUTDOWN Indicates that one or more of the phase voltages has exceeded 130% of nominal, or has exceeded 110% of nominal for 10 seconds. | Check load and load lead connections. | |
| SOE | System Over-ride Event | ||
| SPN: 100, FMI: 1 | Engine Oil Pressure, Below Normal | ||
| SPN: 100, FMI: 3 | Engine Oil Pressure, Voltage Out of Range | ||
| SPN: 100, FMI: 4 | Engine Oil Pressure, Volt. Out/Range | ||
| SPN: 105, FMI: 16 | Intake Manifold Temperature, Above Normal | ||
| SPN: 105, FMI: 3 | Intake Manifold Temperature, Volt. Out/Range | ||
| SPN: 1076, FMI: 10 | Fuel Injection Pump Valve, Abnormal Rt/Chg | ||
| SPN: 1076, FMI: 13 | Fuel Injection Pump Valve, Out of Calib. | ||
| SPN: 1076, FMI: 3 | Fuel Injection Pump Valve, Volt. Out/Range | ||
| SPN: 1076, FMI: 5 | Fuel Injection Pump Valve, Cur. Out/Range | ||
| SPN: 110, FMI: 0 | Engine Coolant Temperature, Above Normal | ||
| SPN: 110, FMI: 3 | Engine Coolant Temperature, Volt. Out/Range | ||
| SPN: 1109, FMI: 31 | Approaching Shutdown | ||
| SPN: 1110, FMI: 31 | Engine Has Shut Down | ||
| SPN: 1569, FMI: 31 | Engine Torque Derate | ||
| SPN: 158, FMI: 17 | Battery Potential, Below Normal | ||
| SPN: 174, FMI: 16 | Fuel Temperature, Above Normal | ||
| SPN: 174, FMI: 3 | Fuel Temperature, Volt. Out/Range | ||
| SPN: 190, FMI: 0 | Engine Speed, Above Normal | ||
| SPN: 2000, FMI: 06 | ECU Failure, Cur. Out/Range | ||
| SPN: 629, FMI: 13 | Controller #1, Out of Calib | ||
| SPN: 97, FMI: 0 | Water In Fuel Indicator, Above Normal | ||
| SPN: 970, FMI: 31 | Auxiliary Engine Shutdown Switch | ||
| STATUS INDICATOR LIGHT DEAD | Faulty connections, no battery voltage | 1. Try the genset Start Switch if the remote Start Switch does not work, and vice versa. 2. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery, vehicle frame and genset. 3. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations. | |
| SWITCH OFF | SWITCH OFF lamp flashes | Indicates Run/Stop/Remote switch is in the STOP position which will prevent automatic starting if an automatic transfer switch is used. Move the Run/Stop/Remote switch to the REMOTE position for automatic starting. | |
| Standard Overcrank | The engine monitor will turn on a fault lamp, activate an external alarm and stop the engine. | ||
| T-26 | Air Compressor Will Not Maintain Adequate Air Pressure But Not Pumping Continuously | ||
| T-27 | Air Compressor Will Not Pump | ||
| T-29 | Air Compressor Will Not Stop Pumping | ||
| T-57 | Engine Will Not Crank Or Cranks Slowly (Air Starter) | ||
| T21 | Reference Transformer (T21) | Check continuity between VR21-1 and T7, apply shorting jumper if no continuity. Replace circuit breaker CB21 if necessary. | |
| TB1-10 | OUTPUT TO RELAY K12, FUSED AT 20 AMPS, ENERGIZED WHEN THE START SIGNAL IS APPLIED AND DE-ENERGIZED AT SHUTDOWN (NORMAL AND FAULT) | ||
| TB1-3 | CONNECTED TO TIME DELAY START/STOP MODULE A15 | ||
| TB1-4 | COMMON ALARM B+ OUTPUT 4 AMP RATED DEVICE MAXIMUM | ||
| TB1-5 | GROUND | ||
| TB1-6 | CONNECTED TO TIME DELAY START/STOP MODULE A15. CONNECT REMOTE START CONTACT OF THE AUTOMATIC TRANSFER SWITCH TO TERMINAL TB1-5 OF MODULE A15. | ||
| TB1-7 | OUTPUT TO TIME DELAY START/STOP MODULE A15, FUSED AT 15 AMPS, AVAILABLE WHEN THE STARTING BATTERIES ARE CONNECTED | ||
| TB1-8 | OUTPUT TO RELAY K11, FUSED AT 20 AMPS | ||
| TB1-9 | B+ INPUT | ||
| TB2-1 | GROUND INPUT FROM SENDER | ||
| TB2-16 | MOMENTARY CONTACT TO GROUND | ||
| TB2-2 | GROUND OUTPUT TO LIGHT/RELAY* | ||
| Three blinks | Service fault | Press Stop once to cause the two-digit, second-level shutdown code to blink. (Pressing Stop again will stop the blinking.) The two-digit code consists of 1, 2, 3, 4 or 5 blinks, a brief pause, and then 1 to 9 blinks. The first set of blinks represents the tens digit | |
| Two blinks | Shutdown due to a loss of engine oil pressure | ||
| UNDER FREQUENCY | Shutdown lamp lights. MESSAGE: UNDER FREQUENCY 313 ï SHUTDOWN | Indicates that engine speed has dropped below 90% of nominal for 10 seconds. | NOTE: Five seconds before shutdown, a Load Dump signal is initi- tated. Contact an authorized service center. |
| VR1 | Voltage Regulator VR1 | ||
| VR21 | Fault in VR21 voltage regulator | Check continuity between VR21-1 and T7, apply shorting jumper if no continuity. Replace circuit breaker CB21 if necessary. | |
| WARNING | Warning lamp lights. MESSAGE: OVERCURRENT 320 − WARNING Indicates that generator output current has exceeded 110% of rated for 60 seconds. | Check load and load lead connections. | |
| WEAK BATTERY 232 | Warning lamp lights. MESSAGE: WEAK BATTERY 232 − WARNING | Indicates battery voltage drops below 60% of nominal for two seconds, during starting. Discharged or defective battery. See Warning message 230, LOW DC VOLTAGE. | |
| a | There is no remote circuit signal (12 VDC at auxiliary relay board A28-TB1-6) because fuse F3 on the ECM has blown. | 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. | |
| blink-blink | Shutdown due to a loss of engine oil pressure | ||
