173 Power Solutions International generator fault/alarm codes with symptom, cause and remedy — compiled from Power Solutions International service and controller documentation.
| Code | Meaning / symptom | Cause | Remedy |
|---|---|---|---|
| 2 | HI ENGINE TEMP LED. Engine shuts down — Indicates engine has overheated (engine temperature has risen above 225°F/110°C) or coolant level is low (sets with coolant level sensor). | Allow engine to cool down completely before proceeding with the following checks: Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary; Check for obstructions to cooling airflow and correct as necessary; Check for a slipping fan belt and tighten if loose; Reset control and restart after locating and correcting problem. Contact your Dealer or Distributor if none of the above | |
| 4 | LOW OIL PRESSURE LED. Engine shuts down — Indicates engine oil pressure has dropped to 15 psi (97kPa). NOTE: See also Step 5 | Check oil level, lines and filters. If oil system is okay, but oil level is low, replenish. Reset control and restart. Contact your Dealer or Distributor if oil pressure is not in the range of 35 to 55 psi (21 to 379 kPa) | |
| 5 | OVERCRANK LED. Engine stops cranking. Or Engine runs, shuts down, and LOW OIL PRESSURE LED — Indicates possible fuel system problem. | Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required; Check for dirty fuel filter and replace if necessary (See Maintenance section of Engine Manual); Check for dirty or plugged air filter and replace if necessary (See Maintenance section of Engine Manual); Refer to Step 4; Reset the control and restart after correcting the problem. Contact your Dealer or Distributor for service if none of the above | |
| 6 | Engine runs and then shuts down, OVERSPEED LED — Indicates engine has exceeded normal operating speed. | Refer to governor adjust procedure. Contact your Dealer or Distributor for service | |
| 8 | LOW FUEL LED. Engine continues to run — Indicates diesel fuel supply is running low. | Check fuel supply and replenish as required | |
| 8 | Low Water Temp LED | ||
| 9 | High Engine Temp Pre-alarm LED | ||
| 10 | Low Oil Pressure Pre-alarm LED | ||
| 11 | Low Fuel LED | Check fuel supply and replenish as required. | |
| 12 | Unit Not In Auto LED | Move the AUTO/OFF/MANUAL switch to the AUTO position for automatic starting. | |
| 13 | FAULT LED on 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 your Dealer or Distributor for service | |
| 13 | Press To Test Button | ||
| 14 | Engine starts from generator control panel, but will not start automatically or from a remote panel. (Note: The AUTO/OFF/MANUAL switch must be in the AUTO position for automatic or remote starting) — Indicates possible fault with remote start circuit. | Check the following: Check wire to ATS; See ATS section for further troubleshooting; Contact your Dealer or Distributor for assistance | |
| 14 | Engine Overheat LED | Reduce load if possible by turning off non-critical loads. Check air inlets and outlets and remove any obstructions to airflow. Open doors or windows in generator area to increase ventilation. | |
| 15 | Engine will not crank — Indicates possible fault with control or starting system. | Check for the following conditions: Fault lamp on. Correct fault and reset control; Poor battery cable connections. Clean the battery cable terminals and tighten all connections; Discharged or defective battery. Recharge or replace the battery; Contact your Dealer or Distributor for assistance if none of the above | |
| 15 | Engine Overheat Shutdown LED | Allow engine to cool down completely before proceeding with the following checks: Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. Check for obstructions to cooling airflow and correct as necessary. Check for a slipping fan belt and tighten if loose. | |
| 16 | No AC output voltage — Indicates possible fault | ||
| 16 | Low Oil Pressure LED | Check oil level, lines and filters. If the oil system is okay but oil level is low, replenish. | |
| 17 | Overcrank LED | Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. Check for dirty fuel filter and replace if necessary (See Maintenance section of Engine Manual). Check for dirty or plugged air filter and replace if necessary (See Maintenance section of Engine Manual). | |
| 18 | Engine Over-speed LED | Refer to governor adjust procedure. Contact your Dealer or Distributor for service. | |