| blink-blink-blink-blink | Cranking exceeded a preset time without starting | ||
| blink-blink-blink-pause-1 to 9 blinks | Service fault | ||
| e008 | No specific name provided for e008 | ||
| high engine coolant temperature | Common fault such as high engine coolant temperature | ||
| high exhaust temperature | Common fault such as high exhaust temperature | ||
| low oil pressure | Common fault such as low oil pressure | ||
| red Shutdown lamp | Shutdown fault | Make adjustments or corrections before restarting the genset | |
| red lamp | Any undedicated (red) fault lamp is energized | Both fault functions are normally factory set and may or may not shut down the generator set. Both fault functions may be factory set optionally for non-shutdown and time delayed after start disconnect or immediate operation. Troubleshooting should be directed to the selected sensor application. If an engine monitor malfunction or sensor is suspected, contact an Onan Distributor. | |
| yellow lamp | Low engine temperature fault circuit is energized | Power outage or power disconnect (blown fuses) | Check power source supplying the coolant heater. If coolant heater, sensor or engine monitor is suspected, contact an Onan Distributor. |
Compiled from Cummins/Onan service manuals and controller documentation. Cause/remedy shown where extracted; always verify against the manual for your exact model.
Green RUN lamp lights following engine start-up.. Remedy: 7. Indicates all engine systems are normal. No corrective action required..
High engine temperature shutdown.. Remedy: Check— a. Coolant level. Replenish if necessary. b. City water cooled sets. Check water flow, valves, etc. c. Check sensor; check thermostat. d. Radiator model, check fan belts, radiator for obstructions, etc..
*High engine temperature light ON. No shutdown.. Remedy: Disconnect wire at TB11-31. Light ON after relay reset. Replace engine monitor board..
*High engine temperature shutdown.. Cause: A. Coolant level. Replenish if necessary. b. City water cooled sets. Check water flow, valves, etc. c. Check sensor; check thermostat. d. Radiator model, check fan belts, radiator for obstructions, etc.. Remedy: A. Coolant level. Replenish if necessary. b. City water cooled sets. Check water flow, valves, etc. c. Check sensor; check thermostat. d. Radiator model, check fan belts, radiator for obstructions, etc..
Low oil pressure shutdown.. Remedy: Check— a. Oil level. Replenish if necessary. b. Sensor. Faulty sensor will shut down engine. c. Refer to engine service manual for troubleshooting guide for oil system..
*Low oil pressure light ON. No shutdown.. Remedy: Disconnect wire at TB11-30. Light ON after relay reset. Replace engine monitor board..
*Low oil pressure shutdown.. Cause: A. Oil level. Replenish if necessary. b. Sensor. Faulty sensor will shut down engine. c. Refer to engine service manual for troubleshooting guide for oil system.. Remedy: A. Oil level. Replenish if necessary. b. Sensor. Faulty sensor will shut down engine. c. Refer to engine service manual for troubleshooting guide for oil system..
Fuel level in coach tanks. Remedy: Prime genset fuel system.
Coolant Loss (External). Remedy: - Check: Coolant level - Cracked or leaking hoses - Loose hose clamps - Radiator or heat exchanger for leaks - Coolant in oil.
Coolant Temp Above Normal. Remedy: - Check: Engine coolant level - High engine temp switch - Fault breaker - Coolant level switch - Perform checks in step 01 - Check: Pressure cap - Coolant pump - Coolant tank - Heat exchanger.
Engine Cranks but will not Start. Remedy: Perform checks in Step 01 - Fuel supply - Spark plugs Perform checks in Step 02 - Battery - Ignition coil - Ignition module Perform checks in Step 03 - Fuel filter - Fuel pump - Carburetor Perform engine leak down test.
Eng Cranks But Will Not Start (Genset). Remedy: - Check: Battery condition - Fuel level in tank - Wire loose at K5 - Wire loose at start/stop preheat switch - Perform checks in step 01 - Check: Fuel pump - B+ at glow plugs - Fuel shutoff solenoid.
Engine Difficult to Start. Remedy: Check - Fuel supply - Carburetor choke - Spark plugs Perform checks in Step 01 - Air cleaner element - Fuel filter - Intake manifold gaskets - Fuel pump - Carburetor - Ignition coil - Ignition module Perform engine leak down test.
Engine Idles Rough. Remedy: Check - Fuel supply - Spark plugs Perform checks in Step 01 - Carburetor choke - Spark plug wires - Ignition coil.
Engine Noise Excessive. Remedy: Check - Exhaust system - Engine mounting Perform checks in Step 01 - Valve lash - Starter to ring gear clearance.
Engine Overspeeds. Remedy: Check - Governor adjustment - Throttle cable Perform checks in Step 01 - Governor ball spacer.
Engine Power Output Low. Remedy: Check - Governor - Throttle cable - Carburetor choke - Fuel filter - Air cleaner element.
Engine Starts but will not Stay Running. Remedy: Check - Fuel supply - Fuel pumps - Fuel lines - Voltage at ignition coil - Carburetor choke - Carburetor.