| 19 | Unit Not In Auto LED | Move the AUTO/OFF/MANUAL switch to the AUTO position for automatic starting. | |
| 20 | Low Fuel LED | Check fuel level and replenish as required. See Engine Manual for fuel system priming procedure. | |
| 21 | Low Coolant Temperature LED | Check for the following conditions: Coolant heater not connected to power supply. Check for blown fuse, open circuit breaker or disconnected heater cord and correct as required. Check for low-coolant level and replenish if required. Look for possible coolant leakage points and repair as required. | |
| 22 | Charger Malfunction LED | Check and repair. Contact Dealer or Distributor for assistance. | |
| 23 | Low Battery LED | Check electrolyte level and charger output or replace the battery. | |
| 24 | Fault LED on but no fault exists. Engine gauges show oil pressure, engine temperature, and frequency (speed) are within normal limits. | Contact your Dealer or Distributor for service. | |
| 25 | Engine Start from Generator Control Panel but will not start automatically or from a remote panel. | Check the following: Check wire to ATS. See ATS section for further troubleshooting. Contact your Dealer or Distributor for assistance. | |
| 26 | Engine will not crank. | Check for the following conditions: Fault lamp on. Correct fault and reset control. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. Discharged or defective battery. Recharge or replace the battery. | |
| 27 | No AC Output Voltage. | Verify output with another meter if ok check meter, if ok check meter fuses. Regulator fuse is blown. Replace fuse. Contact your Dealer or Distributor if voltage build-up causes fuse to blow. Check rotating rectifier for damaged diodes. Replace all diodes if any are failed. | |
| 28 | No Engine Start. | Check Engine Start connections. Investigate why the Engine Control Switch was put in Manual. Contact your Dealer or Distributor for assistance. | |
| 29 | No Engine Stop. | Check Engine Start Timer setting. Check Engine Start Connections. Investigate why the Engine Control Switch was put in Manual. Contact your Dealer or Distributor for assistance. | |
| 30 | ATS will not transfer to Emergency. | Check Engine Start connections, Generator output, and Engine Control Switch. Plug in Power Supply harness. Plug in Limit Switch harness. Check transfer to Emergency Timer setting. Contact your Dealer or Distributor for assistance. | |
| 31 | ATS will not transfer to Normal. | Check Utility and Utility breakers. Plug in Power Supply harness. Plug in Limit Switch harness. Check retransfer to Normal Timer setting. Contact your Dealer or Distributor for assistance. | |
| #14 | PRE-HI ENGINE TEMP LED. Engine continues to operate — Indicates engine has begun to overheat and engine temperature has risen to approximately 215°F (105°C). If generator is powering non critical and critical loads and cannot be shut down. Use the following: | Reduce load if possible by turning off non-critical loads; Check air inlets and outlets and remove any obstructions to airflow; Open doors or windows in generator area to increase ventilation; If engine can be stopped, follow procedure in Step 2 | |
| *3 | PRE LOW OIL PRESSURE LED. Engine continues to operate — Indicates engine oil pressure has dropped to 20 psi (138kPa). If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then follow Step 4 procedure. If engine can be stopped, follow procedures in Step 4. | ||
| *7 | UNIT NOT IN AUTO LED — Indicates AUTO/OFF/MANUAL switch is in the OFF position which will prevent automatic starting if an automatic transfer switch is used. | Move the AUTO/OFF/MANUAL switch to the AUTO position for automatic starting | |
| *9 | LOW FUEL LED. Engine shuts down and LOW OIL PRESSURE LED — Indicates engine has run out of fuel. | Check fuel level and replenish as required. See Engine Manual for fuel system priming procedure | |
| *10 | LOW ENGINE TEMPERATURE LED. Set is in standby mode but not operating — Indicates engine coolant heater is not operating or is not circulating coolant. | Check for the following conditions: Coolant heater not connected to power supply. Check for blown fuse, open circuit breaker or disconnected heater cord and correct as required; Check for low coolant level and replenish if required. Look for possible coolant leakage points and repair as required; Contact your Dealer or Distributor if none of the above | |
| *11 | CHARGER MALFUNCTION LED. Unit continues to run — Indicates possible fault with the battery charging system. If LED is on only when unit is running indicated problem with battery charging alternator. | Check and repair. Contact Dealer or Distributor for assistance | |
| *12 | LOW BATTERY LED — Indicates starting battery voltage is low. | Check electrolyte level and charger output or replace the battery | |
| DTC 11 | Intake cam / distributor position error — MIL Command-ON | Difference between the desired CAM position and actual CAM position is greater than 6.0 (more than 6 CAD BTDC apart) with engine RPMs greater than 1,200; camshaft position sensor, wiring, or ECM issues | Rotate the distributor to change the CAM position; if rotating the distributor does not correct the issue, troubleshoot sensor, wiring, and ECM for issues |
| DTC 16 | Never Crank Synchronized at Sta[...] or running. Adaptive Learn will be disabled during this fault | ||
| DTC 16 | Crank and/or cam could not synchronize during start | ||
| DTC 24 | Exhaust cam position error | ||
| DTC 87 | Fuel pressure lower than expected | ||
| DTC 88 | Fuel pressure higher than expected | ||
| DTC 91 | FP low voltage | ||
| DTC 92 | FP high voltage | ||
| DTC 107 | MAP voltage low | ||
| DTC 108 | MAP pressure high | ||
| DTC 111 | IAT higher than expected stage 1 | ||
| DTC 112 | Oxygen sensor | ||
| DTC 112 | IAT voltage low | ||
| DTC 113 | IAT voltage high | ||
| DTC 116 | ECT higher than expected stage 1 | ||
| DTC 117 | ECT voltage low | ||
| DTC 118 | ECT voltage high | ||
| DTC 121 | TPS1-2 lower than expected | ||
| DTC 122 | Oxygen sensor | ||
| DTC 122 | TPS1 voltage low | ||
| DTC 123 | TPS1 voltage high | ||
| DTC 127 | IAT higher than expected stage 2 | ||
| DTC 129 | BP pressure low | ||
| DTC 134 | EGO1 open / lazy | ||
| DTC 140 | EGO3 open / lazy | ||
| DTC 154 | EGO2 open / lazy | ||
| DTC 160 | EGO4 open / lazy | ||
| DTC 171 | Adaptive-learn gasoline bank1 high | ||
| DTC 172 | Adaptive-learn gasoline bank1 low | ||
| DTC 174 | Adaptive-learn gasoline bank2 high | ||
| DTC 175 | Adaptive-learn gasoline bank2 low | ||
| DTC 182 | FT low voltage | ||
| DTC 183 | FT high voltage | ||
| DTC 187 | Gaseous fuel temperature sender low voltage | ||
| DTC 188 | Gaseous fuel temperature sender high voltage | ||
| DTC 217 | ECT higher than expected stage 2 | ||
| DTC 219 | RPM higher than max allowed govern speed | ||
| DTC 221 | TPS1-2 higher than expected | ||
| DTC 222 | TPS2 voltage low | ||
| DTC 223 | TPS2 voltage high | ||
| DTC 234 | Boost control overboost failure | ||
| DTC 236 | TIP active | ||
| DTC 237 | TIP low voltage | ||
| DTC 238 | TIP high voltage | ||
| DTC 261 | Injector 1 open or short to ground | ||
| DTC 262 | Injector 1 coil shorted | ||
| DTC 264 | Injector 2 open or short to ground | ||
| DTC 265 | Injector 2 coil shorted | ||
| DTC 267 | Injector 3 open or short to ground | ||
| DTC 268 | Injector 3 coil shorted | ||
| DTC 270 | Injector 4 open or short to ground | ||
| DTC 271 | Injector 4 coil shorted | ||
| DTC 273 | Injector 5 open or short to ground | ||
| DTC 274 | Injector 5 coil shorted | ||
| DTC 276 | Injector 6 open or short to ground | ||
| DTC 277 | Injector 6 coil shorted | ||
| DTC 279 | Injector 7 open or short to ground | ||
| DTC 280 | Injector 7 coil shorted | ||
| DTC 282 | Injector 8 open or short to ground | ||
| DTC 283 | Injector 8 coil shorted | ||
| DTC 285 | Injector 9 open or short to ground | ||
| DTC 286 | Injector 9 coil shorted | ||
| DTC 288 | Injector 10 open or short to ground | ||
| DTC 289 | Injector 10 coil shorted | ||
| DTC 299 | Boost control underboost failure | ||
| DTC 301 | Cylinder 1 emissions/catalyst damaging misfire | ||
| DTC 302 | Cylinder 2 emissions/catalyst damaging misfire | ||
| DTC 303 | Cylinder 3 emissions/catalyst damaging misfire | ||
| DTC 304 | Cylinder 4 emissions/catalyst damaging misfire | ||
| DTC 305 | Cylinder 5 emissions/catalyst damaging misfire | ||
| DTC 306 | Cylinder 6 emissions/catalyst damaging misfire | ||
| DTC 307 | Cylinder 7 emissions/catalyst damaging misfire | ||
| DTC 308 | Cylinder 8 emissions/catalyst damaging misfire | ||
| DTC 326 | Knock1 excessive or erratic signal | ||
| DTC 327 | Knock1 sensor open or not present | ||
| DTC 331 | Knock2 excessive or erratic signal | ||
| DTC 332 | Knock2 sensor open or not present | ||
| DTC 336 | CRANK input signal noise | ||
| DTC 337 | Ignition control circuit | Run the diagnostic chart for DTC 337 | |
| DTC 337 | Crank signal loss | ||
| DTC 341 | CAM input signal noise | ||
| DTC 342 | Ignition control circuit | Run the diagnostic chart for DTC 342 | |
| DTC 342 | Loss of CAM input signal | ||
| DTC 359 | Fuel run-out longer than expected | ||
| DTC 420 | Catalyst inactive on gasoline (Bank 1) | ||
| DTC 430 | Catalyst inactive on gasoline (Bank 2) | ||
| DTC 502 | Roadspeed input loss of signal | ||
| DTC 508 | IAC ground short | ||
| DTC 509 | IAC coil open/short | ||
| DTC 520 | Oil pressure sender low pressure stage 1 | ||
| DTC 521 | Oil pressure sender high pressure | ||
| DTC 522 | Oil pressure sender low voltage | ||
| DTC 523 | Oil pressure sender high voltage | ||
| DTC 524 | Oil pressure low | ||
| DTC 562 | ECM system power and ground circuits | Refer to DTC 562 for the power schematic; check for +12 volts switched power at ECM pin 45 with the ignition key ON | |
| DTC 562 | Vbat voltage low | ||
| DTC 563 | Vbat voltage high | ||
| DTC 601 | Microprocessor failure - FLASH | ||
| DTC 604 | Microprocessor failure - RAM | ||
| DTC 606 | Microprocessor failure - COP | ||
| DTC 615 | Start relay coil open | ||
| DTC 616 | Start relay ground short | ||
| DTC 617 | Start relay coil short to power | ||
| DTC 627 | Fuel pump relay coil open | ||
| DTC 628 | Fuel-pump high-side open or short to ground | ||
| DTC 628 | Fuel pump relay control ground short | ||
| DTC 629 | Fuel-pump high-side short to power | ||
| DTC 642 | 5 volt reference signal malfunction | 5 volt reference signal is open or shorted to ground | Follow the DTC diagnostic chart recommendations for that specific DTC |
| DTC 642 | Sensor supply voltage 1 low | ||
| DTC 643 | 5 volt reference signal malfunction | 5 volt reference signal is open or shorted to ground | Follow the DTC diagnostic chart recommendations for that specific DTC |
| DTC 643 | External 5 Volt 1 Reference High | ECM ground connections not OK; voltage present between ECM harness wire pin 4 and engine ground; faulty ECM | Repair the circuit as necessary (refer to Wiring Repairs in Engine Electrical); replace ECM; clear DTC information from the ECM, turn ignition OFF and wait 30 seconds, start engine and operate to full operating temperature, observe MIL and engine performance, check for stored codes |
| DTC 643 | Sensor supply voltage 1 high | ||
| DTC 650 | MIL Control Open — ECM MIL circuit open; MIL command ON | ECM MIL control circuit is open; open bulb or driver device; open circuit between vehicle interface connector pin G and battery positive | Replace the open bulb or driver device; repair the open circuit as required (see wire harness repair) |
| DTC 652 | Sensor supply voltage 2 low | ||
| DTC 653 | Sensor supply voltage 2 high | ||
| DTC 685 | Power relay coil open | ||
| DTC 686 | Power relay ground short | ||
| DTC 687 | Power relay coil short to power | ||
| DTC 916 | Shift actuator feedback out-of-range | ||
| DTC 919 | Shift unable to reach desired gear | ||
| DTC 920 | Shift actuator or drive circuit failed | ||
| DTC 1175 | MegaJector voltage supply low | ||
| DTC 1176 | MegaJector internal actuator fault detection | ||
| DTC 1177 | MegaJector internal circuitry fault detection | ||
| DTC 1178 | MegaJector internal comm fault detection | ||
| DTC 1182 | Fuel impurity level high | ||
| DTC 1183 | MegaJector autozero / lockoff failure | ||
| DTC 1311 | Cylinder 1 misfire detected | ||
| DTC 1312 | Cylinder 2 misfire detected | ||
| DTC 1313 | Cylinder 3 misfire detected | ||
| DTC 1314 | Cylinder 4 misfire detected | ||
| DTC 1315 | Cylinder 5 misfire detected | ||
| DTC 1316 | Cylinder 6 misfire detected | ||
| DTC 1317 | Cylinder 7 misfire detected | ||
| DTC 1318 | Cylinder 8 misfire detected | ||
| DTC 1411 | EMWT1 voltage high | ||
| DTC 1412 | EMWT2 voltage high | ||
| DTC 1413 | EMWT1 voltage low | ||
| DTC 1414 | EMWT2 voltage low | ||
| DTC 1415 | EMWT1 higher than expected stage 1 | ||
| DTC 1555 | Water Intrusion Detection | ||
| DTC 1631 | PWM1-Gauge1 open / ground short | ||
| DTC 1644 | MIL Control Ground Short — ECM MIL control is shorted to ground | MIL control wire shorted to ground between the ECM connector and engine ground; MIL control wire shorted to ground between the vehicle interface connector and vehicle chassis; faulty ECM | Repair the shorted to ground circuit between the ECM connector and engine ground, then go to step (6); repair the MIL control wire short to ground between the vehicle interface connector and vehicle chassis, then go to step (6); replace the ECM |
| DTC 1645 | MIL Control Ground Short To Power — ECM MIL output shorted to voltage; MIL command ON | MIL control circuit shorted to voltage between the ECM connector and engine ground; MIL control wire shorted to voltage between the vehicle interface connector and vehicle chassis; faulty ECM | Repair the shorted to voltage circuit between the ECM connector and engine ground, then go to step (6); repair the MIL control wire short to voltage between the vehicle interface connector and vehicle chassis, then go to step (6); replace the ECM |
| DTC 1654 | Blink code mode confirmation code | ||
| DTC 1669 | PWM9 open / ground short | ||
| DTC 1670 | PWM9 short to power | ||
| DTC 2111 | Unable To Reach Lower TPS — Actual throttle position is 20% greater than the throttle command; MIL ON during active fault; engine shutdown | TPS 1 voltage greater than 2.0 volts at 63%-68% throttle command; TPS 1 signal circuit fault at electronic throttle connector C017 | Check TPS 1 voltage with test light connected to battery voltage at TPS 1 signal pin 6 with key ON; if DST displays TPS 1 voltage less than 0.2 volts go to Step (4) |
Compiled from Power Solutions International service manuals and controller documentation. 14 code numbers mean different things on different controllers; each meaning is listed with the models it applies to. Cause/remedy shown where extracted; always verify against the manual for your exact model.
HI ENGINE TEMP LED. Engine shuts down — Indicates engine has overheated (engine temperature has risen above 225°F/110°C) or coolant level is low (sets with coolant level sensor).. Remedy: Allow engine to cool down completely before proceeding with the following checks: Check coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary; Check for obstructions to cooling airflow and correct as necessary; Check for a slipping fan belt and tighten if loose; Reset control and restart after locating and correcting problem. Contact your Dealer or Distributor if none of the above.
LOW OIL PRESSURE LED. Engine shuts down — Indicates engine oil pressure has dropped to 15 psi (97kPa). NOTE: See also Step 5. Remedy: Check oil level, lines and filters. If oil system is okay, but oil level is low, replenish. Reset control and restart. Contact your Dealer or Distributor if oil pressure is not in the range of 35 to 55 psi (21 to 379 kPa).
OVERCRANK LED. Engine stops cranking. Or Engine runs, shuts down, and LOW OIL PRESSURE LED — Indicates possible fuel system problem.. Remedy: Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required; Check for dirty fuel filter and replace if necessary (See Maintenance section of Engine Manual); Check for dirty or plugged air filter and replace if necessary (See Maintenance section of Engine Manual); Refer to Step 4; Reset the control and restart after correcting the problem. Contact your Dealer or Distributor for service if none of the above.
Engine runs and then shuts down, OVERSPEED LED — Indicates engine has exceeded normal operating speed.. Remedy: Refer to governor adjust procedure. Contact your Dealer or Distributor for service.
Low Fuel LED. Remedy: Check fuel supply and replenish as required..
Unit Not In Auto LED. Remedy: Move the AUTO/OFF/MANUAL switch to the AUTO position for automatic starting..
Overcrank LED. Remedy: Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. Check for dirty fuel filter and replace if necessary (See Maintenance section of Engine Manual). Check for dirty or plugged air filter and replace if necessary (See Maintenance section of Engine Manual)..
Engine Over-speed LED. Remedy: Refer to governor adjust procedure. Contact your Dealer or Distributor for service..
Unit Not In Auto LED. Remedy: Move the AUTO/OFF/MANUAL switch to the AUTO position for automatic starting..
Low Fuel LED. Remedy: Check fuel level and replenish as required. See Engine Manual for fuel system priming procedure..
Low Coolant Temperature LED. Remedy: Check for the following conditions: Coolant heater not connected to power supply. Check for blown fuse, open circuit breaker or disconnected heater cord and correct as required. Check for low-coolant level and replenish if required. Look for possible coolant leakage points and repair as required..
Charger Malfunction LED. Remedy: Check and repair. Contact Dealer or Distributor for assistance..
Low Battery LED. Remedy: Check electrolyte level and charger output or replace the battery..